Industrial Engineering Using IoT

Take costs out

Driverless cars and appliances that manage energy consumption are examples consumer IoT . But the significant component of IoT initiatives  will occur in the business-to-business environment. 70% of IoT applications and value creation will be in the B to B space.


In business-to-business markets, there are three ways in which a supplier can deliver value to its customers. One way is to enable the customer to sell more product, either by capturing additional market share or by expanding the end market. A second way is to enable the customer to reach a higher price point due to the improvement done in the product. IoT has applications in  both of these alaternatives.

But the larger opportunity involves the third route to value creation and capture, namely initiatives that take costs out from the current cost base.

Significant amounts are spent after a  company buys the new equipment.  The costs involve ongoing operating costs – energy use, preventive and corrective maintenance, replacement of consumables and operator time among them. Some are related to commissioning, calibration, inspections, start-and-stop operations and changeovers related to production or customization. Some are related to regulation and record-keeping requirements.


These cost areas can be reduced through use of  IoT.  Contributions that take costs out are to be focused by industrial engineers.

Smart equipment initiatives that are self-funded out of savings realized in the costs  that are presently spent are going to become success stories for companies that focus their investments in that direction and bring those contributions to their customers.


Enterprises have to visualize the cost savings in  the complex customer chains that exist in many business markets.

It often will be the case that the opportunity to take costs out will involve a participant several stages down the customer chain, rather than the supplier’s direct customer.


In one recent case, a corporation approached the challenge of identifying IoT initiatives that made business sense by asking the question, “What data would have a game-changing impact on our business?”  A brain storming team was formed and engineers and sales people collaborated in an ideation session. One idea involved offering a remote monitoring service that could manage performance and detect problems on behalf of customers, many of whom operated the equipment at hundreds of sites. Capturing a database about what was going on with the equipment just prior to instances of failure had the potential to define the improvements that could avoid such failures. Enabling the company’s equipment to provide meaningful data to drive the enterprise’s decisions on new product investments had the potential to ensure that future product development initiatives would be rewarded in the market.


IoT Success stories will come in many flavors, but most of them will require a deliberate and thoughtful approach to generate a real understanding of how to translate new streams of data into value. Focusing on opportunities to take costs out of customers’ existing cost base,  on opportunities to gain a competitive data-driven advantage in markets, and on opportunities to answer the previously unanswered questions that can enable your own enterprise to make sound decisions on investments are three routes through which you can build the foundation for IoT success stories.

Industrial engineers have an important role to play in taking costs out of the production system throug huse of IoT systems in the cost of their factories, cost of supply chain and customer chain.


IoT Articles

You ain't seen nothing yet
IoT offers plentiful ways to add value in business-to-business markets
Industrial Engineer Engineering and Management Solutions at Work
April 2016    |    Volume: 48    |    Number: 4
The member magazine of the Institute of Industrial Engineers


http://www.mckinsey.com/industries/high-tech/our-insights/the-internet-of-things

http://www.pcworld.com/article/2690192/intel-pushes-factory-iot-with-9-million-cost-savings-at-plant.html

http://www.theguardian.com/sustainable-business/2015/mar/16/internet-of-things-energy-costs

http://www.businessinsider.in/How-energy-companies-and-utilities-are-using-the-Internet-of-Things-to-be-more-efficient-and-save-billions/articleshow/47239764.cms

https://www.linkedin.com/pulse/cost-reduction-preventive-maintenance-using-internet-iot-chakraborty

Converting Waste into Wealth - An Example - Using Wood with Imperfections

http://worldinsidepictures.com/this-man-started-with-these-knotted-slabs-of-wood-and-then-transformed-them-into-something-unique-and-beautiful/

See how a person uses wood pieces with imperfections to convert them into beautiful objects that people from far away places buy with enthusiasm.

March 4th Week - Industrial Engineering Revision Plan

Industrial Engineering Techniques Application 

Technical Processes (Engineering Processes)
Managerial Processes (Related to Technology Area Management)

Business Processes
Managerial Processes (Related to Business Area Management)

In every article the role of industrial engineer and relevant technique of industrial engineering  is to be specifically mentioned.  Please help me by writing a comment on what can be included to serve that purpose.

20th March - Birthday of Man of Productivity - Low Prices and High Incomes

Frederick Winslow Taylor - A Pioneer Industrial Engineer
http://nraoiekc.blogspot.com/2012/04/frederick-winslow-taylor-pioneer.html
Date of Birth: 20th March, 1856
Contribution of Taylor to Industrial Engineering
Shop Management
Scientific Management

March 4 Week (22 to 26)

Facility Layout - Review Notes

Product Design and Process Selection—Services

Total Quality Management: and Six Sigma - Process Capability and Statistical Quality Control

Operations Consulting and Reengineering

Supply-Chain Strategy - Review Notes

Strategic Capacity Management

Just-in-Time and Lean Systems - Review Notes

Forecasting - Operations Management Review Notes

Aggregate Sales and Operations Planning - Review Notes

Inventory Control - Review Notes for Chase et al.

28 March

Subject Update: Principles of Management

http://nraomtr.blogspot.com/2015/04/principles-of-management-subject-update.html

29 March

Subject Update: Marketing Management

http://nraomtr.blogspot.com/2015/01/marketing-management-subject-update-2015.html

Developing and Employing First Class People in an Organization - F.W. Taylor

The aim in each establishment should be:

(a) That each workman should be given as far as possible the highest grade of work for which his ability and physique fit him.

(b) That each workman should be called upon to turn out the maximum amount of work which a first-rate man of his class can do and thrive.

(c) That each workman, when he works at the best pace of a first-class man, should be paid from 30 per cent to 100 per cent according to the nature of the work which he does, beyond the average of his class.

And this means high wages and a low labor cost. 

These conditions not only serve the best interests of the employer, but they tend to raise each workman to the highest level which he is fitted to attain by making him use his best faculties, forcing him to become and remain ambitious and energetic, and giving him sufficient pay to live better than in the past.

Under these conditions the writer has seen many first-class men developed who otherwise would have remained second or third class all of their lives.

Is not the presence or absence of these conditions the best indication that any system of management is either well or badly applied? And in considering the relative merits of different types of management, is not that system the best which will establish these conditions with the greatest certainty, precision, and speed?

In comparing the management of manufacturing and engineering companies by this standard, it is surprising to see how far they fall short. Few of those which are best organized have attained even approximately the maximum output of first-class men.

Source
F.W. Taylor, Shop Management

Next Topic

http://nraoiekc.blogspot.com/2013/08/confronting-soldiering-slow-pace-of.html

F.W. Taylor - Shop Management - With Appropriate Sections
http://nraoiekc.blogspot.com/2016/03/fw-taylor-shop-management-with.html


Updated on 24 March 2016, 3 August 2013

F.W. Taylor Scientific Management - With Appropriate Sections

Scientific Management - Themes

1. Importance of National Efficiency

2. Foundation of Scientific Management

3. Soldiering and Its Causes

4. Underlying Philosophy for the Old Systems of Management

5. Scientific Management - Introduction

6. THE PRINCIPLES OF SCIENTIFIC MANAGEMENT

7. Illustrations of Success of Scientific Management - - Pig Iron Handling

8. Background for Development of Scientific Management - -Midvale Steel Company Machine Shop

9. Elaborate Planning Organization - Need and Utility

10. Illustrations of Success of Scientific Management - Bricklaying Improvement by Gilbreth

11. Illustrations of Success of Scientific Management - Bicycle Balls Inspection Example

12. Scientific Management in Machine Shop

13. Development of Science in Mechanic Arts

14. Study of Motives of Men

15. Scientific management in its essence

16. Role of Top Management in Implementing Scientific Management

17. Scientific Management Summarized

The Principles of Scientific Management - Reassessment after 100 Years in 2011

Scientific management was published in 1911.

Relevance of The Principles of Scientific Management 100 Years Later
Special Issue of
Journal of Business and Management – Vol. 17, No. 1, 2011
Link for full journal
http://www.chapman.edu/business/_files/journals-and-essays/jbm-editions/jmb-vol-17-01.pdf

Industrial Engineers and the Make in India Initiative in India

There is an article "Industrial Engineers and the Manufacturing Renaissance" in Industry Week.
http://www.industryweek.com/education-training/industrial-engineers-and-manufacturing-renaissance?page=1

NC State University's Industrial Engineering Profesor Paul Cohen made some interesting points that are relevant to Industrial Engineering Education in India.

We have entered the era of Manufacturing 2.0, where both shop floor employees and engineers will need new skills for more advanced manufacturing.

One of the primary skills is the ability to use information technology to connect all the pieces of a more complex, interdependent manufacturing environment. Additive manufacturing will contribute to a very distributed supply chain and it is to be in a network as designs can be sent over the network to 3D printing firms.

There is also a major challenge in teaching engineers how to design products to take advantage of 3D printing.  Certain geometries that can’t be produced with other processes can be produced using  3D printing processes.

Industrial engineers can identify cost reduction opportunties in producing components using 3D printing processes.

Industrial engineers in particular deal with people from the shop floor to the boardroom. So they should be able to communicate with everybody. So education in communication skills is essential for IEs.

The U.S. does not have enough industrial engineers moving through the educational pipeline. Cohen cites a 2012 article in The New York Times that examined the production ramp-up for Apple’s iPhone. The article noted that 8,700 industrial engineers were needed to oversee the 200,000 employees of Foxconn who would manufacture the phones. Apple estimated that it would take nine months to find that number of engineers in the U.S. But in China, it took only 15 days. That shows China is developing more IEs

According to Cohen, U.S., produces 3,300 industrial engineers a year.

How many IEs are produced in India through universities.  In India, we need to recognize the importance of IE stream and take steps to strengthen the stream.

3D Printing - Digital Printing - Engineering Economic and Cost Analysis

https://www.xometry.com/blog/3d-printing-vs-injection-molding-breakeven/

Production Time Study App - Gustavo Yuji Sousa

 I have developed an Industrial Engineering App to support Time Study. There are a lot of unique features as Email Reports and Non-Cyclic records segregation useful to determine machine efficiency and operator workload.    

https://www.linkedin.com/pulse/production-time-study-app-gustavo-yuji-sousa-6108421674439307264

March 3rd Week - Industrial Engineering Revision Plan

Operations - Production Management starts in this week


March 3 week (15 - 19 March 2016)

Developing Enterprisewide or Company Wide Marketing Orientation
Management of Marketing Department and Function

Operations - Production Management 

Introduction to the Field of Operations Management
Operations Strategy and Competitiveness - Review Notes

Optimizing the Use of Resources with Linear Programming

Learning Curves - Review Notes

Operations Project Management

Process Analysis - Operations Management

Product Design - Review Notes

Manufacturing Process Selection and Design

20th March - Birthday of Man of Productivity - Low Prices and High Incomes

Frederick Winslow Taylor - A Pioneer Industrial Engineer

http://nraoiekc.blogspot.com/2012/04/frederick-winslow-taylor-pioneer.html

Date of Birth: 20th March, 1856

Contribution of Taylor to Industrial Engineering

Shop Management

Scientific Management

In the marketing management articles you will come across marketing productivity discussion. Industrial engineers are concerned with marketing productivity and they improve marketing processes to improve their productivity. The various activities in marketing are studied by IEs to understand the processes and activities to redesign them improving their efficiency. Second, marketing is related to exchange of ideas. Industrial engineers come up with many ideas of process improvement, and they have to know the marketing steps to market and sell their ideas.

Operations Management Area - Main focus area for IEs for Improvement

IEs have to improve both technical and management processes

Operations management in engineering organizations is the main area for industrial engineering activity. In operations management activity, there are many areas where engineering is the primary knowledge discipline and IEs are the people to improve these areas for productivity improvement, cost reduction and waste elimination. Hence IEs have to study operations management in detail as they will be involved improving technical processes as well as managerial processes in operations managment area.

Industrial Engineering IE 1.0 - IE 2.0 - IE 3.0

My comment in IIE Linked in Group.

Yes Lean is an improvement in industrial engineering  over the system that was designed by Taylor and his followers. If Taylorism gave IE 1.0, Lean gave IE 2.0. IT gave IE 3.0. But we IE professionals are not able to write our history properly and support contributors to IE development adequately.

https://www.linkedin.com/groups/75670/75670-6113368730438295553

March 2nd Week - Industrial Engineering Revision Plan

March 2nd week



Marketing Communication: Channels and Promotion Tools
Advertising



Sales Promotion 
Marketing Public Relations


Sales Process and Sales Training
Direct Marketing




Online Marketing
Marketing and New Product Development



International and Global Marketing
Sales Force Management

New Product Industrial Engineering

Industrial Engineering

On the one hand, the Industrial segment requires technology intensive products with long product cycles. On the other, consumers are demanding radical and connected solutions that have the potential to transform lives and businesses. However, in both cases, demand is shifting towards emerging markets. Companies must address the need for product localization, new technologies and features and conform to regulations for environment and safety.

Tech Mahindra brings more than a decade’s experience in end-end engineering solutions and services for the consumer goods and industrial segments. Our significant technology expertise We in off-highway equipment, machinery, electrical and electronic equipment and HVAC systems and across various next generation technologies such as Machine to Machine (M2M) applications, Internet of Things, intelligent systems, etc. means we deliver future ready connected engineering solutions that transform businesses.


New Product development

Derivative products design
Platform changes
Innovation and technology programs
Prototype, test and validate
New features and feature upgrades
Advanced analysis
Appearance


Systems Engineering

System and subsystem performance prediction
DFSS/DFR/DoE studies
Six Sigma for process improvements
Testing for EHS/Regulatory requirements (RoHS, UL)
Reliability Engineering
Reliability Test Plan creation and testing
Failure Root Cause Analysis
FRACAS
Warranty Analysis
Software reliability estimation and prediction
Electronics Engineering
Software development and verification
Develop diagnostic and testing software tools
Firmware development
PCB layout design and development
CAD Management
3D database development
Engineering Change Management
Top down design
Harnessing
Customization
Technical Publications
Cataloging services
Analysis
Structural analysis
Thermal analysis
CFD analysis
Dynamic system simulation
Mold flow
Competitive Benchmarking
Continuous benchmarking based on cost, features and performance
Data for strategic decision making
Analysis for multi-generation product and technology plans
Identifying cost-out opportunities
Address key performance gaps

Value Engineering
Teardown and competitive Benchmarking analysis
Component simplification
Material change and modularity
Should Costing


Supplier Change
Global Sourcing
Raw material and component sourcing
EHS and supplier audits
Supplier selection, development, quality and program management
3rd party lab qualifications and regulatory certifications


Process Engineering

Plant design and engineering
3d modeling and plant simulation
Digital manufacturing
P&ID, plant layout design
Electrical and civil engineering
Manufacturing engineering
Methods and Planning
Tools and fixture design
NC and CMM programming
Industrial Automation
Real time data collection
Controller programming
HMI, SCADA
Test automation
Robotics
System engineering
Robot programming
Advanced process control
Knowledge based self-training

Manufacturing Operations Management

http://www.techmahindra.com/services/integrated_engineering_solutions/vertical%20competencies/industrial.aspx






Job About Océ - Industrial Engineer New Product Introductions (NPI)
You cannot apply for this job anymore..


Job has expired on July 22, 2015

Océ Technologies - Industrial Engineer New Product Introductions (NPI); 

Accelerating manufacturing performance by building and successfully delivering global manufacturing/operations for new products
Specifications - (explanation)
Location Venlo
Function types Technical, Laboratory positions, Research, Development, Innovation
Scientific fields Natural Sciences, Engineering, mechanical engineering or electrical engineering
Hours 40.0 hours per week
Education University Graduate
Job number AT 48281

About employer Océ Technologies
Short link  www.academictransfer.com/28638

Job description
Great career opportunity for an Industrial or Manufacturing Engineer with NPI experience! Looking for an international oriented job where you are challenged to create a full-scale lean manufacturing operation? Then you should apply for this job!

Your challenge as Industrial Engineer

You are responsible for designing, implementing a full-scale lean manufacturing operation, a unique opportunity to build world class manufacturing for new products in which the rules have yet to be fully defined. Therefore you are building and maintaining relationships with your counterparts at the (local) innovation centers in Netherlands and Canada. And you liaise and engage with counterparts at the supply center in Germany as well. You drive global NPI and process changes involved in a strong project team across geographies.

With your strong interpersonal skills, enthusiasm and NPI experience you build and inspire successful a global manufacturing processes and organization. Effective and efficient manufacturing methods and processes are crucial in your operation. With your experience, you implement and ensure outstanding product quality, short assembly lead times and ‘short time to market’. The introduction of effective production concepts processes and methods result in a cost effective and accelerated production at our supply centers.

To ensure successful industrialization, operations and excellent performance with outstanding quality and short assembly lead time, you engage with key stakeholders at product development in Netherlands and in Canada during product design phase. You identify project risks in time and define risk reduction and mitigation plans for the product and for the manufacturing processes.

You provide guidance and support to your Industrial Engineering colleagues as well as other teams together building a successful international Manufacturing organization by preparing and aligning plans and deliverables. You act as a Project coach for the Industrial Engineers in the multi disciplinary Project team. Focusing on the team’s interpersonal development draws the team together, ensuring it grows further as a high performing, winning team.

To maintain effective operations as well as enhancing actual performance you are continuously identifying opportunities for improvement. You analyze data, workflow, KPI reports and forecasts and translate these into appealing plans challenging your stakeholders (e.g. Quality Assurance, Procurement, Supply Chain) to improve the way we work every day.

This position is based in Venlo, the Netherlands, and you report to the Manager Manufacturing Machines.
Requirements
Academic level of working and thinking, educational background in mechanical engineering or electrical engineering. Master degree is preferred
About 5 years ‘hands-on’ industrial engineering experience in a manufacturing/assembly environment with high-tech product or capital goods and complex production processes. Proven experience in NPI is required , experience with flatbed machines is preferred
Experience with and in-depth knowledge of Lean Manufacturing and advanced improvement methodologies is a must. Experience in coaching winning teams is a plus
Ability to outperform on quality, timeline and realization of improvements and innovations. Developing clear strategies and processes – long-term thinker
Strong conceptual, analytical and presentation skills, keen eye for processes and presentation. And outstanding interpersonal and influencing skills necessary to gain acceptance and achieve delivery over different sites
Capable in defining and/or programming KPIs for visual monitoring of manufacturing processes, IT know how beyond MS Office is desired
Excellent communication and presentation skills in English. Profound knowledge of Dutch is required
Permission to work in the Netherlands, no relocation needed
Willing to travel, 10/15% on a yearly base – mainly to Germany and sometimes to Canada
Conditions of employment
What do we have to offer you?

We offer you a versatile and challenging job in an international high-tech and fast paced organization. Since Océ is facing multiple growth opportunities in the world of printing today, your role in building and enhancing manufacturing processes and organization is crucial. You will work together with many stakeholders across geographies, continuing to develop a performance driven mindset for a best in class organization. If you are looking for a next career step in a changing international organization, global scope having lots of responsibilities and where you are challenged to create and deliver a world class lean manufacturing operations for new products, this is the job you are looking for!

Benefits

Besides a challenging working environment, scope for personal and professional development you will receive an interesting package of employment conditions;
Competitive salary
Full-time job – a 40-hour week with flexible hours
38 vacation days
Commuting allowance
Thirteenth month payment and holiday allowance
Employer
About Océ
Océ is a global leader in digital imaging, industrial printing and collaborative business services. Océ’s mission is to accelerate new digital print technologies and transform them into local printing products and services for blue-chip multinationals around the globe and creative studios around the corner. A Canon Group Company, Océ operates a vast global network of R&D centres to connect emerging digital print technologies to future markets.
Department
Manufacturing
Manufacturing is responsible for the manufacturing and in time delivery of ‘best-in- class’ high mix low volume Océ products within the Canon Organization. Challenges within the Manufacturing organization are enhancing the Lean philosophy, improving and growing the industrialization (methods) for ink and print heads as well as developing a ‘world class’ supply base and value chains.

https://www.academictransfer.com/employer/Oce-Technologies/vacancy/28638/lang/en/






There are many steps that go into creating new products, and you may be searching for the right industrial engineering Toronto firm to assist you with all aspects of the product design and development process. Some companies have the infrastructure in place in-house to design and develop new products, but others may need access to a few services or to a complete range of services. When you are searching for the best industrial engineering Toronto firm to work with for your product development project here are a few points you should pay attention to.

The Initial Research Process

Before a product can be designed, thorough market research and analysis must be conducted. You do not want to waste your firm’s valuable time or financial resources creating a prototype that has no useful or needed purpose. You also do not want your product to be priced higher than what consumers may be willing to pay for it. In addition, you do not want to create a product that has already been created, and because of this, a part of the initial research process involves researching patents and securing patents for your company’s own unique ideas.

Creating a Prototype

The right industrial engineering Toronto firm will complete all of this research up-front on your behalf, streamlining the research process for you and laying the groundwork for a solid product development process. In addition, the industrial engineering firm will also go through all aspects of the prototype development process. During this process, a cost analysis will be completed by an industrial engineering firm to help you to better plan for the manufacturing aspect of the product. Different versions of a model or prototype may also be created in some cases, and these may have different features and a different cost analysis. Your own company may need to review the different prototypes of cost analysis in order to better determine which prototype to move forward with in production.

There are many factors to consider as you prepare to design a new product and bring it to market. One of the best steps that you can take to simplify the entire process and to ensure that the product that you create is a superior one that is cost effective to produce is to work with an industrial engineering Toronto firm. Through this effort, you will receive all of the knowledgeable support and guidance necessary throughout the product design process.

For more info, call 416-537-0505 or Click Here to Contact us.
https://www.inertiaengineering.com/searching-for-the-right-industrial-engineering-toronto-firm/

https://www.inertiaengineering.com/turn-key-product-development/product-engineering/


https://www.inertiaengineering.com/contact/