Thursday, March 30, 2023

Software Engineering - Industrial Engineering in Software Engineering


Is the full capability of the #hardware exploited for value creation? An industrial engineer can evaluate periodically.  Software engineering component of industrial engineering.
#IndustrialEngineering #Productivity #CostReduction #InformationSystems  #SoftwareEngineering
https://nraoiekc.blogspot.com/2020/07/industrial-engineering-in-data-center.html



An industrial engineering approach to software development
D.N. Card, R.A. Berg
Abstract
Many different tools and techniques have been developed to increase software quality and productivity. However, periodic acquisition of improved methods and tools, by itself, does not ensure continual improvement. To be effective, new technology must be integrated into an underlying process. That process must be managed explicitly. This paper describes an industrial engineering approach that treats software development as a process distinct from its unique application to any specific project. Its essential elements include formal process definition, software measurement, process engineering, and quality control. Although already successfully embedded in many manufacturing processes, application of industrial engineering techniques to software remains a novelty. Nevertheless, this approach provides the software enterprise with a long-term plan for improving software quality and productivity.
Journal of Systems and Software
Volume 10, Issue 3, October 1989, Pages 159-168



SWE Industrial Engineering - Software Engineering Process Improvement Function


This guide was written to help organizations establish and sustain a process improvement group as the
focal point of a software engineering process improvement program.

The guide is  concerned with the technology used in existing and improved processes and the human side of stimulating a higher quality process. 

The term technology is used throughout this guide in the broadest sense. For example, this use of the term would include software inspection as a peer review technology for detecting errors in software development work products; computer-aided software engineering (CASE) as a technology providing automated support for performing activities and creating work products in the software development process; and change management as a technology for planning and implementing organizational change.

How do organizations move from their current state to one where there is continuous improvement? First, they must establish an organizational commitment to quality; next, they must create an entity in the organization that is the focal point, some group responsible for facilitating actions supporting that commitment; and finally, they must carefully plan each step to move from the current situation to the desired one. In the software industry, the organizational focal point is a software engineering process group, and the model for the step-by-step change is the process improvement cycle. 


The Process Improvement Cycle
Software process improvement is a continuous cycle. 

1. Set expectations based on capabilities of new technologies and benchmarking.
2. Assess the current practice inside the organization.
3. Analyze the variance between expectation and practice.
4. Develop and Propose changes that will reduce the variance and thereby improve the process.
5. Plan the integration of the improvements into the existing process and update the process definition. If a formal process definition does not exist, it should be documented now.
6. Implement the improvements.
7. Perform the process as it is now defined.
8. Start over.

The Process Group - Industrial Engineering Group

The software engineering process group is the focal point for process improvement. Composed of line practitioners who have varied skills, the group is at the center of the collaborative effort of everyone in the organization who is involved with software engineering process improvement. Group size is usually equal to 1-3% of the development staff.


Following are ongoing activities of the process group:

• Obtains and maintains the support of all levels of management.
• Facilitates software process assessments.
• Works with line managers whose projects are affected by changes in software engineering practice, providing a broad perspective of the improvement effort and helping them set expectations.
• Maintains collaborative working relationships with software engineers, especially to obtain, plan for, and install new practices and technologies.
• Arranges for any training or continuing education related to process improvements.
• Tracks, monitors, and reports on the status of particular improvement efforts.
• Facilitates the creation and maintenance of process definitions, in collaboration with managers and engineering staff.
• Maintains a process database.
• Provides process consultation to development projects and management.

The process group is not part of product development but is staffed by practitioners. As a result, it has expertise in software engineering.

An improved process also allows easier acquisition and adoption of new technology because that technology can be acquired in direct support of defined processes. The process definition necessary to a disciplined software process is also prerequisite to reasoned analysis about what software tools and methods best support the goals and the creation of products and systems within the organization.

Improvement Activity Plan Implementation Steps
1. Overview
 •Goals and objectives
 •Related policies
 •Needs analysis
2. Technology description
3. Enabling technology
 description
4. Sources for technology
 and related services
5. Purchases
6. Tailoring
7. Education and training
8. Technology selection
 procedure
9. Evaluation procedures
10. Schedule and responsibilities



A process that is not well understood and articulated cannot be managed or improved. Just as manufacturers must select activities and tools for a particular product line, software organizations must also define and implement appropriate processes for each major development effort. Software, by its nature, is very easy to change. Because software practitioners are well-educated professionals who readily take independent action, a well articulated and understood process is essential to the orderly and predictable operation of a software development organization.

A well-defined and articulated description is prerequisite to process improvement. As Card and Berg [Card89] state, "periodic acquisition of improved methods and tools, by itself, does not ensure continual improvement. To be effective, technology must be integrated into an underlying process. That integration must be managed explicitly." Increases in quality and productivity, along with the successful use of technology, depend directly on a well articulated and well-understood process.


Card and Berg [Card89]: An industrial engineering approach to software development
D.N. Card, R.A. Berg,  Journal of Systems and Software, Volume 10, Issue 3, October 1989, Pages 159-168  https://www.sciencedirect.com/science/article/abs/pii/0164121289900290



Describing the Existing Process
Building a process definition for an organization begins with describing what exists. Eventually, the definition of what should exist is also created, and replaces the initial description.

Recommended reading for those beginning the task of describing or defining software process:
[Humphrey89], Ch. 13, "Defining the Software Process."

Any of a number of different methods may be used; one of the simplest, ETVX [Radice85], is described below. Another straightforward method with tool support is described in [Kellner89]. Whatever the method, describing the existing process should result in documentation of how software products are actually developed and maintained in a given organization.

4.1.1. Documenting the Process: One Approach

One very accessible approach to writing a process description is presented in [Radice85]. Radice considers a process to be made up of software activities, which must be defined. A defined activity is one which has:
(1) a list of entry criteria that should be satisfied before beginning the tasks, (2) a set of task descriptions that indicate what is to be accomplished, (3) a validation procedure to verify the quality of the work items produced by the tasks, and (4) a checklist of exit criteria that should be satisfied before the activity is viewed as complete. (p. 83)

Radice calls this the E (Entry Criteria) T (Tasks) V (Validations) X (Exit Criteria) process architecture. Using ETVX to describe each phase of software activity should result in a consistent description of software development processes. Gaps—missing activities or a missing E, T, V, or X for an activity—that appear in the process description indicate where immediate process improvement may be needed. For example, the exit criteria for module design may not have been defined or may not match the entry criteria for the next activity. On the most abstract level, process definition is simply the determination of what stages and activities will be used by a given software organization. 

[Radice85] lists the following phases for a commercial product:

• Requirements and planning
• Product-level design
• Component-level design
• Module-level design
• Code
• Unit test
• Functional verification test
• Product verification test
• System verification test
• Package and release
• Early support program
• General availability
E, T, V, and X must be defined for each activity.

 Types of Measurement

In general, there are two types of measures: product and process. Product measures describe the characteristics of each system component being produced or maintained. Typical product measures are size, cost, complexity, quality (number of defects), and resources consumed to develop or maintain the component. Process measures describe aspects of the process used to produce or maintain those components, and are attributable to the human processes that create the product. Typical process measures are defect rates, repair rates, and production rates. Broader measures such as labor turnover, learning curve, communications overhead, and degree of overall adherence to the defined process also relate to process. In fact, a single measure may apply to both process and product, depending upon its usage and one’s point of view. Both types of measures may be collected on individual components or across groups of components; when product measures are aggregated, they often provide information about the process.


Defect Prevention
Several process information files are needed to support the defect prevention process. 
• The defect file contains a record of each defect and information such as originator, description, resolution, disposition, and effort to repair.
• The action item file contains the action items that arise out of a causal analysis of the defects. These items are suggestions for improving the process so that future defects would not be manifest in the software product.

 The process group should capture the history of the improvement efforts. The group should collect, catalog, and maintain reports and other artifacts related to attempts to improve the process. In many organizations, these products are lost when personnel change, and the improvement lessons must be learned all over again. Records should include: an indication of what went well and what did not go well; a description of how problems were handled; and suggestions for improving performance on similar tasks in the future. Capturing and reviewing lessons learned can be a part of the development life
cycle. The challenge is to make this information available to those who need it, past the life of a project.

Beginning Continuous Improvement
The process of introducing an improvement includes selecting a candidate technology, tailoring the technology and the training for its use, and using the technology on a pilot basis. Feedback should be collected and the full implementation plan is developed  in light of the pilot experience.

One key long-term activity is the installation, over and over again, of new procedures and technology that support process improvement. These installations should begin with a pilot (prototype) installation—a controlled experiment. Pilots are essential when an organization has no experience with a technology, or when the technology will be applied in a new domain or with inexperienced staff. This is true even if the technology seems to be mature, as with software inspections, or even if the organization has excellent in-house resources, such as a technical working group with some experience in cost estimation. If a technology is new to an organization, it cannot be considered mature in that context. Appendix D presents an extended discussion of this phenomenon. This chapter describes some considerations for executing a pilot effort.

Process Consultation
The process group spends a significant proportion of its time coaching others and problem solving, based on the examples of best practices developed in other organizations. This consulting and broad awareness of the quality of particular efforts is indispensable for the success of the overall process improvement program.

As the focal point for process improvements, the process group spends a significant proportion of its resources meeting with those whom it serves. The group’s consulting activities include:

• Helping to set realistic expectations for improvement activity results.
• Tailoring process priorities, definitions, standards, training, and other process
materials.
• Suggesting methods for improving a specific process if a working group has not
already done so.
• Analyzing process measurement data.
• Facilitating improvement planning meetings and activities.
• Demonstrating improvement technology. (For example, serving as a moderator
for inspections until a project can develop its own inspection moderators.)
• Referring groups with similar interests to each other so that they can help each
other.
Process group members must have or develop good consulting skills; they need the ability
to listen and clarify, and to collaborate in problem solving with those who seek their help. If
process group members have access to training or expert advice (especially in the form of
"shadow" consulting) in this area, they should take advantage of it.

Process Group Membership
Process group members should collectively have experience from throughout the software life cycle.

Members of the process group are advocates for improvement. They are software professionals assigned, generally full time, to help the organization increase the maturity of its
software process. Members should be carefully selected with the goal of balancing the experience and educational background of the group as a whole.

Selecting the Process Group Leader

The process group leader must be an acknowledged technical leader,
with these characteristics:
• Extensive experience in or knowledge of the software process.
• Experience advocating improved software development processes, methods,
and tools—that is, improved quality and productivity.
• Experience in management or project leadership.
• Knowledge of the software development environment

Robert L. Grady and Deborah L. Caswell, Software Metrics: Establishing a Company-Wide Program, Prentice-Hall, 1987.
• H. J. Harrington, The Improvement Process: How America’s Leading Companies Improve Quality, McGraw-Hill, 1987.
• Watts Humphrey, Managing the Software Process, Addison-Wesley, 1989.
• Rosabeth Moss Kanter, The Change Masters: Innovation for Productivity in the
American Corporation, Simon and Schuster, 1983.

• Marvin Weisbord, Productive Workplaces: Organizing and Managing for Dignity, Meaning, and Community, Jossey-Bass, 1987.


Process Management Approach - Card
The process management approach includes three essential activities: process definition,
process control, and process improvement. An undefined process cannot be controlled. An
uncontrolled process cannot be improved consistently. Because improvement means
change, attempting to improve an unstable process often leads to further instability. Figure
B-3 shows how these elements are connected by the common threads of performance data
and corrective action.

The process definition activity provides a prescription for performing work. Measuring the
initial process performance establishes a baseline against which subsequent performance
can be compared. The process control activity is concerned with identifying and correcting
special causes of poor quality, to keep the process performing as intended. That is, it seeks
to maintain key quality parameters within pre-defined control limits. The process improvement activity seeks to identify and rectify common causes of poor quality by making basic
changes in the underlying process.



Software Design Improvement

Until recently, hardware designers left many important product quality considerations to be handled by manufacturing engineers. Because software does not go through a corresponding manufacturing phase, the software engineer must deal with those producibility concerns directly [Card90]. That is, the software system must be designed to be easy to implement and maintain. This is in addition to satisfying the customer’s functional requirements.

 Process Design Improvement
Once the process has been defined and controlled, management can turn its attention to improving the underlying process. This can be done by simplifying the process and by inserting appropriate new technology. [Turner78] suggests five questions that should be asked about each process element:
1. Is this activity necessary or can it be eliminated?
2. Can this activity be combined with another or others?
3. Is this the proper sequence of activities?
4. Can this activity be improved?
5. Is the proper person doing this activity?
Initial process improvement efforts should be concentrated at leverage points: those activities that require the most effort and produce the most problems (see, for example, Pareto
analysis in [Grady87]). Improvement actions should be evaluated in situ by studying their
effect on actual process performance.

An Introduction to Technological Change
This topic  addresses the fundamentals of implementing technological change in software organizations. The process group can greatly improve its odds for success if it understands and acquires some skills in managing the technological and organizational change attendant to process improvement.

 It is an introduction to the basic knowledge that is prerequisite to effective and predictable technological change in the context of software engineering. 


Technology Mapping

Mapping is a simple but powerful way to determine whether a technology is likely to succeed in an organization. The mapping process essentially involves: 1) examining the technology to be implemented for aspects of context that have been built into it and 2) comparing ("mapping") the results of this examination to the results of the organizational context analysis. If there is minimal overlap, the risk is high that implementing the technology will be complex and unpredictable and will require more resources, especially in pilot efforts. If there is a significant overlap, the chances of success are greater. The comparison should take into account the fact that some aspects of context may carry more weight than others. Context analysis is a useful step to take just prior to beginning a search for a technology. It
can help narrow the candidate field by noting major aspects of context, such as application domain, technical compatibility, and budget, which would seriously constrain possible matches. Once the list is pared down to a half dozen or so technologies, mapping is a major step in the final selection process.

Mapping  is necessary because all software engineering technologies are based on a set of assumptions. Certain application domains or classes of application domains—for example, real-time embedded, MIS, scientific—may be assumed when a technology is developed. Certain types of users—for example, ordinary citizen, engineer, scientist, bank teller—may also be assumed. Certain technical requirements—machine type and size, operating system, network type—are usually stated. The easiest technologies to eliminate from a candidate list are those with the least overlap with the organization’s context; as the list shrinks, the mapping process requires more detective work and attention to subtleties such as software engineering terminology, life-cycle phase coverage and definition, and style of work in groups. Even a technology that is well targeted to a particular market niche cannot take all variations of an organization in that niche into account. The best test of a new technology is a series of pilot uses, thoroughly evaluated.

When an organization is dealing with newer and softer technologies, mapping becomes critical. If transfer mechanisms are people-based, they are heavily influenced by frame of reference and by the skills of the people who must translate between frames of reference in the
transfer process.

Boundary Spanners
Boundary spanners are people who are comfortable in multiple frames of reference; they
can work effectively as members of a business organization, with management and engineers, and on professional society committees. Examining the process of communicating in
different languages provides a useful analogy to the services boundary spanners perform.
Because the mapping process is similar to translation between languages, it is best done by
boundary sponsors who are the equivalent of multi-lingual. If these people have extensive
experience in translation, they will know when to proceed cautiously; they will understand
the need, for example, to define carefully terms that most people will assume are well understood.
Boundary spanners are common outside organizations in the technology advocate roles described in Figure D-3. These boundary spanners play an important role in getting new products from research into the marketplace, in articulating the new technology in universities and professional communities, in marketing the technology once it becomes a product, and in supporting new users.

 In their role, boundary spanners typically serve on technical working groups or as members of the process group "porting" technology experience from one organizational group to another; they
connect the inside of the organization to the outside world. They track technology directly
[Carlyle88]; they may also track it by serving on outside working groups such as the IEEE
Computer Society standards committees. Having largely internalized context analysis
results for their own organization, they effectively scan for and select candidate
20 technologies. People who perform this role best have had experience in a number of
contexts; criteria for boundary spanners are much the same as for members of process
group


See search results of SEI software process improvement

Software Development Processes
https://opendsa-server.cs.vt.edu/ODSA/StandaloneModules/20221129151902/html/IntroProcess.html


Software Engineering

The Top 10 Blog Posts of 2022 - CMU Software Engineering Institute
https://insights.sei.cmu.edu/blog/the-top-10-blog-posts-of-2022/


SWE Body of Knowledge

https://sceweb.sce.uhcl.edu/helm/SWEBOK_IEEE/data/swebok_chapter_01.pdf

https://sceweb.sce.uhcl.edu/helm/SWEBOK_IEEE/data/swebok_chapter_02.pdf





 

Ud. 30.3.2023
Pub. 29.7.2020











Industrial Engineering in Computer Engineering and Information Technology


Ubiquity of Industrial Engineering Principle - Industrial Engineering is applicable to all branches of engineering.


High Velocity SAS Coding: Application of IE to software Development
http://www.wuss.org/proceedings08/08WUSS%20Proceedings/papers/app/app09.pdf


Is the full capability of the #hardware exploited for value creation? An industrial engineer can evaluate periodically.  #Software engineering component of industrial engineering.



Industrial engineering of software
www.dtic.mil/dticasd/sbir/sbir011/AF94-2.doc
Optimization and Performance of Computer
________________________
_________________________

_________________________ 
_________________________

Productivity of Programmers


__________________________
Safety and Health of Computer Operators and Users
Computer Vision Syndrome (CVS) - Causes and Suggestions for Prevention
___________________________

Kaizen - Software Development and Products


Kaizen and Software Engineering
http://blog.eweibel.net/?p=489
by Patrick Weibel, Software Architect

___________________________

Value Engineering - Software



Competing on Speed in Software Development - Video Lecture by Mary Poppendieck
Ideas to reduce complexity and increase speed of development are given in the lecture

Engineering Economics Related to Software Development and Products


Software Engineering Economics, 1983, Barry Boehm
http://csse.usc.edu/csse/TECHRPTS/1984/usccse84-500/usccse84-500.pdf

Software Engineering Economics and Best Practices of Internetbased Software Development
http://www.mitre.org/news/events/tech04/briefings/1477.pdf

Embedded system engineering economics
http://www.ece.cmu.edu/~ece649/lectures/13_product_economics.pdf


___________________________

Saturday, March 25, 2023

Industrial Engineer’s Digest: Improving Factory Performance - 2021 Book

 


https://www.onlineclothingstudy.com/2021/05/industrial-engineers-digest-learn.html





This book is written in 5 parts

Part-I: Industrial engineering basics

Part-II: Data capturing, calculations, and reports

Part-III: How-to guides

Part-IV: Improve factory performance

Part-V: Advanced reading

The print version of this book “Industrial Engineer’s Digest: Learn, Practice and Improve Factory Performance” is now available on the Amazon store. You can purchase the book in your country-specific Amazon store.

Amazon.in

Amazon.com 

Amazon.co.uk 

Amazon.ca 

Amazon.de

Amazon.com.au




To be a successful IE.

First, you need to learn the manufacturing process, then learn the industrial engineering concepts - learn IE tools, methods of improving various processes and activities. 

Next thing you need to apply your learning in the process where applicable. 




Updated 25.3.2023

Pub. 12.5.2021


Thursday, March 23, 2023

Industrial Engineering in Agricultural Engineering

 


What is Agricultural Engineering?


Agricultural engineering, also known as agricultural and biosystems engineering, is the field of study and application of engineering science and designs principles for agriculture purposes, combining the various disciplines of mechanical, civil, electrical, food science, environmental, software, and chemical engineering to improve the efficiency of farms and agribusiness enterprises[1] as well as to ensure sustainability of natural and renewable resources.[2]


An agricultural engineer is an engineer with an agriculture background. Agricultural engineers make the engineering designs and plans in an agricultural project, usually in partnership with an agriculturist who is more proficient in farming and agricultural science.

https://en.wikipedia.org/wiki/Agricultural_engineering


What Agricultural Engineers Do
Agricultural engineers solve problems concerning power supplies, machine efficiency, the use of structures and facilities, pollution and environmental issues, and the storage and processing of agricultural products.
https://www.bls.gov/ooh/architecture-and-engineering/agricultural-engineers.htm

Agricultural engineers solve problems related to agricultural equipment, water quality and water management, biological products, livestock facilities, food processing, and many other agricultural areas.

Graduates in this  program are employed for the purpose of

designing and managing food production systems
protecting surface and ground water quality
designing natural resource management systems
developing and managing bioprocessing systems
designing off-road vehicles and agricultural equipment
designing animal production facilities and environmental control systems.
https://www.abe.iastate.edu/undergraduate-students/careers/agricultural-engineering-careers/


Industrial Engineering in Agricultural Engineering.

Product Industrial Engineering

Facilities Industrial Engineering

Process Industrial Engineering

Tuesday, March 21, 2023

Industrial Engineering Philosophy - Delaney

 





Industrial  Engineering is essentially a philosophy with a materialistic and a human  aspect.

 The materialistic aspect  is  based on the conception that business of enterprise can only succeed  if it renders a real service. To serve people, then, industry must make  products that people can buy. The only way a service or product can  get wide distribution is by making its cost low. The main obstacle to  low cost is waste — waste of time, of material, of energy.


If methods of tasks are not evaluated for the time taken, some or many tasks may use  the  complicated and time consuming elements.  The basic aim of the Industrial Engineer is that of saving time. Eor  this, he uses the strictly objective approach compounded of two elements  which are ANALYSIS and MEASUREMENT respectively.  They bring imagination, discovery and ingenuity down to rational terms.

 Through ANALYSIS of tasks, a vast lot of isolated and apparently unrelated pieces of information and phenomena are uncovered within the task as well across tasks. These are  brought together, sorted out and compared. Theories are evolved regarding elements common across tasks and  further observations are made until some practical solution that takes less time is found.  Typical of the analytical phase are the several techniques of method  study ranging from the flow process chart to the micro-motion study.  Here, analysis is used to eliminate waste of time and effort. The job  is simplified: back-tracking is avoided, unnecessary handling is eliminated, short cuts are taken, the design is changed to save material.


 Using MEASUREMENT  procedures are evaluated  in terms of time and cost. Time study is industry's tool for measuring the productive capacity of its human and mechanical resources. It is the  measurement of work and one of its end result is a number which expresses  the time that should normally be taken to complete a given task. Time  study is concerned with the question: "How long should it take ?" along with  "How long does it take ?" That is a vastly different matter which  calls for skill, judgment and careful training. Not only the time taken  has to be recorded accurately but the effect of working pace on that  time has to be appreciated. This is called "performance rating".  


We might say that through his techniques, the Industrial Engineer  creates time.  In the present instance, the "fait accompli" is the  steady increase in the productivity per individual and per unit of resource in industry.  where. It is safe to say, on the basis of all available data, that production per average individual is increasing at the rate of about 3 percent  per  year. It is what makes possible the shorter hours and higher wages.

 Where will it lead us, no one can foresee or dares to foretell. Yet, an  article published in "Business Week" June 1952, is quite revealing.  It deals with the astounding results and implications of farm mechanization. In the span of a generation, over two million men have been  dropped from farm employment and, yet with almost no increase in  tilled acreage, our (North America's) farm output has increased by 40%  and our output per worker by 60%. Since 1920, the output per man  hour has doubled.



The Industrial Engineer, His Philosophy and the Scope of His Activities

Walter Delaney

Relations Industrielles / Industrial Relations, Vol. 9, No. 2 (MARCH 1954), pp. 149-155 (7 pages)

https://www.jstor.org/stable/23066854


DELANEY, Walter, B.A., Waste  and Humidity Controller,  Dominion  Textile Company Lim










Industrial Engineering is Engineering Plus Productivity - Industrial Engineering Philosophy


INDUSTRIAL ENGINEERING PHILOSOPHY


I would like to state the philosophy of industrial engineering as engineering systems can be redesigned or improved and installed periodically for productivity increase or improvement. The primary drivers of productivity improvement are developments in basic engineering disciplines and developments in industrial engineering (developments in productivity science, productivity engineering and productivity management). The additional drivers are developments in related disciplines, for example, economics, mathematics, statistics, optimization techniques, ergonomics, psychology and sociology etc. - Narayana Rao, 1 April 2021.


Industrial Engineering - History

https://nraoiekc.blogspot.com/2013/10/industrial-engineering-history.html


How many Industrial Engineers can a Company Employ for Cost Reduction?

For $100 million cost, there can be one MS IE and 6 BSIEs.

https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html





Industrial Engineering is Engineering Plus Productivity Philosophy - Science - Engineering - Management


Product Industrial Engineering = Product Design Engineering + Product Productivity Philosophy - Science - Engineering - Management


Process Industrial Engineering = Process Design Engineering + Process Productivity Philosophy - Science - Engineering - Management


Facilities Industrial Engineering = Facilities Design Engineering + Facilities Productivity Philosophy - Science - Engineering - Management

Human Effort Industrial Engineering = Mechanic Arts + Human Effort  Productivity Philosophy - Science - Engineering - Management



Productivity Philosophy - Science - Engineering - Management in engineering formally started as important activities in the first annual convention of ASME.  May be we can look for call for productivity and cost reduction of engineered products in some earlier engineering writings also. But the ASME presidential lecture (1880) is a formal call for the engineering community and it was answered with a solutions provided by various members of  the ASME in subsequent years.

The concern for management and productivity issues  occupied the attention of the first ASME  president. Thus ASME's attention to the topic is there right from its founding . In fact, R.H. Thurston  the first ASME president, in his inaugural address (1880), included productivity improvement  and  economy among the objects of the society in his inaugural address. 

"We are now called upon to do our part in the work so well begun by our predecessors, and so splendidly carried on by our older colleagues during the past generation. We have for our work the cheapening and improvement of all textile fabrics, the perfecting of metallurgical processes, the introduction of the electric light, the increase of facilities for rapid and cheap transportation, the invention of new and more efficient forms of steam and gas engines, of means for relieving woman from drudgery, and for shortening the hours of labor for hard-working men, the increase in the productive power of all mechanical devices, aiding in the great task of recording and disseminating useful knowledge; and ours is the duty to discover facts and to deduce laws bearing upon every application of mechanical science and art in field, workshop, school, or household."  - Thuston. R. H. Thurston. President's inaugural address. Transactions ASME, 1, 1880, pp. 14-29.




Industrial engineering department was advocated by F.W. Taylor as a department that improves engineering elements based on experiments and science that was motivated by shop operations experience to increase productivity and reduce costs. He termed the department as "elementary rate fixing department."

The productivity concept as developed by Taylor, Gilbreth, and Miles has multiple dimensions and attributes.  Important of them are quality and human comfort, safety and health.

Industrial engineering Principles, Methods Tools and Techniques
http://nraoiekc.blogspot.com/2012/03/industrial-engineering-principles.html

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications
http://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html

Industrial Engineering 4.0 - IE in the Era of Industry 4.0 - Blog Book
http://nraoiekc.blogspot.com/2017/12/industrial-engineering-40-ie-in-era-of.html


This is the 2000th Post of this blog.

Ud. 21.3.2023, 2.1.2022, 25.6.2022
Pub 25.1.2020

Industrial Engineering Philosophy

 INDUSTRIAL ENGINEERING PHILOSOPHY


I would like to state the philosophy of industrial engineering as "engineering systems can be redesigned or improved and installed periodically for productivity increase or improvement." The primary drivers of productivity improvement are developments in basic engineering disciplines and developments in industrial engineering (developments in productivity science, productivity engineering and productivity management). The additional drivers are developments in related disciplines, for example, economics, mathematics, statistics, optimization techniques, ergonomics, psychology and sociology etc. - Narayana Rao, 1 April 2021.

Engineering developments are continuously monitored by IEs for their productivity effect and productivity engineering is developed appropriately. Thus engineering and industrial engineering grow together and help the society in becoming resource efficient.


(C) Narayana Rao K.V.S.S.



The Industrial Engineer, His Philosophy and the Scope of His Activities
Walter Delaney
Relations Industrielles / Industrial Relations, Vol. 9, No. 2 (MARCH 1954), pp. 149-155 (7 pages)
https://www.jstor.org/stable/23066854

DELANEY, Walter, B.A., Waste  and Humidity Controller,  Dominion  Textile Company Lim

Important points of the above paper.
Industrial Engineering Philosophy - Delaney



At the core of Taylor’s philosophy was a belief that any job could be studied, and that best practices could be learned and taught. If one man could make three pairs of shoes in a day and another only two, why? 

Taylor said that managers could learn from a skilled craftsman and encapsulate for others. In Taylor’s words, management, planning and control of work  had “… laws as exact and clearly defined … as the fundamental principles of engineering …”

Taylor was intently focused on “maximum prosperity,” for business as well as workers which he called “THE principle object of management.” Maximum prosperity meant both lower costs for businesses and higher wages for laborers. And the recipe for achieving both was the elimination of inefficiencies through development of productivity science or waste elimination.



The development of science related to productivity improvement, and modifying engineering and management systems to utilize productivity science in engineering activities and organizations are the major activities of industrial engineers. We can say productivity science, productivity engineering and productivity management are the major components of industrial engineering. - Narayana Rao.
Principles of Industrial Engineering, Proceedings of the 2017 Industrial and Systems Engineering Conference, K. Coperich, E. Cudney, H. Nembhard, eds., pp. 890-895.


Updated on 21.3.2023, 6 July 2022,  8 April 2021,  25.6.2022
First posted on 2 April 2021


Industrial Engineering - History

https://nraoiekc.blogspot.com/2013/10/industrial-engineering-history.html


How many Industrial Engineers can a Company Employ for Cost Reduction?

For $100 million cost, there can be one MS IE and 6 BSIEs.

https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html


Do it. It is Real Engineering. Industrial Engineering is Engineering Primarily.
Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use for industrial engineering. 
Best Practices in #IndustrialEngineering 



















Sunday, March 19, 2023

Introduction to the Principles of Teaching - Edward L. Thorndike - 1906

I am writing about teaching and learning in Industrial Engineering blog as Industrial engineers have to train operators in new methods. They have to provide knowledge or information also about the new method to the operators and develop positive attitudes and feelings in them regarding the new methods. Basic principles of teaching and learning are applicable to training process also.


 The Aims of Education.—Education as a whole should make human beings wish each other well, should increase the sum of human energy and happiness and decrease the sum of discomfort of the human beings that are or will be, and should foster the higher, impersonal pleasures. These aims of education in general—good will to men, useful and happy lives, and noble enjoyment —are the ultimate aims of school education in particular. 

Its proximate aims are to give boys and girls health in body and mind, information about the world of nature and men, worthy interests in knowledge and action, a multitude of habits of thought, feeling and behavior and ideals of efficiency, honor, duty, love and service. The special proximate aims of the first six years of school life are commonly taken to be to give physical training and protection against disease; knowledge of the simple facts of nature and human life; the ability to gain knowledge and pleasure through reading and to express ideas and feelings through spoken and written language, music and other arts; interests in the concrete life of the world; habits of intelligent curiosity, purposive thinking, modesty, obedience, honesty, helpfulness, affection, courage and justice; and the ideals proper to childhood. 

The special proximate aims of school life from twelve to eighteen are commonly taken to be physical health and skill; knowledge of the simpler general laws of nature and human life and of the opinions of the wisest and best; more effective use of the expressive arts; interests in the arts and sciences, and in human life both as directly experienced and as portrayed in literature; powers of self-control, accuracy, steadiness and logical thought, technical and executive abilities, cooperation and leadership; habits of self-restraint, honor, courage, justice, sympathy and reverence; and the ideals proper to youth.


The schools must prepare for efficiency in the serious business of life as well as for the refined enjoyment of its leisure.


The Special Problem of the Teacher.— It is the problem of the higher authorities of the schools to decide what the schools shall try to achieve and to arrange plans for school work which will attain the desired ends. Having decided what changes are to be made they entrust to the teachers the work of making them. The special problem of the teacher is to make these changes as economically and as surely as is possible under the conditions of school life. His is the task of giving certain information, forming certain habits, increasing certain powers, arousing certain interests and inspiring certain ideals. 

The principles of teaching may mean the general principles applicable to the formation of all habits or the highly specialized rules of procedure for forming the habit of correct use of shall and will; they include the laws valid for the acquisition of any knowledge and the discussion of the particular difficulties in teaching the spelling of to, two and too. But the problem is always fundamentally the same:— Given these children to be changed and this change to be made, how shall I proceed? Given this material for education and this aim of education, what means and methods shall I use?


The sciences of biology, especially human physiology and hygiene, give the laws of changes in bodily nature. The science of psychology gives the laws of changes in intellect and character.



Elements of Psychology by E.L. Thorndike  1905

https://archive.org/details/elementspsychol01goog


Principles of Teaching - Thorndike 1906

https://archive.org/details/in.ernet.dli.2015.157121



















Friday, March 17, 2023

Industrial Engineering - Frederick Taylor's Productivity System for Rapidly Attaining The Maximum Productivity.

 


Industrial Engineering - Frederick Taylor's Productivity System for Rapidly Attaining The Maximum Productivity. 

Part 1 - Advantages.

Part 2 - Faults in the Current Piece Rate Systems.

Part 3 - Establishment of Methods Improvement & Rate Fixing Industrial Engineering Department.

Part 4 - The Law for Proper Cutting Speed for Machines

Part 5 - Importance of The Scientific Rate-fixing Department.

Part 6 - Improvement of Machine Elements.






Frederick Taylor's Productivity System for Rapidly Attaining The Maximum Productivity - Part 1

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system.html


Frederick Taylor's Productivity System - 2 - 1895 - Part 2 - Faults in the Current Piece Rate Systems

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system_22.html


Frederick Taylor's Productivity System - 3- 1895 - Part 3 - Establishment of Methods Improvement & Rate Fixing Industrial Engineering Department

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system_24.html

 

Frederick Taylor's Productivity System - 4 - 1895 - Part 4 - The Law for Proper Cutting Speed

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system_21.html


Frederick Taylor's Productivity System - 5 - 1895 - Part 5 - Importance of The Scientific Rate-fixing Department

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system_68.html


Frederick Taylor's Productivity System - 6 - 1895 - Part 6 - Improvement of Machine Elements

https://nraoiekc.blogspot.com/2018/07/frederick-taylors-piece-rate-system_79.html

Frederick Taylor's Piece Rate System for Rapidly Attaining The Maximum Productivity - Part 1


Frederick Taylor's Productivity System for Rapidly Attaining The Maximum Productivity - Part 1


The advantages of this system of management (Taylor's Piece Rate System) are :

The manufactures are produced cheaper under it.
The system is rapid  in attaining the maximum productivity of each machine and man




TAYLOR, F. W., "A Piece-Rate System, Being a Step Toward Partial Solution of the Labor Problem,"
Transactions of the American Society of Mechanical Engineers 16, 856-903, 1895

A PIECE-RATE SYSTEM: BEING A STEP TOWARD PARTIAL SOLUTION OF THE LABOR PROBLEM.

BY FRED W. TAYLOR.

The ordinary piece-work system involves a permanent antagonism between employers and men, and a certainty of punishment for each workman who reaches a high rate of efficiency. The demoralizing effect of this system is most serious. Under it, even the best workmen are forced continually to act the part of hypocrites, to hold their own in the struggle against the encroachments of their employers.

The system introduced by the writer, however, is directly the opposite, both in theory and in its results. It makes each workman’s interests the same as that of his employer, pays a premium for high efficiency, and soon convinces each man that it is for his permanent advantage to turn out each day the best quality and maximum quantity of work.

The writer has endeavored in the following pages to describe the system of management introduced by him in the works of the Midvale Steel Company, of Philadelphia, which has been employed by them during the past ten years with the most satisfactory results.

The system consists of three principal elements :

( i ) An elementary rate-fixing department.

( 2 ) The differential rate system of piece-work.

( 3 ) What he believes to be the best method of managing men who work by the day.




Elementary rate-fixing differs from other methods of making piece-work prices in that a careful study is made of the time required to do each of the many elementary operations into which the manufacturing of an establishment may be analyzed or divided. These elementary operations are then classified, recorded, and indexed, and when a piece-work price is wanted for work the job is first divided into its elementary operations, the time required to do each elementary operation is found from the records, and the total time for the job is summed up from these data. While this method seems complicated at the first glance, it is, in fact, far simpler and more effective than the old method of recording the time required to do whole jobs of work, and then, after looking over the records of similar jobs, guessing at the time required for any new piece of work.

The differential rate system of piece-work consists, briefly, in offering two different rates for the same job, a high price per piece in case the work is finished in the shortest possible time and in perfect condition, and a low price if it takes a longer time to do the job, or if there are any imperfections in the work. (The high rate should be such that the workman can earn more per day than is usually paid in similar establishments.) This is directly the opposite of the ordinary plan of piece-work in which the wages of the workmen are reduced when they increase their productivity.

The system by which the writer proposes managing the men who are on day-work consists in paying men and not positions. Each man’s wages, as far as possible, are fixed according to the skill and energy with which he performs his work, and not according to the position which he fills. Every endeavor is made to stimulate each man’s personal ambition. This involves keeping systematic and careful records of the performance of each man, as to his punctuality, attendance, integrity, rapidity, skill, and accuracy, and a readjustment from time to time of the wages paid him, in accordance with this record.

The advantages of this system of management are :

First. That the manufactures are produced cheaper under it, while at the same time the workmen earn
higher wages than are usually paid.

Second . Since the rate-fixing is done from accurate knowledge instead of more or less by guess-work, the motive for holding back on work, or “ soldiering ”, and endeavoring to deceive the employers as to the time required to do work, is entirely removed, and with it the greatest cause for hard feelings and war between the management and the men.

Third. Since the basis from which piece-work as well as day rates are fixed is that of exact observation, instead of being founded upon accident or deception, as is too frequently the case under ordinary systems, the men are treated with greater uniformity and justice, and respond by doing more and better work.

Fourth, It is for the common interest of both the management and the men to cooperate in every way, so as to turn out each day the maximum quantity and best quality of work.

Fifth. The system is rapid, while other systems are slow, in attaining the maximum productivity of each machine and man ; and when this maximum is once reached, it is automatically maintained by the differential rate.

Sixth. It automatically selects and attracts the best men for each class of work, and it develops many first-class men who would otherwise remain slow or inaccurate, while at the same time it discourages and sifts out men who are incurably lazy or inferior.

Finally. One of the chief advantages derived from the above effects of the system is, that it promotes a most friendly feeling between the men and their employers, and so renders labor unions and strikes unnecessary.

There has never been a strike under the differential rate system of piece-work, although it has been in operation for the past ten years in the steel business, which has been during this period more subject to strikes and labor troubles than almost any other industry. In describing the above system of management the writer has been obliged to refer to other piece-work methods, and to indicate briefly what he believes to be their shortcomings.


1. Capital demands fully twice the return for money placed in manufacturing enterprises that it does for real estate or transportation ventures. And this probably represents the difference in the risk between these classes of investments.

2. Among the risks of a manufacturing business, by far the greatest is that of bad management ; and of the three managing departments, the commercial, the financiering, and the productive, the latter, in most cases, receives the least attention from those that have invested their money in the business, and contains the greatest elements of risk. This risk arises not so much from the evident mismanagement, which plainly discloses itself through occasional strikes and similar troubles, as from the daily more insidious and fatal failure on the part of the superintendents to secure anything even approaching the maximum work from their men and machines.

3. It is not unusual for the manager of a manufacturing business to go most minutely into every detail of the buying and selling and financiering, and arrange every element of these branches in the most systematic manner and according to principles that have been carefully planned to insure the business against almost any contingency which may' arise, while the manufacturing is turned over to a superintendent or foreman, with little or no restrictions as to the principles and methods which
he is to pursue, either in the management of his men or the care of the company’s plant.

4. Such managers belong distinctly to the old school of manufacturers ; and among them are to be found, in spite of their lack of system, many of the best and most successful men of the country. They believe in men, not in methods, in the management of their shops ; and what they would call system in the office and sales departments, would be called red tape by them in the factory. Through their keen insight and knowledge of character they are able to select and train good superintendents, who in turn secure good workmen; and frequently the business prospers under this system (or rather, lack of system) for a term of years.

5. The modem manufacturer, however, seeks not only to secure the best superintendents and workmen, but to surround each department of his manufacture with the most carefully woven network of system and method, which should render the business, for a considerable period at least, independent of the loss of any one man, and frequently of any combination of men.

6. It is the lack of this system and method which, in the judgment of the writer, constitutes the greatest risk in manufacturing; placing, as it frequently does, the success of the business at the hazard of the health or whims of a few employees.

7. Even after fully realizing the importance of adopting the best possible system and methods of management for securing a proper return from employees and as an insurance against strikes and the carelessness and laziness of men, there are difficulties in the problem of selecting methods of management which shall be adequate to the purpose, and yet be free from red tape, and inexpensive.

8. The literature on the subject is meagre, especially that which comes from men of practical experience and observation. And the problem is usually solved, after but little investigation, by the adoption of the system with which the managers are most familiar, or by taking a system which has worked well in similar lines of manufacture.

9. Now, among the methods of management in common use there is certainly a great choice ; and before describing the “differential rate” system it is desirable to briefly consider the more important of the other methods.

10. The simplest of all systems is the “day-work” plan, in which the employees are divided into certain classes, and a standard rate of wages is paid to each class of men ; the laborers all receiving one rate of pay, the machinists all another rate, and the engineers all another, etc. The men are paid according to the position which they fill, and not according to their individual character, energy, skill, and reliability.

11. The effect of this system is distinctly demoralizing and levelling; even the ambitious men soon conclude that since there is no profit to them in working hard, the best thing for them to do is to work just as little as they can and still keep their position. And under these conditions the invariable tendency is to drag them all down even below the level of the medium.

12. The proper and legitimate answer to this herding of men together into classes, regardless of personal character and performance, is the formation of the labor union, and the strike, either to increase the rate of pay and improve conditions of employment, or to resist the lowering of wages and other encroachments by the part of employers.

13. The necessity for the labor union, however, disappears when men are paid, and not positions ; that is, when the employers take pains to study the character and performance of each of their employees and pay them accordingly, when accurate records are kept of each man’s attendance, punctuality, the amount and quality of work done by him, and his attitude towards his employers and fellow-workmen.

As soon as the men recognize that they have free scope for the exercise of their proper ambition, that as they work harder and better their wages are from time to time increased, and that they are given a better class of work to do— when they recognize this, the best of them have no use for the labor union.

14. Every manufacturer must from necessity employ a certain amount of day-labor which cannot come under the piece-work system ; and yet how few employers are willing to go to the trouble and expense of the slight organization necessary to handle their men in this way ? How few of them realize that, by the employment of an extra clerk and foreman, and a simple system of labor returns, to record the performance and readjust the wages of their men so as to stimulate their personal ambition, the output of a gang of twenty or thirty men can be readily doubled in many cases, and at a comparatively slight increase of wages per capita!

15. The clerk in the factory is the particular horror of the old-style manufacturer. He realizes the expense each time that he looks at him, and fails to see any adequate return ; yet by the plan here described the clerk becomes one of the most valuable agents of the company.


Part 2. Frederick Taylor's Productivity System - 2 - 1895 - Part 2 - Faults in the Current Piece Rate Systems



Go to  Part 1 -  Part 2   -  Part 3 -  Part 4 - Part 5 - Part 6


Updated 17.3. 2023, 6 November 2021,   7 December 2018, 8 November 2018, 21 July 2018

Wednesday, March 15, 2023

February - Industrial Engineering Knowledge Revision Plan







A New Initiative started in May 2019



February 1st Week  1 to 5


The Nature of Organizing - Review Notes
Departmentation in Organizations - Review Notes



Line-Staff Authority and Decentralization - Review Notes
Effective Organizing and Organizational Culture - Review Notes



Summary - Principles - Organizing
Human Resource Management and Selection




Performance Appraisal and Career Strategy
Manager and Organization Development



Summary - Principles - Staffing
Resourcing; A Function of Management


Feb 2nd week  8 to 12



Human Factors and Motivation
Leadership - Koontz and O'Donnell - Review Notes






Supervision - Introduction - Public Administration Point of View
Committes and Group Decision Making - Review Notes




Communication - Koontz and O'Donnell - Review Notes
Summary of Principles - Directing - Leading



The System and Process of Controlling - Review Notes
Control Techniques and Information Technology




Productivity Control
Overall Control and Preventive Control - Review Notes

Feb 3rd Week  15 to 19



Summary - Principles of Controlling
Global and Comparative Management



Organizing - Global Management Issues - Review Notes
Staffing - Global Management Issues



Leading - Global Management Challenges
Controlling - Global Management Challenges - Review Notes



Management and Entrepreneurship: Science, Theory and Practice
Managerial Skills



Principles of Management - List
Principles of Management - Subject Update Articles Recent Years


February 4th Week 22 to 26


Marketing Management Revision Articles


The Marketing Concept Kotler
Marketing Strategy - Marketing Process - Kotler's Description



Scanning of Environment for Marketing Ideas and Decisions
Marketing Strategy - Differentiating and Positioning the Market Offering



Management of Marketing Department and Function
Marketing Research and Market Demand Forecasting


Consumer Behavior
Analysis of Consumer Markets


Organizational Buying Processes and Buying Behavior
Market Segmentation and Selection of Target Segments



One Year Industrial Engineering Knowledge Revision Plan


January - February - March - April - May - June

July - August - September - October - November - December


Birthdays

1 - John Little (1928)
2
3 - Stephen Ross (1944), Raghuram Rajan (1963)
4
5 - James Tobin (1918)
6
7
8 - Joseph Schumpeter (1883)
9
10
11 - Thomas Edison (1847)
12 -  Russell Ackoff (1919), John J. Donovan (1942)
13
14 - Sakichi Toyoda (1867),  Eugene F. Fama (1939)
15
16 - Stephen R. Barley (1953)
17
18
19
20
21 - Kenichi Ohmae (1943)
22
23
24
25
26
27 - Irving Fisher (1867)
28 - Carl Barth (1860)
29 - Taiichi Ohno (1912)


Updated 15.3.2023,  3 February 2018
16 February 2016

.

Tuesday, March 14, 2023

Production Industrial Engineering - Six Sigma Case Studies in Machining Processes


Six sigma method attempts to reduce defects and improve the process output parameters while achieving the lowest variance. In the direction of defect reduction, six sigma study helps in moving towards zero defects. Six sigma method has to be used by industrial engineers in all process improvement studies using process charts.

Six Sigma Simple Explanation


DMAIC Method

Six sigma method determines the best factor level combination that gives the optimal output with the least variation.

Hence the starting point is the output variable whose measurement or measure is to be optimized and its variability made minimum. The next step is the identification of factors that have an effect on the output variable of interest. The third step is determining the possible levels of each factor that can be employed.

With this as the input information, Taguchi method of experimental design is used to determine number of experiments to be done. The experiments are done and results are statistically analyzed to get the factor level combination that gives the best output variable with the least variance.

Further improvement of the system can be done by engineering modifications that  permit more levels of the factors or introduction some completely new factor that can five better performance of the output variable. Industrial engineers have to look for engineering improvements on a continuous basis. Industrial engineering is primarily engineering improvement.


Six Sigma Case Studies  in Machining Processes



2018

Materials Today: Proceedings
Volume 5, Issue 1, Part 1, 2018, Pages 104-112
Optimization of Process Parameters based on Surface Roughness and Cutting Force in MQL Turning of AISI 4340 using Nano Fluid


The aim of this research work is focused on optimization of process parameters under Minimum Quantity Lubrication (MQL) using nano fluid in turning of AISI 4340. A study of effect of process parameters in turning of AISI 4340  on the cutting force generated and machined surface roughness is carried out. In the experiment conducted, five values of feed rate, three values of depth of cut, two values of cutting speed and tool nose radius respectively, are used. The test pieces were turned on a CNC lathe machine.  

From result analysis, it was found that, feed rate played a major role in producing lower surface roughness followed by depth of cut whereas cutting speed has least significance in producing lower surface roughness.  It was observed that MQL with nano fluid (MWCNT) showed lowest surface roughness as compared to conventional flood system. Thus, with proper selection of process parameters under MQL mode with nano coolant, it is possible to achieve good surface roughness, reduce tool wear while maintaining the cutting forces and temperatures at reasonable levels.



Development of Six Sigma methodology for CNC milling - PDF
Mar 30, 2018 - Six sigma implementation during milling process.  Numerical Control (CNC) machine operation. 
by MN Ismail

Development of Six Sigma methodology for CNC milling process improvements
October 2017, IOP Conference Series,  Materials Science and Engineering 257(1):012009
https://www.researchgate.net/publication/320791815_Development_of_Six_Sigma_methodology_for_CNC_milling_process_improvements

Justifying Six Sigma Projects in   Manufacturing Management

Tapan P. Bagchi, Narsee Monjee Institute of Management Studies, Shirpur
NMIMS Review, 2012
The paper gives justification for investing reducing sigma of ball bearing outer race and inner race grinding operation.
http://www.nmims.edu/NMIMSmanagementreview/pdf/april-may-2012/05-justifying-six-sigma-projects.pdf




Six-sigma Project on Coolant/Chip System Improvement – Batch 1
2011
IMTMA organized a formal program focused at “performance of the coolant & swarf management on machine tools” through Six-sigma approach during May/ June 2011.
http://www.imtma.in/index.php?page=6&subid=178

Improvement of a Production Process with The Use of Six Sigma - PDF
Key words: production process, Six sigma, improvement, Critical-to-quality tree, machine tools (saw, milling machine, CNC turning machine, grinding)
by I Veža - ‎2004 


2006
Ready for Six Sigma

To upgrade machining process capability, Prof. Jerard is conducting research on the process capability of machine tools.

 Currently, CNC manufacturers are providing  two indicators of precision: positioning accuracy and repeatability. But what is the standard deviation of a machine tool?  For example, a machine tool with a standard deviation of 0.002 in. can achieve a six sigma quality level  only when the tolerance band of a part is 0.022 in. If the standard deviation doubles to 0.004 in.,  jump from six sigma quality level to 66,800 defects per million (three sigma).

If machine tools have be made with smaller standard deviations,  error sources such as machine axis squareness, encoder inaccuracy, tool and workpiece deflection, thermal expansion, tool runout and tool wear etc. have to be understood and their impact on standard deviation has to be found. Many of these factors change with time, environmental conditions and usage.


http://americanmachinist.com/beyond-cutting-zone/ready-six-sigma


Updated on 14 March 2023,  19 September 2020,  21 September 2019, 6 March 2015