Industrial Engineering Knowledge Center: Online Handbook of Industrial Engineering

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Online Handbook of Industrial Engineering - Narayana Rao

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Dr. K.V.S.S. Narayana Rao, Professor, National Institute of Industrial Engineering, Mumbai, India.

Author of Principles of Industrial Engineering, Functions of Industrial Engineering and Focus Areas of Industrial Engineering.

Industrial Engineering is System Efficiency Engineering.

Machine Effort and Human Effort Industrial Engineering.

It is continuous improvement engineering. There are product design engineers, process design engineers, facilities planning engineers, production operations engineers, facilities maintenance engineers, product service engineers. There are industrial engineers. Industrial engineers observe, do studies and use recorded data on time, cost and productivity, develop science and based on the science do improvement engineering or productivity engineering. Quality of product or the output and human comfort & safety are part of focus areas of industrial engineering as all engineering changes have to be done taking into consideration quality and human aspects.

Industrial Engineering has three components:

Systems Efficiency Engineering, and Systems Design, Installation and Improvement Management, and Machine Effort and Human Effort Engineering. The functions of industrial engineering are research, productivity science, productivity engineering, productivity management, productivity communication and training, productivity measurement, productivity analysis. Articles describing various methods and techniques under each component/function are included in this handbook. Many of these articles are globally popular online articles with thousands of page views and visitors.

Online Handbook - Click on Link to go to the Article/Essay/Chapter

Introduction to Industrial Engineering

Basic Principles of Industrial Engineering - Narayana Rao

1. Develop science for each element of a man - machine system's work related to efficiency and productivity.

2. Engineer methods, processes and operations to use the laws related to the work of machines, man, materials and other resources.

3. Select or assign workmen based on predefined aptitudes for various types of man - machine work.

4. Train workmen, supervisors, and engineers in the new methods, install various modifications related to  the machines that include productivity improvement devices and ensure that  the expected productivity is realized.

5. Incorporate suggestions of operators, supervisors and engineers in the methods redesign on a continuous basis.

6. Plan and manage productivity at system level.

(The principles were developed on 2 July 2016 (During Birthday break of 2016 - 30 June 2016 to 7 July 2016). 

The principles were developed by Narayana Rao based on principles of scientific management by F.W. Taylor)

Principles of Industrial Engineering - Narayana Rao - Detailed List

 Productivity science

 Productivity engineering

 Industrial Engineering is applicable to all branches of engineering

 Principles of (machine) utilization economy to be developed for all resources used in engineering systems.

 Industrial engineering optimization

 Industrial engineering economics

 Implementation team membership and leadership

 Human effort engineering for increasing productivity

 Principles of motion economy to be used in all IE studies in the area of human effort engineering

 Operator comfort and health are to be taken care of.

 Work measurement

 Selection of operators

 Training of operators, supervisors and engineers

 Productivity training and education to all

 Employee involvement in continuous improvement of processes and products for productivity improvement.

 Productivity incentives

 Hearty cooperation

 Productivity Management

 System level focus for productivity

 Productivity measurement

 Cost measurement

The principles were presented at the Annual Conference of IISE 2017 at Pittsburgh, USA. The paper is in the proceedings of the conference. The presentation made at the conference is given below.

________________

Principles of Industrial Engineering - Narayana Rao

https://www.youtube.com/watch?v=pU8CdWfZZdU

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Industrial Engineering - History

Industrial Engineering - Definition and Explanation

Focus of Industrial Engineering

THE PURPOSE AND EVOLUTION OF INDUSTRIAL ENGINEERING

Fundamentals of Industrial Engineering
Basic Principles of Industrial Engineering

Levels of Industrial Engineering in an Enterprise.

Enterprise Level to Engineering Element Level Industrial Engineering.

Industrial Engineering Strategy - Enterprise Level Industrial Engineering.

Facilities Industrial Engineering.

Process Industrial Engineering - Process Machine Effort Industrial Engineering - Process Human Effort Industrial Engineering.

Operation Industrial Engineering.

Element Level Analysis in Industrial Engineering.

Pioneers and Expert Practitioners of Industrial Engineering

Frederick Winslow Taylor - A Pioneer Industrial Engineer

Frank B. Gilbreth: Some of His Industrial Engineering Achievements

Harrington Emerson - A Pioneer Industrial Engineer

Henry Laurence Gantt (1861-1919) - Industrial Engineer

Shigeo Shingo - The Japanese Industrial Engineer

Industrial Engineering and Scientific Management in Japan

The Component Areas of Industrial Engineering

Machine Effort Industrial Engineering

Human Effort Engineering

Systems Efficiency Engineering - A Focus Area of Industrial Engineeering

Systems - Factory, Facilities, Processes, Products

Industrial Engineering and Systems Design

Human Effort Engineering - Methods, Techniques and Related Issues

Work Station Design - An Activity of Human Effort Engineering

Principles of Motion Economy

Motion Study - Human Effort Engineering

Motion Study - Operation Analysis - Questions

Ergonomics - Introduction

Man Machine Interface Devices - Design and Use - Industrial Engineering

Biomechanics in Industrial Engineering Curriculum

Safety Aspect of Human Effort Engineering - A Manual to Support

Safety Gloves

Human Effort - Nature and Effects

The Concept of Human Effort Engineering: HR Dimension

Systems Efficiency Engineering - Methods, Techniques and Related Issues

Efficiency: A Focus Area of Industrial Engineering - Jesse Brogan

Method Study

Process Analysis - Questions/Check List

Installing Proposed Methods

5S System - Work Place Design (Industrial Engineering)

Fact Gathering for Office System Efficiency Engineering Studies

Value Engineering - Introduction

___________

Value Engineering Introduction - Miles Way

https://www.youtube.com/watch?v=BHH-QZ29EOo

___________

Statistical Quality Control – Industrial Engineering (LTC)

Operations Research - An Efficiency Improvement Tool for Industrial Engineers

Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers

Systems Design, Installation and Improvement Management Methods, Techniques and Related Issues

Engineering Economy or Engineering Economics: Economic Decision Making by Engineers

Productivity Measurement

Systems Engineering - INCOSE View

System Engineering Process and Its Management

Functions of Industrial Engineering

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Focus Areas of Industrial Engineering

Engineering has two aims:
To develop effective products and processes that satisfy customers.
To develop efficient products and processes that give profits and satisfaction to the producers (both managers-capitalists and employees).

Industrial engineering is focused on efficiency while the functional engineers are focused on effectiveness.

Both engineering streams have big data bases of knowledge, information and data that are to be used to do the design and execution work successfully to the satisfaction of customers.

Industrial engineering developed its knowledge based over 140 years. The academic discipline of industrial engineering was started in 1908. But the call for development of this engineering branch was given in 1880.

Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.

Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.

Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.

Industrial Engineering Optimization: Optimizing industrial engineerng solutions created in Product Industrial Engineering and Process Industrial Engineering.

Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.

Industrial Engineering Economics: Economic analysis of industrial engineering projects.

Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.

Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.

Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.

Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.

Process Industrial Engineering

The scope of process industrial engineering is very big. Engineering processes are large in number because of large number of engineering branches. Within each branch there are different areas of subjects. Within each subjects there are large number of processes. For illustration, in the subject of manufacturing alone there are number of fundamental processes. Within each fundamental process, say for example, machining, there are number of machine tools. Continuously, developments are taking place in machine tools, cutting tools and accessories that have an effect on productivity. Industrial engineers have to monitor, establish relationships with representatives of sellers and consultants to know the developments, evaluate them and implement them in their organization as quickly as possible. There is reengineering opportunity each time a new development in any engineering element is adopted. Creative application of new technology as well as problem solving ideas is required all the time in industrial engineering.

Process Industrial Engineering - Methods and Techniques

Operation Process Chart
Flow Process Chart
Seven Waste Model
Value Stream Mapping

Productivity Analysis and Improvement of Processing Operations

Identifying, Analyzing and Installing High Productivity Equipment and Machines

Identifying, Analyzing and Utilizing High Productivity Special Processes

Developing special purpose machines

Installing accessories for productivity improvement

Using Jigs and Fixtures

Using more productive tools

Using new lubricants

Using new cutting fluids

Cutting parameters optimization

Process parameters optimization

SMED

Poka Yoke

Machine Work Study

Operation Analysis

Process Analysis

Electric power consumption analysis and reduction

Predictive maintenance

Preventive maintenance

OEE improvement

Manufacturing Cost Policy Deployment (MCPD)

Productivity Analysis and Improvement of Inspection Operations

Statistical Process Control
Acceptance Sampling
High Productivity Inspection Techniques and Instruments
Inspection Fixtures

Productivity Analysis and Improvement of Material Handling Operations

Plant Layout Studies
Cellular Layouts
Developments in Material Handling Equipment
Robots for Loading and Unloading Machines
AGVs
Conveyors

Analysis of Temporary Delays

Shigeo Shingo is to be appreciated for providing detailed discussion on this issue in his book, "A Study of the Toyota Production System from an Industrial Engineering Point of View."

Reduction of batch quantities
Reduction of safety stocks
Reduction of demand fluctuations