Industrial Engineering Knowledge Center: Introduction to Process Industrial Engineering Module

The objective of process industrial engineering is value addition to the organization through cost reduction by productivity engineering. Week after week, measurable value addition can be done by industrial engineers through creative redesign based on new technical developments, special IE studies of processes and operations, involvement all employees of the organization, and through the consulting inputs.

Models for Value Addition by Industrial Engineering Departments

Value Creation Model for Industrial Engineering - Productivity Engineering

India - Value Creation Model for Industrial Engineering Through Productivity Engineering

Introduction to Process Industrial Engineering

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https://www.youtube.com/watch?v=yIpkLPpsA18
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Processes produce, operate, and maintain engineering products and equipment. Process plan is a term to describe the steps followed in the process with specified equipment in various operations. Selection of the equipment is a part of process planning procedure in connection with producing a specific product or service.

Process industrial engineering continuously improves processes or more specifically process plan to increase their productivity. It is engineering effort to increase productivity and reduce cost first and then human effort engineering task to design the activity of the operators in handling machine controls, tools and materials.

Process industrial engineering is based on productivity of science of processes concerned. Industrial engineers require basic knowledge of the engineering involved in the process. They need to know the principles involved process planning of the technology involved.

Industrial Engineering Process Study for Process Improvement

Process study includes number of studies of various aspects of process, operations involved in the process and elements of operations. Number of industrial engineering measurements are done in the study.

Industrial Engineering Process study for Process Productivity Improvement.

https://www.academia.edu/104924486/Process_study_Method_study FREE DOWNLOAD

The standard recording devices used in industrial engineering for process improvement are process charts. The first one is the operation process chart that shows value adding material transformation and inspection that follows it till the part or the assembly is completed. Each step of the operation process chart requires detailed data gathering and analysis. The second chart is flow process chart that shows in addition transportation, temporary delays and storage associated with the process. These two process charts show or highlight description of the process for investigation by the industrial engineering team. Associated with these charts, are additional details including the product design drawings and process plans. A process is composed of operations. Each operation needs to analyzed at its element level. "Operation analysis" is the name given to this task and Maynard and Stegemerten described this task in detail in a book. For each operation, they recommended an operation analysis sheet.

Process industrial engineering module will be the biggest module in this course. It will contain productivity science of turning developed by Taylor over a period 26 years. The important discoveries made by Taylor and the detailed discussion presented by him will be covered first. Industrial engineers have to continue research in various processes following this model. Even though research for productivity improvement is taking place, it is not getting consolidated at the present in a proper manner. This gap was identified in principles of industrial engineering (2017). Industrial engineering researchers have to take this research activity with more focus and create a visible and accessible knowledge base to make industrial engineering more effective.

It will be a followed by number of essays related to recent developments in metal cutting theory to develop the basic engineering knowledge in machining processes. Number of elements will be identified that have an effect on productivity. In the course, number of case studies are already offered and will be offered to illustrate how productivity improvement is being achieved in various companies by redesigning some or other engineering element.

Principles of process planning in metal cutting will be the next topic. This will give us an understanding how the process plan is developed at the synthetic phase. Developing process plan based on the given part drawing is synthesis of the process plan.

Operation process chart will be discussed next. As part of operation process plan, operation analysis and machine work study will be covered in detail.

The three operations or activities covered in flow process chart are taken up next. Toyota production system (TPS) came into existence with a fresh attack on these activities and then did improvement of value adding operation and inspection to become the highest productivity enterprise of the world. Shigeo Shingo presented the industrial engineering profession with a great book that explains the TPS in industrial engineering terms. This book is a must read for industrial engineers of the current day. Lean is the brand name given to the description of TPS by MIT research team. TPS It is basically focused on reducing inventory that occurs because of temporary delays, setup cost, fear of defectives in a batch, transportation and safety stocks. It developed solutions that minimize the root causes of inventories and in the process developed least waste production system.

Value Analysis Techniques - Utility in Process Industrial Engineering

Miles provided 13 ideas as value analysis techniques.

Avoid generalities
Get all available costs
Use information from the best source
Blast create and refine
Use real creativity
Identify and overcome roadblocks
Use industry experts to extend specialized knowledge
Get a dollar sign on key tolerances
Utilize vendors’ available functional products
Utilize and pay for vendors’ skills and knowledge
Utilize specialty processes
Utilize applicable standards
Use the criterion, “would I spend my money this way?”

From above list, given by Miles in value engineering many apply to process industrial engineering also. We will cover them in the related notes.

It is important once again to highlight that to do process and operation improvements, open mind is needed, not empty mind. Industrial engineers and other managers and executives have to bring with them substantial engineering knowledge and have the knowledge resources to tap further to do effective process improvement.

Industrial Engineering Process study for Process Productivity Improvement.

https://www.academia.edu/104924486/Process_study_Method_study

Knowledge Required for Process Industrial Engineering Application and Practice

https://nraoiekc.blogspot.com/2022/10/knowledge-required-for-process.html

An attempt is made in the follow collections to present note and present some news related to various operations in processes.

News - Information for Value-Adding Operation Analysis

News - Information for Inspection Operation Analysis

News - Information for Material Handling and Transport Operation Analysis

News - Information for Analysis of Delays in Processes