Module of Industrial Engineering ONLINE Course
Modules
- Introduction to Industrial Engineering
- Contribution of Taylor, Gilbreth, Emerson, Maynard, Barnes, Shigeo Shingo
- Productivity Science
- Productivity Engineering -
- IE Economic Analysis
- IEOR
- IE Statistics - Six Sigma Optimization
- Human Effort Industrial Engineering
- IE Measurements
- Productivity Management
- Applied Industrial Engineering
- Industrial Engineering 4.0
- Industrial Engineering Case Studies
Applied Industrial Engineering - IE in Various Branches of Industrial Engineering
Industrial engineering is primarily an engineering discipline with productivity orientation. It major application is in incremental improvement of processes that give benefit within one year and hence it became closely allied with management in increasing profits, reducing costs and providing the company with the potential to reduce prices and increase profit. Hence Taiichi Ohno said industrial engineering is profit engineering. If a company is not using IE, it is losing an opportunity.
The application of industrial engineering is in processes of all engineering branches. Engineering activities like product design, production, maintenance of machines in factories, and service of consumer items are important engineering activities. In addition material handling and storage also involve engineering. Unfortunately, industrial engineering profession has not given enough attention to makes its presence in various engineering branches visible and systemic. Only limited attempts were done to create textbooks that discuss IE in specific engineering branches.
Industrial Engineering in Chemical Engineering
Industrial Engineering in Civil Engineering
Industrial Engineering in Computer Engineering and Information Technology
Industrial Engineering in Electrical Engineering
Industrial Engineering in Electronics Engineering
Industrial Engineering in Health Care
Information Systems Industrial Engineering - Information Systems Engineering
Industrial Engineering in Textile Engineering
Applied Industrial Engineering in New Technologies
IE in New Technologies - IE with New Technologies
Implementation of Industrial Engineering Principles and Techniques in New Technologies (Engineering Processes) and Business Processes
Lesson 433
Lesson 434
435
Industrial Engineering in Data Center Design and Processes
436
Solar Energy Industrial Engineering.
437
Biotechnology Industrial Engineering
438
Nanotechnology Industrial Engineering
439
Electric Batteries and Productivity Applications. - Productivity and Industrial Engineering (IE) in Battery Manufacturing
441
Productivity Automation Engineering - Automation and Productivity
A Good Example of Applied IE - Improving Processes using New Technologies
Industry 4.0 Technology and Manual Assembly
By Amanda Aljinovic
March 15, 2023
Digital work instructions, cobots, radio frequency identification (RFID), augmented reality (AR) and other Industry 4.0 technologies can help. These technologies are designed to provide cognitive and physical support to people on the assembly line. How can engineers decide when such technologies are a worthwhile investment?
In a case study, industry 4.0 technologies application in a gear-box assembly line was studied.
Seven Industry 4.0 technologies were considered: RFID, digital work instructions, pick-to-light technology, AR, cobots, automated guided vehicles, and ergonomic manipulators.
Four quantitative criteria were used to rank the technologies: total investment cost, worker effort, workspace utilization and cycle time reduction.
RFID is one of the most important technologies for identifying and tracking assemblies in a production system. It provides precise information about the locations or states of goods in real-time and serves as a capstone for the establishment of the IoT within production.
Digital instructions are proven to reduce the assembly time and errors with complex assemblies.
Pick-to-light systems use LEDs on racks or shelves to show assemblers where to pick parts for an assembly and how many to retrieve. The lights guide assemblers through each step in the process. These systems are often connected with warehouse management systems.
AR also offers the possibility of significant improvement in cycle time, error rate, mental strain, worker focus.
Cobots are particularly desirable when people are confronted with heavy loads and repetitive, tedious activities. People can share the same workspace with the cobots, allowing managers to allocate tasks in a more flexible, efficient way.
AGVs can eliminate the need for people to transport parts and assemblies to and from the assembly line.
The ergonomic manipulator is an electronic device developed to improve ergonomics at the fifth assembly workstation. The device reduces the amount of physical effort needed to handle heavy components that must be mounted to the gearbox.
This article is a summary of a research paper co-authored by Aljinovic, Nikola Gjeldum, Ph.D., Boženko Bilic, Ph.D., and Marko Mladineo, Ph.D.
Industrial Engineering 4.0
442
Industrial Engineering 4.0 - IE in the Era of Industry 4.0
443
Industry 4.0 - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)
444
Augmented Reality - Exploration
445
Autonomous Robots - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)
446
Data Analytics Period in Productivity Improvement - Productivity Engineering and Management
447
Cloud Computing - Engineering Economic and Financial Analysis
448
IoT Technology - Exploration - Industrial Engineering Point of View
449
Simulation and Forecasting - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)
Specific Industries and Technologies
456
Productivity and IE in Tire Manufacturing - Applied Industrial Engineering
457
Industrial Engineering in Health Care
458
Productivity Engineering of Tractors and Agriculture - Smart/Intelligent/Autonomous/IoT Tractors
459
Industrial Engineering of Welding Processes
460
Productivity and IE in Printed Circuit Board Manufacturing
461
Die Casting Productivity - Bibliography
462
Productivity Success Story - Coca Cola
463
Productivity and IE in Motor and Generator Manufacturing
464
Productivity and IE in Motor Vehicle Metal Stamping
465
Productivity and IE in Screw, Nut, and Bolt Manufacturing
466
Productivity and IE in Spring Manufacturing
467
Productivity and IE in Iron and Steel Forging
468
Productivity and IE in Automobile Manufacturing
469
Productivity in Machine Shops - Industrial Engineering and Lean Thinking
470
Productivity and IE in Paint, Coating, and Adhesive Manufacturing
471
Productivity and IE in Motorcycle and Scooter Manufacturing
472
Productivity and IE in Pharmaceutical and Medicine Manufacturing
473
Grinding - Productivity Science and Productivity Engineering - Opportunities for 2020 and Beyond
474
Productivity and IE in Dies , Jig, and Fixture Manufacturing
475
Productivity and IE in Apparel Manufacturing
https://nraoiekc.blogspot.com/2014/01/productivity-and-ie-in-apparel.html
476
Productivity and IE in Electronic Assembly Manufacturing
https://nraoiekc.blogspot.com/2014/02/productivity-and-ie-in-electronic.html
477
Productivity and IE in Iron and Steel Pipe and Tube Manufacturing
https://nraoiekc.blogspot.com/2014/02/productivity-and-ie-in-iron-and-steel_9830.html
478
Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Deployed AI use cases such as close loop process control for hydro-erosion, and upskilling 100% of the workforce.
They reduced unit manufacturing cost by 9% and improved OEE by 9%.
479
CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.
CEAT deployed Fourth Industrial Revolution use cases like advanced analytics to optimize cycle times and digitalization of operator’s touchpoints.
The site reduced cycle times by 20%, process scrap by 46%, and energy consumption by 15% .
Overall, this resulted in approximately a 2.5 times increase in export and OEM sales in two years.
480
4. Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
The site deployed 40+ 4IR use cases by operating in garage mode and leveraging IIoT & democratized platform for advanced analytics.
It improved manufacturing cost by 43% while proactively enhancing quality and reducing energy by 41%.
481
5. .Ericsson - Lewisville Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
The use of digital twins led to substantial enhancements: a 25% increase in throughput and a 50% reduction in unplanned downtimes.
482
6. Foxconn - Shenzen Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Shenzhen factory uses computer-controlled autonomous manufacturing in the dark, basically without assembly line workers in the production of electrical equipment components used in smartphones. It is equipped with an automated optimization system for Machine Learning and AI devices, an intelligent self-maintenance system, and an intelligent real-time monitoring system.
The factory’s production efficiency has been increased by 30% and the inventory cycle reduced by 15%.
483
7. GlaxoSmithKline (GSK) Hertfordshire Plant - Industrial Engineering 4.0
The GSK plant has applied advanced technologies throughout its manufacturing operation, using advanced analytics and neural networks. This has improved line speeds at the site by 21%, cut downtime, increased yields, and delivered an OEE (overall Equipment effectiveness) improvement of 10%.
GSK has applied deep-learning image recognition to detect quality defects, and is using artificial intelligence to optimise machine throughput.
By implementing digital twin technologies, it has boosted capacity by 13%, while cycle time monitoring and the use of digital visualisation tools have cut cycle times by 9%.
484
8. Haier - Hefei Plant - Industrial Engineering 4.0 - Industry 4.0 WEF-McKinsey Lighthouse
Haier’s Hefei air conditioner factory applied advanced algorithms, digital twins, knowledge graphs and other cutting-edge technologies in the research and development (R&D), production and testing of household central AC systems, resulting in a 33% increase in energy efficiency, a 58% drop in the defect rate, a 49% increase in labour productivity and a 22% drop in unit manufacturing costs.
485
9. Ingrasys - Taoyuan, Taiwan Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
By deploying AI use cases across order forecasting, warehouse and production scheduling, product design, quality and assembly-testing domains, Foxconn Industrial Internet’s Taiwan factory has achieved a 73% increase in production efficiency, a 97% reduction in product defects, a 21% reduction in lead time and a 39% decrease in unit manufacturing costs.
486
10. Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant
Johnson Xi’an replaced its manual facility with a Fourth Industrial Revolution-enabled new factory in 2019. This facility includes digital twins for technology transfer and material handling, intelligent automation of continued process verification (CPV) and batch execution processes.
This has shortened the product transfer time by 64% during site relocation and has enabled a 60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.
487
11. K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
K-water launched a next-generation AI water treatment plant to reduce production costs, improve responsiveness and reduce human error. It is being scaled across 40+ other sites.
It has helped K-water to reduce its chemical usage by 19%, improve labour efficiency by 42% and reduce power consumption by 10%.
488
12. LONGi Solar - Jiaxing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Jiaxing site implemented more than 30 Fourth Industrial Revolution use cases, using AI and advanced analytics to boost manufacturing operations.
The site achieved a 28% reduction in unit manufacturing costs, a 43% cut in yield loss and an 84% decrease in production lead time within one year, while also lowering energy consumption by 20%.
489
13. Mondelēz - Beijing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Mondelez - Sricity
Mondelēz Beijing implemented 38 Fourth Industrial Revolution use cases, such as an AI-powered dough-making lights-off workshop and gas consumption optimization by machine learning. As a result, Mondelēz Beijing has achieved a 28% net revenue growth and 53% increase in labour productivity while reducing GHG emissions by 24% and food waste by 29%.
490
14. Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Novo Nordisk has invested in digitalization, automation and advanced analytics, building a robust Industrial Internet of Things operating system to be scaled across their manufacturing footprint, increasing equipment efficiency and productivity by 30%.
491
16. Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
The site implemented Fourth Industrial Revolution use cases such as data flow integration, digital twin, machine learning across end-to-end value chain (from R&D to customers).
As a a result, the innovation lead time accelerated by 72%, shutdown days for trial were reduced by 21%, and order horizon from customers improved 14-fold.
The plant leverages 4IR capabilities such as data science, AI and machine learning across end-to-end value chain from R&D to retail customers. Altogether, it has been improving productivity and enabling faster reaction to market needs while growing production capability.
492
17. Quaker Houghton - Industrial Engineering 4.0 - Intelligent Die Casting
493
19. S Schneider Electric - Hyderabad
Over four years, the plant reduced its energy consumption by 59 per cent, improved waste optimisation by 64 per cent, decreased CO2 emissions by 61 per cent, and reduced water consumption by 57 per cent.
To improve energy efficiency and thereby reduce CO2 emissions, the Hyderabad team focused on the highest energy consumers in the plant: air compressors and chillers. An IoT-enabled device, Equaliser 4.0, was installed to regulate the compressors, thereby improving their efficiency. For the chillers, a data-driven energy management system with closed-loop control was fitted to constantly monitor and adjust energy consumption in real-time, optimising energy efficiency.
494
20. T The Coca-Cola Company - Ballina
The site implemented digital, and analytics use cases. As a result, it improved cost by 16% while expanding its SKU portfolio by 30%
495
21. U Unilever - Sonepat
Unilever Sonepat implemented 30+ Fourth Industrial Revolution use cases in its E2E supply chain. Top use cases included boiler and spray dryer process twins, as well as customer data-informed no-touch production planning and inventory optimization.
This improved service by 18%, forecast accuracy by 53%, conversion cost by 40% and Scope 1 carbon footprint by 88%.
496
23. W Western Digital - Bang Pa-In
497
26. Z Zymergen - Emeryville
Biotechnology firm Zymergen brought robotics and artificial intelligence (AI) to bioengineering labs, traditionally highly manual sites.
Innovation rates soared, allowing Zymergen to use bioengineering for products previously were not feasible.
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498
Course End Summary - Part 1 - IEKC IE Online Course - Engineering in Industrial Engineering
499
Course End Summary - Part 2 - IEKC IE Online Course - Support from Non-Engineering Subjects
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1. Additive Manufacturing Productivity
Assembly Design Framework for Additive Manufacturing Based on Axiomatic Design Concept
https://www.xcdsystem.com/iise/abstract/File7673/UploadFinalPaper_2655.pdf
Yosep Oh, University at Buffalo; Sara Behdad, University at Buffalo, SUNY
Abstract:
AM productivity
According to the design for assembly (DFA) concept, design features should be integrated into a few physical parts to reduce design complexity. However, building up a single product can have some negative effects on the AM productivity by increasing buildup time and cost. In this paper, a design framework using the assembly concept is proposed with the aim of letting the AM productivity reach an allowable level. The design framework is developed based on an Axiomatic Design (AD) approach, where AM productivity elements including buildup time, assembly time and the amount of support are considered as non-functional requirements (nFRs). The AM productivity is assessed by the Information Axiom to choose the best design. The proposed design framework can help engineers design and evaluate AM products.
Interesting references cited in the paper
* Thomas, D.S. and Gilbert, S.W., 2014, Costs and Cost Effectiveness of Additive Manufacturing - A Literature Review and Discussion, NIST.
* Oh, Y. and Behdad, S., 2016, Assembly Based Part Design to Improve the Additive Manufacturing
Productivity: Process Time, Cost and Surface Roughness, ASME IDETC, Charlotte, NC, USA.
* Zhang, Y., Bernard, A., Gupta, R.K. and Harik, R., 2014, Evaluating the Design for Additive Manufacturing: A Process Planning Perspective, Procedia CIRP, 21, 144–150.
* Thompson, M.K., 2013, Improving the Requirements Process in Axiomatic Design Theory, CIRP Annals - Manufacturing Technology, 62, 115–118.
2. Biomanufacturing (Biotechnology) Productivity
Productivity in Biomanufacturing
Researchers are examining the possibility of taking advantage of the natural differences in productivity among cells that are used in biomanufacturing. They foster mutations to create genetic variability and then use microchips to analyze the behavior of individual cells, choosing the most prolific for larger-scale production.
https://www.technologyreview.com/s/424695/why-is-biomanufacturing-so-hard/
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3. Productivity and Nanotech
Productive Nanotech Systems
https://www.foresight.org/roadmaps/Nanotech_Roadmap_2007_main.pdf
Related
OSRAM Boosts LED Chip Productivity With Nanotechnology
Aug 27, 2014
https://www.nanowerk.com/nanotechnology-news/newsid=37099.php
4. Electric Batteries and Productivity Applications
Productivity and Industrial Engineering (IE) in Battery Manufacturing
https://nraoiekc.blogspot.com/2014/02/productivity-and-ie-in-battery.html
Nano One Enhances Pilot Productivity and Files a New Patent
Vancouver B.C. Dr. Stephen Campbell, Principal Scientist at Nano One Materials, today announced that Nano One has filed a patent related to yield improvements in its process for the manufacture of lithium metal oxide cathode materials for use in advanced lithium ion batteries.
August 2017
https://nanoone.ca/nano-one-enhances-pilot-productivity-files-new-patent/
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5. IoT and Productivity
McKinsey Global Institute Report
THE INTERNET OF THINGS: MAPPING THE VALUE BEYOND THE HYPE
JUNE 2015
You can donwload the report from the web
(Link)
How the Internet of Things will reshape future production systems
By Vineet Gupta and Rainer Ulrich
September 2017
https://www.mckinsey.com/business-functions/operations/our-insights/how-the-internet-of-things-will-reshape-future-production-systems
6. New Technology and Equipment for Productivity
PONSSE INTRODUCES NEW TECHNOLOGY FOR PRODUCTIVITY AND ERGONOMICS
Virtual reality (VR) training simulator.
http://www.ponsse.com/fr/media-archive/nouvelles/ponsse-introduces-new-technology-for-productivity-and-ergonomics
How Does Technology Affect Productivity?
Apr 9, 2014
AIM's March 2014 Business Confidence Survey asked two questions.
1. "Has technology allowed your company to produce more goods or provide more services than a decade ago with the same or fewer employees?
2. Can you quantify the economic effect?"
62 percent of the employers who responded said "yes" to the first question.
Among them only some could quantify the benefits. The gains reported in productivity were in the 10-25 percent range. At the limits, one manufacturer doubled output without adding workers, and a non-profit service provider more than tripled productivity.
Regarding profit improvement, some manufacturers remarked that productivity improvements did not strengthen their bottom lines due to downward pressure on prices. Some companies in services industries cited offsetting costs from new regulations.
https://blog.aimnet.org/AIM-IssueConnect/bid/103010/How-Does-Technology-Affect-Productivity
Trend 5: Technology enables greater productivity in infrastructure industry
https://home.kpmg.com/xx/en/home/insights/2017/01/trend-5-technology-increases-productivity-risk.html
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7. Productivity in Hotels
New JW Marriott hotel rides on technology for productivity
25 March 2017
The 634-room luxury hotel has "taken the initiative to implement new technologies and processes to improve the efficiency of its operations, as well as the overall guest experience" One of the systems is the (hotel's) use of the Knowledge Touch rostering system to better manage and allocate manpower during peak periods by analysing business volume and needs. the hotel has also adopted Radio Frequency Identification (RFID) technology to track and replace worn-out items such as linen in hotel rooms and has freed up valuable manpower for more productive uses .
http://www.asiahoreca.com/news/1164711/new-jw-marriott-hotel-rides-on-technology-for-productivity
JW Marriott Resort Saves $100K with Push-to-Talk Tech
12/09/2010
https://hospitalitytech.com/jw-marriott-resort-saves-100k-push-talk-tech
8. Industrial Engineering with New Materials
Engineering Materials for Cost Reduction
https://www.imetllc.com/engineering-materials-for-cost-reduction/
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9. Smart Manufacturing for Electronics Products
https://www.plm.automation.siemens.com/media/global/it/Siemens-PLM-Smart-manufacturing-for-electronics-wp_tcm56-57766.pdf
10. Inspection in the age of smart manufacturing
Tom Austin-Morgan, 05 November 2018
http://www.eurekamagazine.co.uk/design-engineering-features/technology/inspection-in-the-age-of-smart-manufacturing/192747/
Related
Smart Inspection Systems: Techniques and Applications of Intelligent Vision
Duc T. Pham, R J Alcock
Elsevier, 09-Dec-2002 - Technology & Engineering - 240 pages
https://books.google.co.in/books?id=i7EMwG0Cqk4C
Ud. 16..5.2024, 10.4.2023, 24.5.2022, 5.5.2022, 22.4.2022, 9.3.2022
Pub 30.5.2021
ReplyDeleteIndustrial Engineering in Chemical Engineering
Lesson 426 of Industrial Engineering ONLINE Course - Applied Industrial Engineering Module
https://nraoiekc.blogspot.com/2012/01/industrial-engineering-in-chemical.html
Very happy to present the last module of the IE Online Course. Applied Industrial Engineering Module of Industrial Engineering Online Course Notes.
ReplyDeleteUbiquity of Industrial Engineering Principle - Industrial Engineering is applicable to all branches of engineering.
Last year, I could not provide all the modules.
#IndustrialEngineering #productivity #CostReduction
https://nraoiekc.blogspot.com/2021/05/applied-industrial-engineering.html
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