Friday, September 29, 2023

Industrial Engineering Definitions - 1911 to 2020

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Industrial Engineering Definitions



Going (1911)


Industrial engineering directs the efficient conduct of manufacturing, construction, transportation, or even commercial enterprises of any undertaking, indeed in which human labor is directed to accomplishing any kind of work . Industrial engineering has drawn upon mechanical engineering, upon economics, sociology, psychology, philosophy, accountancy, to fuse from these older sciences a distinct body of science of its own . It is the inclusion of the economic and the human elements especially that differentiates industrial engineering from the older established branches of the profession (Going, 1911) [1].

Going is the first person to give a full definition of industrial engineering. Diemer explained IE as the meaning given by F.W. Taylor.

Maynard


“Industrial engineering is the engineering approach applied to all factors, including the human factor, involved in the production and distribution of products or services.” (Maynard, 1953) [2]

Lehrer


“Industrial engineering is the design of situations for the useful coordination of men, materials and machines in order to achieve desired results in an optimum manner. The unique characteristics of Industrial Engineering center about the consideration of the human factor as it is related to the technical aspects of a situation, and the integration of all factors that influence the overall situation.” (Lehrer, 1954) [3]

ASME


Industrial Engineering: The art and science of utilizing and coordinating men, equipment, and materials to attain a desired quantity and quality of output at a specified time and at an optimum cost. This may include gathering, analyzing, and acting upon facts pertaining to building and facilities layouts, personnel organization, operating procedures, methods, processes, schedules, time standards, wage rates, wage payment plans, costs, and systems for controlling the quality and quantity of goods and services. (ASME Standard 'INDUSTRIAL ENGINEERING TERMINOLOGY, 1955.)


AIIE


“Industrial engineering is concerned with the design, improvement, and installation of integrated systems of men, materials, and equipment. It draws upon specialized knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design, to specify, predict, and evaluate the results to be obtained from such systems.” (AIIE, 1955). [4]

Nadler


"Industrial engineering may be defined as the art of utilizing scientific principles, psychological data, and physiological information for designing, improving, and integrating industrial, management, and human operating procedures." (Nadler, 1955) [5]


Lyndal Urwick


“Industrial engineering is that branch of engineering knowledge and practice which

 1. Analyzes, measures, and improves the method of performing the tasks assigned to individuals,
2. Designs and installs better systems of integrating tasks assigned to a group,
3. Specifies, predicts, and evaluates the results obtained.

It does so by applying to materials, equipment and work specialized knowledge and skill in the mathematical and physical sciences and the principles and methods of engineering analysis and design. Since, however, work has to be carried out by people; engineering knowledge needs to be supplemented by knowledge derived from the biological and social sciences.” (Lyndall Urwick, 1963) [6]

ASME - Maynard


Maynard reported in his second edition of the IE Handbook,  the Concept developed by the Committee of the Management Division of the American Society of Mechanical Engineers as:

"The art and science of utilizing and coordinating men, equipment, and materials to attain a desired quantity and quality of output at a specified time and at an optimum cost. This may include gathering, analyzing, and acting upon facts pertaining to building and facilities, layouts, personnel organization, operating procedures, methods, processes, schedules, time standards, wage rates, wage payment plans, costs and systems for controlling the quality and quantity of goods and services." (Maynard, 1963) [6b]

AIIE (Revised)


"Industrial engineering is concerned with the design, improvement and installation of integrated systems of people, materials, information, equipment and energy. It draws upon specialized knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design, to specify, predict, and evaluate the results to be obtained from such systems." [7]


 Sawada


"Industrial engineering is an art for creating the most efficient system composed of people, matters, energy, and information, by which a specific goal in industrial, economic, or social activities will be achieved within predetermined probabilities and accuracy. The system may be for a small single work station, a group, a section, a department, an institution or for a whole business enterprise. It may be also be of a regional, national, international, or inter-planetary scope."(Sawada, 1977) [8]

Narayana Rao


“Industrial Engineering is Human Effort Engineering. It is an engineering discipline that deals with the design of human effort in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved.” (Narayana Rao, 2006) [9]


Narayana Rao (2009)


"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved."(Narayana Rao, 2009) [10]

Yamashina


Total Industrial Engineering is  "a system of methods where the performance of labor is maximized by reducing Muri (unnatural operation), Mura (irregular operation) and Muda (non-value added operation), and then separating labor from machinery through the use of sensor techniques."  (Yamashina)
"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering-based management staff-service discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved."(Narayana Rao, 2011) [Added to this knol on 14.9.2011]

Narayana Rao (2017)

Industrial engineering defined as system efficiency engineering has application in all branches of engineering.  Productivity improvement is needed in engineering systems of all branches and therefore industrial engineering needs to be used in all branches of engineering. It needs to be taught in all engineering branches. (Principles of Industrial Engineering, Narayana Rao, K.V.S.S., 2017) [11].

Principles of Industrial Engineering

Very Popular and Well Appreciated Video with 9075+ views. 
IISE Conference presentation (2017) 

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References

1. Going, Charles Buxton, Principles of Industrial Engineering, McGraw-Hill Book Company, New York, 1911, Pages 1,2,3
2. Maynard, H.B., “Industrial Engineering”, Encyclopedia Americana, Americana Corporation, Vol. 15, 1953
3. Lehrer, Robert N., “The Nature of Industrial Engineering,” The Journal of Industrial Engineering, vol.5, No.1, January 1954, Page 4
4. Maynard, H.B.,  Handbook of Industrial Engineering, 2nd Edition,  McGraw Hill, New York, 1963.
5. Nadler, Gerald, Motion and Time Study", McGraw-Hill Book Company, Inc., New York, 1955
6. Urwick, Lyndall, F., “Development of Industrial Engineering”, Chapter 1 in Handbook of Industrial Engineering, H.B. Maynard (Ed.), 2nd Edition, McGraw Hill, New York, 1963.
6b. Maynard H.B., (Editor), Industrial Engineering Handbook,Second Edition, Sec. 1, pp.115, 116, New York, McGraw-Hill Book Co. 1963.  Quoted in Harold E. Smalley and John R. Freeman, Hospital Industrial Engineering, New York, Reinhold Publishing Corporation, 1966, pp.10-11.
8. Sawada, P.N., "A Concept of Industrial Engineering," International Journal of Production Research, Vol 15, No. 6, 1977, Pp. 511-22. 
9. Narayana Rao, K.V.S.S., “Definition of Industrial Engineering: Suggested Modification.” Udyog Pragati, October-December 2006, Pp. 1-4.
10. Narayana Rao K.V.S.S.,   Industrial Engineering
11. Principles of Industrial Engineering.  2017 IISE Annual Conference Proceedings; Norcross (2017): 890-895.   https://www.proquest.com/docview/1951119980

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Process - Method - Motion - Machine Effort - Human Effort - Industrial Engineering Terms


Process describes the steps or operations involved producing a part or a product (Operation Process Chart and Flow Process Chart of Parts)

In the process chart, material transformation operations, inspection operations, material handling operations and storage operations take place. To facilitate the operations, we need production planning and communications.

We all know process plans. Process plan is the term used to describe the steps undertaken in material transformation operation to convert raw material into part especially using machine tools. We can extend the idea and say that process is described through process plan, inspection plan, material handling plan, storage plan, production plan (quantity plan) and communications plan.

Also in each operation there is machine effort and human effort. To describe human effort, we use the term motion. We study motions and improve human effort to make it more productive, comfortable and safe.

Method is another popular term. Method is basically the arrangement of  raw material (input), machine, machine controls, cutting tools and hand tools, jigs & fixtures, finished parts disposal channels and bins and man at the work station. The method that is arrangement of the work station as well as the facilities design (if operator has to go fetch some inputs) determines the motions to be made by the operators. The selection of tools etc. also became part of method. But they are basically specified as part of the process. Hence motion study was extended as method study. Method and motion have to be studies together.


IISE Terminology

PROCESS. (1) A planned series of actions or operations (e.g., mechanical, electrical, chemical, inspection, test) which advances a material or procedure from one stage of completion to another. (2) A planned and controlled treatment that subjects materials or procedures to the influence of one or more types of energy (e.g., human, mechanical, electrical, chemical, thermal) for the time required to bring about the desired reactions or results.

PROCESS CHART. A graphic, symbolic representation of the specific steps in a processing activity. (FLOW PROCESS CHART, OPERATION PROCESS CHART, MAN-PROCESS CHART, FLOWCHART, MULTIPLE ACTIVITY PROCESS CHART, OPERATOR PROCESS CHART.)

PROCESS CHART SYMBOLS. Graphical symbols or signs used on process charts to depict the type of events that occur during a process. 

PROCESS DESIGN. The act of prescribing the production process to produce a product as designed. This may include specifying the equipment, tools, fixtures, machines, and the like required: the methods to be used: the personnel necessary; and the estimated or allowed times. 

PROCESS ENGINEER. An individual qualified by education, training, and/or experience to prescribe efficient production processes to safely produce a product as designed and who specializes in this work. This work includes specifying all the equipment, tools, fixtures, human job elements, and the like that are to be used and, often, the estimated cost of producing the product by the prescribed process. 

PROCESSING. The carrying out of a production process. 

PROCESS PLANNING. A procedure for determining the operations or actions necessary to transform material from one state to another.

PROCESS SHEET. A sketch, diagram or listing of the operations in the sequential order necessary to accomplish the desired result (such as transforming material from one state to another).

PROCESS TIME. (1) Time required to complete the machine or process-controlled portion of a work cycle. (2) Time required to complete an entire process.

https://www.iise.org/Details.aspx?id=2598

METHOD. (1) The procedure or sequence of motions by workers and/or machines used to accomplish a given operation or work task. (2) The sequence of operations and/or processes used to produce a given product or accomplish a given job. (3) A specific combination of layout and working conditions; materials, equipment, and tools; and motion patterns involved in accomplishing a given operation or task.

METHODS ANALYSIS. That part of methods engineering normally involving an examination and analysis of an operation or a work cycle broken down into its constituent parts for the purpose of improvement, elimination of unnecessary steps, and/or establishing and recording in detail a proposed method of performance.

METHODS ENGINEERING. That aspect of industrial engineering concerned with the analysis and design of work methods and systems, including technological selection of operations or processes, specification of equipment type and location, design of manual and worker-machine tasks. May include the design of controls to insure proper levels of output, inventory, quality, and cost. (WORK DESIGN)

METHODS STUDY. A systematic examination of existing methods with the purpose of developing new or improved methods, tooling, or procedures.

METHODS TIME MEASUREMENT (MTM). A proprietary predetermined time standards system.

https://www.iise.org/Details.aspx?id=2592

MOTION ANALYSIS. The study of the basic divisions of work involved in the performance of a given operation for the purpose of eliminating all useless motions and arranging the remaining motions in the best sequence for performing the operation. (PRINCIPLES OF MOTION ECONOMY.)

MOTION CYCLE. The complete sequence of motions and activities required to do one unit of work or to perform an operation once. 

MOTION ECONOMY. (PRINCIPLES OF MOTION ECONOMY)

MOTION STUDY. (MOTION ANALYSIS.)
https://www.iise.org/Details.aspx?id=2592

PRINCIPLES OF MOTION ECONOMY. A general listing of common sense steps and procedures to simplify and improve the effectiveness of manual work.
https://www.iise.org/Details.aspx?id=2598


WORK DESIGN. The design of work systems. System components include people, machines, materials, sequence, and the appropriate working facilities. The process technology and the human characteristics are considered. Individual areas of study may include analysis and simplification of manual motion components: design of jigs, fixtures, and tooling; human-machine analysis and design; or the analysis of gang or crew work. (Synonyms: ergonomics, job design, methods engineering, methods study, motion study, operation analysis, work simplification, motion economy.)
https://www.iise.org/Details.aspx?id=2612


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Related Articles  - Industrial Engineering

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Originally posted on Knol (Knol Number 1984)


Updated on 29.9.2023,  18.3.2022, 26 July 2020,  20 May 2020, 18 February 2012





Sunday, September 24, 2023

F.W. Taylor - Biography - Some Important Events and Opinions by Others

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20 March 1856 - Birthday of  F.W. Taylor (Father of Industrial Engineering and Industrial Management)

F.W. Taylor - Biography - Book - Some Important Events and Opinions by Others


FREDERICK V. TAYLOR: FATHER OF SCIENTIFIC MANAGEMENT
BY  FRANK BARKLEY COPLEY
IN TWO VOLUMES
VOLUME I
HARPER AND BROTHERS, PUBLISHERS, NEW YORK AND LONDON, MCMXXIII
COPYRIGHT, 1923, BY HARPER & BROTHERS
THE PLIMPTON PRESS • NORWOOD • MASSACHUSETTS
PRINTED IN THE UNITED STATES OF AMERICA


CONTENTS
VOLUME ONE
BOOK I — ANCESTRY AND BOYHOOD

CHAPTER

I. The Taylor and Winslow Families 23
II. Frederick Taylor's Parents 43
III. The Boy Fred 55
IV. How he did not Become a Lawyer 69
V. He Enters Industry 77
VI. His Call to go on in Industry 86

BOOK II — HIS GENERAL WORK AT MIDVALE

I. The Industrial World in 1878 97
II. Far-Advanced Midvale 106
III. Taylor's Rise at Midvale 116
IV. His Success as a Subordinate 125
V= His Success as a Subordinate (Concluded) 138
VI. His Executive Temperament 148
VII. His Fight with his Men 157
VIII. His Hold upon his Men 165
IX. His Hold upon his Men {Concluded) 178
X. His Work as a Mechanical Engineer 190

BOOK III — DEVELOPING HIS SYSTEM AT MIDVALE

I. The " Systematic Soldiering " he had to Overcome . . . 205
II. First Steps in Applying Science to Management 216
III. Origin and Nature of Time Study 223
IV. Beginning his Metal-Cutting Investigation 237
V. Limit of Metal-Cutting Progress at Midvale 246
VI. From Experimentation to Standardization 253
Vll. Leading Features of his Svstemization 263
VIII. Organization Previous to Taylor 274
IX. Taylor's Functional Organization 284
X. The Functional Principle and the General Manager. . 294
XI. Taylor's Wage Principles and Methods 304
XII. Towards Industrial Democracy 314
XIII. Good-bye to Midvale 332

BOOK IV — THE CONSULTING ENGINEER IN
MANAGEMENT

I. The Genius of Taylor's System 345
II. Analysis and Classification as a Basis for Control 351
III. Accounting made Contributory to Control 363
IV. With Mr. Whitney's Company 372
V. He Starts a New Profession 386
VI. His First Statement of his System 397
VII. The Thorny Path of the Reformer 416
VIII. At Cramp's Shipyards 429
IX. Various Work for Various Clients 445
X. In the Simonds Shop 456





R.L. Barnes, in his book Motion and Time Study, in the chapter 3 History of Motion and Time Study had written that it is generally agreed that Time Study had its beginning in the machine shop of the Midvale Steel Company in 1881 originated by F.W. Taylor. That led me to search the internet for this fact and made me come across some interesting articles about Taylor.

Taylor described his time study experience in Piece Rate Paper.

Frederick Taylor, late in the year of 1874, when he was eighteen, seized upon the chance to learn, in the shop of a small Philadelphia pump-manufacturing company whose proprietors were acquainted with his family, the trades of the pattern-maker and the machinist.

This Philadelphia concern in whose employ Fred Taylor learned his trades was known as the Enterprise Hydraulic Works, and the firm that owned it while he was there was first Ferrell & Jones and then Ferrell & Muckle. The works were situated in Race Street, down near the Schuylkill River.

In 1881, when the Navy's Ordnance Bureau invited fifteen American steel manufacturers to submit proposals for forgings for six-inch all-steel guns, Midvale was the only plant that could undertake the work for it alone had developed a complete system of experimentation and of records.

To Brinley must be awarded the main credit, not only for these triumphs in the technic of steel making, but also for the organization of the working force. By 1882, when he left Midvale, and was succeeded as superintendent by Davenport, he had put practically every operation in the works, down to the handling of coal, upon a piece-work basis.

In speaking of Taylor's work at Midvale, Carl Barth says: " He constantly investigated tools and other small appliances that gave minor trouble or fell short of giving entire satisfaction, and in discovering the cause of their shortcomings, was able to effect highly-desirable improvements. Many of these improvements probably could easily have been made by anyone else who had taken the trouble Taylor did to investigate. The basis of it lay in the fact that it was Taylor's genius to recognize the importance of trifles."

He exerted himself on these trips pretty strenuously also. "As we travelled almost every day," Taylor wrote in 1910, " we were obliged to carry very heavy loads in pack baskets on our backs. My load averaged over eighty pounds, and in some cases was as high as 125 pounds and I many times carried this load more than eight miles per day over the rough trails in the woods." This despite the fact that he " weighed then only 145 pounds."

Taylor is a Great Engineer - Father of Industrial Engineering


The engineering type of man [says J. E. Otterson ] works for the solution of a single technical or engineering problem and is concerned with the determination of the solution rather than the application of that solution to practical activities. The true type has the capacity to concentrate continuously on a single problem until the solution has been reached. He is interested in the determination of cause and effect and of the laws that govern phenomena. He is disposed to be logical, analytical, studious, synthetical and to have an investigating turn of mind. The predominating characteristic that distinguishes him from the executive is his ability to concentrate on one problem to the exclusion of others for a protracted period, to become absorbed in that problem and to free his mind of the cares of other problems. He does not submit readily to the routine performance of a given amount of work. He deals with laws and abstract facts. He works from text books and original sources of information. Such men are Edison, Steinmetz, the Wright Brothers, Curtiss, Bell, Pupine, Fessenden, Browning. These men are the extreme of the engineering type; they have enormous imagination, initiative, constructive powers. [Mr. Taylor was in reality an engineer rather than an executive.] Taylor is also a great engineer. He applied his wonderful inventive genius to many small engineering issues that could reduce the cost of operations and converted the solutions into productivity increasing engineering changes. He applied the same approach to the invention of management methods.

Taylor is Simulatneously a Great Executive - Father of Industrial Management and Productivity Management


Taylor's writings, Piece Rate System, Shop Management and Scientific Managemet are considered as the core of Industrial Management in 1912. There were other authors, who wrote on the same lines as author and or have taken different approach, but the committee on management that reported on the status of industrial management knowledge in 1912, categorically named Taylor as the prime thinker in Industrial Management.

The executive type takes the conclusions of the engineer and the laws developed by the engineer and applies them to the multitude of practical problems that come before him. His chief characteristic is that he works with a multitude of constantly changing problems at one time. He concentrates on one problem after another in rapid succession. In many instances he has not the time to obtain all of the facts and he must arrive at a conclusion or make a decision based upon partial knowledge. He must rapidly assimilate available facts and fill in what is lacking from the ripeness of his own experience, frequently calling on his powers of judgment, and even of intuition. He is a man of action, boldness, ingenuity, force, determination, aggressiveness, courage, decision; he is possessed with the desire to get things done, impatient of delay. He works from a handbook, a newspaper, or nothing at all. Such men are Schwab, Goethals, Pershing, Farrell, Hindenburg, Hoover.

Even to this day many engineers consider their work done when they have designed and built and demonstrated the possibilities of a piece of apparatus. They seem to feel that the efficient operation of it is not in their province. Mr. Taylor felt otherwise. To him, perfection in design was worthless without efficiency in operation, and at an early date he turned his attention to the efficient utilization of human effort.


BOOK III

DEVELOPING HIS SYSTEM AT MIDVALE

http://archive.org/stream/frederickwtaylor01copl/frederickwtaylor01copl_djvu.txt


 Taylor was a man of intellect. His purpose to get output had its roots in his desire to make the most economical use of his shop's facilities. From the start he was a true engineer in that he was a true
economist, with all the economist's hatred of waste and his instinct for conservation.

He himself came to define the problem of the machine shop as that of "removing metal from forgings and castings in the quickest time."  It sounds like the simplest of propositions that herein is involved the whole economy of such a shop.

He found that his master task or problem of getting metal out in the quickest time naturally divided itself into two principal sets of detail problems,  the one having to do with the mechanics of the shop's equipment, and the other with the workers' operation of that equipment.

Right at the outset of his career as an industrial economist he was confronted by the deeply significant fact (which his fellow engineers as a class and industrial folk in general were very slow in getting a grip on) that as there is no machinery so automatic that it does not have to be cared for and have its work supplied to it by human beings, all other industrial problems are swallowed up in the problem of human relations.

Taylor set out accurately to determine on a basis of fact what his men ought to be able to do with their equipment and materials. Based on his successful experience, he prescribed a responsibility for factory management and described as  "gathering ... all the great mass of traditional knowledge which in the past has been in the heads of the workmen and in the physical skill and knack of the workman, and recording it, tabulating it, and, in many cases, finally reducing it to laws, rules, and even to mathematical formulae." This is the responsibility of factory manager. Earlier when the workman worked for himself, he had done it as best as he could. Now that he joins a factory to share in the benefits that factory system will bring to leverage his skill and provide more income, managers have the responsibility to develop science of each task done in the factory. Just like scientists who work on physical problems collect data, managers in their role as management scientists (a role assigned to them by Taylor) have to gather data by studying the tasks being done by workmen. The name given to this by Taylor is "Time Study." Time study gathers all data on tasks done workers and records the time taken for each element of the task. From the data that is collected, the relation between the engineering components of the elements of task and the time taken for completing the elements is developed. This understanding has to be used to reduce the time taken for improving engineering components to increase productivity and reduce cost.

Here, then, aside from his action in clearly defining his  master problem as foreman, was his beginning with the scientific method in connection with management — the beginning which, because it was the logical one and his qualities were what they were, made it inevitable that he should extend the scientific method to all of the elements of management and so bring into existence all of the phenomena of Scientific Management or of that coherent and logical whole destined to become known as the Taylor System.

Taylor's Industrial Engineering - Improvement of Machine Tools and Cutting Tools


Taylor, started in the 1880's, led the work of scientifically studying the speeds at which the machines should be run in the shop, thereby bringing about, as one feature of his work — and it was a feature that deeply wounded the pride of the English — the development of excellence, as by shaping and heat treatment, in metal-cutting tools themselves.

Mention has been made of the fact that Sellers as early as 1876 attempted to have the cutting tools used in his plant issued to the workmen ready ground to shapes and angles adopted as standard after some investigating. This may be taken as illustrating that all along Taylor had contemporaries who approached and grappled with problems of management in a truly scientific spirit. However, it also illustrates that the work of these other men was unsystematic and confined to a single element or only a few of the elements of management so that, as Taylor came to express it, there was "great unevenness or lack of uniformity shown, even in our best run works, in the development of the several elements which together constitute what is called the management."

Taylor was the only one who started at the beginning both in his thinking and in his action  which is to say that he was the only one who, seeing that it is the task of management to bring about the most economical use of labor and equipment entering into production, and seeing also that to fulfill this task the management must determine what the output of the labor aided by the equipment should be, resolutely set out to do this and stuck to it.

This man for two years and a half, I think, spent his entire time in analyzing the motions of the workmen in the machine shop in relation to all the machine work going on in the shop — all the operations, for example, which were performed while putting work into and taking work out from the machines were analyzed and timed. I refer to the details of all such motions as are repeated over and
over again in machine shops. I dare say you gentlemen realize that while the actual work done in the machine shops of this country is infinite in its variety, and that while there are millions and millions of different operations that take place, yet these millions of complicated or composite operations can be analyzed intelligently and readily resolved into a comparatively small number of simple elementary operations, each of which is repeated over and over again in every machine shop. As a sample of these elementary operations which occur in all machine shops, I would cite picking up a bolt and clamp and putting the bolt head into the slot of a machine, then placing a distance piece under the back end of the clamp and tightening down the bolt. Now, this is one of the series of simple operations that take place in every machine shop hundreds of times a day. It is clear that a series of motions such as this can be analyzed, and the best method of making each of these motions can be found out, and then a time ... the exact time which a man should take for each job when he does his work right, without any hurry and yet  does not waste time can be determined and specified. This was the general line of one of the investigations which we started at that time.

Time study was begun in the machine shop of the Midvale Steel Company in 1881, and was used during the next two years sufficiently to prove its success. In 1883, Mr. Emlen Hare Miller was employed to devote his whole time to " time study," and he worked steadily at this job for two years.  He was the first man to make " time study " his profession.

The Midvale Steel Works started the " profession of time study."

Time study "consists of two broad divisions, first, analytical work, and second, constructive work.

The analytical work of time study is as follows:

a. Divide the work of a man performing any job into simple elementary movements.
b. Study the movements and pick out all useless movements and discard them.
c. Study, one after another, just how each of several skilled workmen makes each elementary movement, and with the aid of a stop watch select the quickest and best method of making each elementary movement known in the trade.
d. Describe, record and index each elementary movement, with its proper time, so that it can be quickly found.
e. Study and record the percentage which must be added to the actual working time of a good workman to cover unavoidable delays, interruptions, and minor accidents, etc.
f. Study and record the percentage which must be added to cover the newness of a good workmen to a job, the first few times that he does it. (This percentage is quite large on jobs made up of a large number of different elements composing a long sequence infrequently repeated. This factor grows smaller, however, as the work consists of a smaller number of different elements in a sequence that is more frequently repeated.)
g. Study and record the percentage of time that must be allowed for rest, and the intervals at which the rest must be taken, in order to offset physical fatigue.

The constructive work of time study is as follows:

h. Add together into various groups such combinations of elementary movements as are frequently used in the same sequence in the trade, and record and index these groups so that they can be readily found.
i. From these several records, it is comparatively easy to select the proper series of motions which should be used by a workman in making any particular article, and by summing the times of these movements, and adding proper percentage allowances, to find the proper time for doing almost any class of work.

Important Constructive Work of Engineering


j. The analysis of a piece of work into its elements and the time taken for doing it almost always reveals the fact that many of the working conditions and the machines and tools accompanying the work are defective. For instance, tools being used and the machines used need perfecting. The sanitary conditions may be bad. The knowledge so obtained leads frequently to the constructive work of a high order, to the standardization (improvement) of tools and conditions, to the invention of superior methods and machines.

He established what one of his associates calls the " unalterable rule that all time study for rate setting must be done not merely with the knowledge but with the co-operation of the worker." Productivity improvement has to happen in factories. It is the joint responsibility of managers and workers.

Somewhere along about 1881 it clearly was presented to him that his problem of getting metal cut in the quickest time involved studying both what his men could do (man work study) and what the machines could do (machine work study). Hence his two types of experiments and it is highly probable, by the way, that his machine experiments, or those which constituted a " study of the art of cutting metals," were to a large extent inspired by what he observed while developing " accurate motion and time study of men."

The most important discovery of immediate value that Taylor made in the early stage of his experiments on cutting metals  was that " a heavy stream of water poured directly upon the chip at the
point where it is being removed from the steel forging by the tool would permit an increase in cutting speed, and therefore in the amount of work done, of from thirty to forty per cent."

The discovery of Taylor was used by Midvale in a new shop,  which was opened in 1884. In this new shop, each machine was " set in a wrought iron pan in which was collected the water (supersaturated with carbonate of soda to prevent rusting) which was thrown in a heavy stream upon the tool for the purpose of cooling it. The water from each of these pans was carried through suitable drain pipes beneath the floor to a central well from which it was pumped to an overhead tank from which a system of supply pipes led to each machine." And Taylor added : " Up to that time, so far as the writer knows, the use of water for cooling tools was confined to small cans or tanks from which only a minute stream was allowed to trickle upon the tool and the work, more for the purpose of obtaining a water finish on the work than with the object of cooling the tool and, in fact, these small streams of water are utterly inadequate for the latter purpose."

It interesting to note this comment of Taylor. In spite of the fact that the shops of the Midvale Steel Works until recently [1906] have been open to the public since 1884, no other shop was similarly fitted up [with water supply for the machines] until that of the Bethlehem Steel Company in 1899, with the exception of a small steel works which was an off-shoot in personnel from the Midvale Steel Company.

One of the other great opportunities which the building of the new shop gave him was that of beginning the experiments with belting that, extending over a period of nine years, furnished him with material for a paper which, presented to the A.S.M.E. in 1893, drew from Henry R. Towne, who himself had experimented with belting, this comment: The present paper is modestly entitled " Notes on Belting," but could be more fittingly described as a treatise on the practical use of belts. Its thirty-four pages contain more new and useful information than is found in any other paper that has come to my knowledge.

In his paper On the Art of Cutting Metals (page 32), Taylor listed his variables as follows: "
(a) the quality of the metal which is to be cut
(b) the diameter of the work
(c) the depth of the cut;
(d) the thickness of the shaving;
(e) the elasticity of the work and of the tool;
(f) the shape or contour of the cutting edge of the tool, together with its clearance and lip angles;
(g) the chemical composition of the steel from which the tool is made, and the heat treatment of the tool;
(h) whether a copious stream of water or other cooling medium is used on the tool;
(j) the duration of the cut, i.e., the time which a tool must last under pressure of the shaving without
being reground;
(k) the pressure of the chip or shaving upon the tool;
(1) the changes of speed and feed possible in the lathe;
(m) the pulling and feeding power of the lathe."

Barth, who completed these metal-cutting experiments, has made an improved statement of the variables.

Taylor pursued his metal-cutting investigation long after he left Midvale over a period of a quarter of a century. Not until 1906 did he publish anything about it. However, his high-speed steel, which was one of the by-products of this investigation, was exhibited at the Paris Exposition of 1900.

I am well within the limit, gentlemen, in saying [he testified in 1912] that not one machine in twenty in the average shop in this country is properly speeded.

Our experiments have been of two kinds: first, the reduction of the control and operation of machines from rule of thumb to science, and, second, the examination and standardization of human actions
and work with relation both to maximum efficiency and maximum speed.

Next study all the elements as they effect the speed and output, whether they are connected with the machine alone or with the man and the machine combined; then find the one or more elements which
limit the speed of output; centre on the most important, and correct them one after another. This generally involves a combination of study of the man with the machine and involves in many cases minute time observations with the stop watch.


His time study and his metal-cutting investigation were indeed closely connected and interwoven  having for their common purpose the cutting down of time to the minimum consistent with the doing of good work. In like manner his belting experiments, which were an offshoot of his metal-cutting investigation, had mainly for their purpose the saving of time through the avoidance of delays and interruptions.

Incidentally we can see this purpose as the general cause of the outpouring of his ingenuity in mechanical invention. His great steam-hammer was designed to work faster than any other thing of its kind. He built a new chimney on top of an old one to save " a loss of at least one or two months in
time." And here is the machine-tool table he invented early at Midvale, the table being the part of the machine on which work is place to be operated on. It usually takes much time to set the work on the table and secure it by clamping, and Taylor just could not stand the spectacle of the machine standing
idle while this was being done. So what he invented was a "false" table, or one that was separable from the machine  this, of course, permitting new work to be made entirely or nearly ready on a table while the machine continued busy. Then his study of cutting tools led him to invent a new tool holder further to expedite the work. This, roughly described, enabled a tool to be held in various positions to correspond to various surfaces, and thus made it possible for one tool to take the place of several of different shapes.

He hastened the establishment among tools of a beautiful order. Not only a place for everything and everything in its place, but also everything in proper variety, sufficient quantity, and the pink o£ condition. And with a beautiful economy of storage space and facility of finding just what was wanted.

Another high development Taylor brought about at Midvale was his system of oiling machines. This device for maintaining things in standard condition created no end of amusement among Taylor's fellow officers, and the wonder of it still is talked about. All we can do here is to indicate its general nature.

To begin with, he had a man go over every machine and the moving parts connected with it and chalk every oil hole and every surface that required oiling. Then he had another man cover the same ground to make sure that nothing had escaped the first. This done, he had a high-grade mechanic study the best order in which holes and surfaces should be oiled, and these places then were consecutively numbered by stamping.

For the oil holes he had made two sets of wooden plugs, one set with round heads and the other with square, and each set was numbered to correspond to the numbers of the oil holes. While one set was in the oil holes, the other set was kept in a box bored with holes to correspond to the oil holes. In like manner he had made for the surfaces to be oiled two sets of small hooks, one with round and the other with square tags.

Taylor's Poka-Yoke (much before Shigeo Shingo)


In the morning, the operator of a machine found the oil holes fitted with square-headed plugs, and at the surfaces to be oiled hung the hooks with the square tags. Before starting his machine he was required to replace the " square " objects with the " round " ones, and as he did this to oil the hole or surface and at noon, when another oiling was called for, he was required to replace the " round " plugs and hooks with the " square." The object, of course, was to make him give attention to each and every hole and surface, and do this in the proper order  and at any time it could be seen whether all his " square " or " round " plugs and hooks were in place as might be called for. Incidentally the plugs, which were cylindrical and made a neat fit in the holes, kept dust from getting in and cutting the bearings.

Lists were made out of all the oil holes and surfaces to be oiled, these stating to what parts of the machines the holes conducted the oil, and the kind of oil to be used in each case. Duplicates of these lists were filed in the office and here we can see an early development of the principle of reducing all recurrent procedure to standard practice and recording it. The ordinary way is to leave such procedure entirely to some individual, who in the course of time may work out for it a pretty good method. All of this knowledge, however, he carries in his head so that if he falls ill, the procedure suffers, and if he quits the business, some one else must work it out all over again. Taylor not only required the management to determine right at the start the best method, but by his records he made the business independent of the comings and goings of individuals, and his records served as insurance against mistakes, failures of memory, and human fallibility in general.

 Looking at it from this angle, we see that Taylor assumes the aspect simply of a manager of such thoroughness and force that he leaped from a quarter to a half century ahead of the crowd of managers, and did more than any other one individual to wake management up and blaze a trail for it to follow.

The term general manager indeed implies one having an outlook upon all the steps in the accomplishment of an organization's task.

The shop, and indeed the whole works, should be managed, not by the manager, superintendent, or foreman, but by the planning department. The daily routine of running the entire works should be carried on by the various functional elements of this department, so that, in theory at least, the works could run smoothly even if the manager, superintendent and their assistants outside the planning room were all to be away for a month at a time.

Proper extra pay for the extra effort called for by a scientifically set task will induce the worker to make the extra effort continuously.

It undoubtedly was because of this as well as of the high wages he paid that Taylor never again had any trouble with working people after his early experience at Midvale.

Says H. L. Gantt in Industrial Leadership : "The authority to issue an order involves the responsibility to see that it is properly executed. The system of management which we advocate is based on this principle, which eliminates bluff as a feature of management, for a man can only assume the responsibility for doing a thing properly when he not only knows how to do it, but can also teach somebody else to do it." It should not be difficult for anyone to understand why working people, apart from any question of wages, found it a satisfaction to work for men who could show them as well as tell them, and who incidentally assumed the responsibility for the implements and all the conditions upon which the fulfillment of the tasks depended.

There also was the fact that through his development of standard practice for the care of machinery
and belting and his instruction-card and tickler system, he had cut down the repair force of the works about a third.

Three years later, when he became a consulting engineer, he apparently foresaw that unless he had an impartial critic of the efficiency of his methods in the form of a proper cost-keeping system, he would be at a disadvantage in dealing with the opposition that his experience had taught him would be sure to arise wherever he tried to introduce his methods. Thus his approach to the scientific study of accounting was mainly from the particular angle of cost accounting. And to say that when he turned his attention to this subject there was no general recognition of the importance of accurately determining, on a basis of ascertained and recorded fact, the group and unit costs of products is to put it mildly — how mildly will be appreciated when it is pointed out that as late as the year 1921 the Federal Trade Commission reported that about ninety per cent of industrial and commercial firms did not know what their costs were.

Mr. Towne said among other things:
To ensure the best resuhs, the organization of productive labor must be directed and controlled by persons having not only good executive ability, and possessing the practical familiarity of a mechanic or engineer with the goods produced and the processes employed, but having also, and equally, a practical knowledge of how to observe, record, analyze, and compare essential facts in relation to wages, supplies, expense accounts, and all else that enters into or affects the economy of production and the cost of the product.

The fact that Taylor called his paper of 1895 simply A Piece-Rate System, with the cautious subtitle A Step Toward Partial Solution of the Labor Problem, signifies that he  was conscious that his work was only beginning in the development of a comprehensive system. He was also promoting among engineers the need to study in the " labor end" along with machine end.

Taylor said in the address he made in Cleveland just before his death:

I have before me something which has been gathering in for about fourteen years, the time or motion study of the machine shop. It will take probably four or five years more before the first book will be ready to publish on that subject. There is a collection of sixty or seventy thousand elements affecting machine shop work. After a few years — say three, four or five years more — some one will be ready to publish the first book giving the laws of the movements of men in the machine shop — all the laws, not only a few of them. Let me predict, gentlemen, just as sure as the sun shines that is going to come in every trade. Why? Because it pays, and for no other reason. Any device which results in an increased output is bound to come in spite of all opposition; whether we want it or not, it comes automatically.

In Taylor's lifetime these studies resulted in the publication of two books: Concrete Plain and Reinforced (1905), and Concrete Costs (1912).

Related Articles

Taylor's Industrial Engineering in Taylor's Papers

Notes on Belting, Piece Rate System, Shop Management, Art of Metal Cutting, Scientific Management
https://nraoiekc.blogspot.com/2019/06/taylors-industrial-engineering.html

Taylor's Industrial Engineering in New Framework - Narayana Rao

https://nraoiekc.blogspot.com/2019/07/taylors-industrial-engineering-in-new.html

Principles of Scientific Management of F.W. Taylor and Practice Implications
https://www.youtube.com/watch?v=5jru9fo94q4

20th March - Date of Birth:  Frederick Winslow Taylor

Celebrate the birthday by reading his works and reflecting on them.

Updated  24.9.2023, 20 March 2020 - Birthday of Taylor (Taylor Birth Year 1856)

20 March 2017 - Birthday of Taylor (Taylor Birth Year 1856)

First published on 20 June 2015

Saturday, September 23, 2023

Industrial Engineering in Companies and Practice - History

New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  #FREE #Download.

In 0.1% on Academia.edu. 3600+ Downloads so far.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


Companies associated with Taylor

Midvale Steel

Bethleham Steel

Johnson  - Johnstown

https://www.jstor.org/stable/3113574

https://www.jstor.org/stable/3113574 



1912

Finally, on December 6, 1912, at the annual meeting of the American Society of Mechanical Engineers (ASME), in New York City, it was officially labeled industrial engineering as a new field of engineering as an answer to the necessity of a professional group of people dedicated to solving problems related to management and manufacturing (Martin-Vega 1.7).

Martin-Vega, Louis A. "The Purpose and Evolution of Industrial Engineering." Maynard´s Industrial Engineering Handbook. Ed. Kjell B. Zandin. 5th ed. New York. McGraw-Hill, 2004. 1.4-13.

https://www.linkedin.com/pulse/inside-look-industrial-engineering-mary-eugenia-mora/



1920

Navy Yard Administration as a Problem in Industrial Engineering

By Commander James Reed (C. C.), U. S. Navy

April 1920 Proceedings Vol. 46/4/206

https://www.usni.org/magazines/proceedings/1920/april/navy-yard-administration-problem-industrial-engineering

1925

RM. Barnes worked as IE in Gleason Works (1925-26)

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


1945

Boeing started IE department from existing Fac tory Cost Accounting Department

https://www.jstor.org/stable/23785965

Industrial Engineering - History


Industrial engineers (IE) are employed and productivity improvement and cost reduction are practiced in many companies using IE  philosophy, principles, methods, techniques and tools.


New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  #FREE #Download.

In 0.1% on Academia.edu. 3600+ Downloads so far.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0




What is industrial engineering?

__________________



https://www.youtube.com/watch?v=T7mtfiNQBUc
__________________


Was Industrial Engineering Department started by F.W. Taylor - The Father of Industrial Engineering?


Yes. It was started by him in 1885.
Frederick Taylor's Industrial Engineering Department for Process Improvement for Productivity Increase - 1885.



Frederick Taylor established the first department in factory doing industrial engineering work of process improvement for increase in productivity and cost reduction. The name he gave it to the department is "Elementary Rate Fixing."  Its function is to breakdown the process into elements and find the best way of doing each  by observing number of persons doing the same element and finding the best way through time study. The next step is to find science behind the way of doing the elements. Then from the best ways of doing each element, a new process is developed and the operators are trained in it. The final step of rate fixing refers to specifying the time required to do each element and the piece rate for it. The Piece rate of a component is fixed by first developing the detail at element level. The operators are provided the instruction sheet at the element level so that they know the time specified for each element and make effort to do it in that time. Taylor stated that operators are motivated to do well when they know the goal clearly and receive feedback quickly. The elementary rate fixing department has the responsibility to develop productivity science, do productivity engineering and do productivity management.

Based on the statements of Taylor, we can say elementary rate fixing department was established in 1885 by Taylor.


The Call for Cost Reduction by Engineers - ASME President - 1880


The first president of ASME in his presidential address in 1880 exhorted mechanical engineers to understand the relation between elements of engineering design and production and elements of cost accounting that determine the production cost as well as the life cycle cost of engineering items. Even though attention to cost was given by civil engineers earlier, the call by ASME president led to the emergence of a branch/discipline of engineering termed "Industrial Engineering." 

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.




Pennsylvania State College, USA introduced the first industrial engineering major in 1907. Hugo Diemer was the faculty who introduced it. He authored a book in 1911 which he explained the role of industrial engineering. Principles of Industrial Engineering, a book in industrial engineering by Charles B. Going was published in 1911. Charles taught industrial engineering subject in a module on works management organized at Columbia University by Prof. Walter Rautentruanch.

James Gunn is given the credit for using the term "industrial engineer" first in an article in 1901. He wanted a new engineer to emerge "production" or "industrial".  The "industrial" or "production" engineer of Gunn understands the cost accounting and cost analysis in relation to engineering activities. The term industrial engineer appealed to some. Subsequently the course in industrial engineering was also started. Even production engineering emerged as a separate branch that focused much more on the technical function of creating process plans, instructing and training operators. The focus of industrial engineering became productivity, efficiency and cost reduction.

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.


Evolution of Industrial Engineering - James Gunn, Towne, Taylor, Diemer, Going, Barnes


Background for Development of Industrial Engineering


The late-nineteenth-century factory initially was a collection of skilled machinists and mechanical artisans working in a big work areas based on their skills. The management of production activity was basically done a first-line supervisor, the  foreman. He organized materials and labor, directed machine operations, recorded costs, hired and fired employees, and basically the principal production management. The manager or general manager above him looked after external issues related to supplies of goods and services.

In the 1870s and 1880s, critics began to attack the model of the factory wherein each operator worked according his personal methods and mostly worked under a piece rate system. Their critique became the basis for the best-known effort to encourage coordination within the firm during the first half of the twentieth century under production manager. Shop Management theory and practice was proposed by F.W. Taylor.  The changes in management that occurred during period were  known under various labels - systematic management, scientific management, efficiency engineering. As stated above, in 1901, the term "industrial engineering" was proposed and in 1908, it became a course, and a branch of engineering. Shop Management and subsequent books fostered greater sensitivity to the manager’s role in production and led to greater diversity in industrial practice also as managers selectively implemented ideas and techniques.

The attack on traditional factory management originated in two late-nineteenth-century developments. The first was the maturation of the engineering profession,  based on formal education and mutually accepted standards of behavior and formally educated engineers embraced  scientific experimentation and analysis in place of sporadic developments based on experience. The second development  was the rise of systematic management, an effort among engineers and sympathizers to substitute system for the informal methods that had evolved with the factory system.  The factories replaced traditional managers who focused less on production methods with engineers  and managerial systems replaced guesswork and ad hoc evaluations.  By the late 1880s, cost accounting systems, methods for planning and scheduling production and organizing materials, and incentive wage plans were developed. Their objective was an unimpeded flow of materials and information. Systematic management sought to extract the efficiency benefit required to run a factory by developing science for each work element. It also developed planning systems that helped in realizing the organization's goals through work of managers and operators. It promoted decisions based on performance by giving wages based on merit rating and incentives based on quantity of output rather than on personal qualities and relationships.

Contribution of F.W. Taylor


In the 1890s,  Frederick Winslow Taylor, became the most vigorous and successful proponent of systematic management. As an executive in production engineering and management,  he introduced factory accounting (cost accounting) systems and based on those records made engineering changes in systems that gave lower cost of operation and production. Taylor explained his systems through papers and discussions in meetings of American Society of Mechanical Engineers (ASME). The systems and practices developed by Taylor permitted engineers and managers to use operating records to guide their engineering and production management actions. Taylor focused on reducing metal cutting times through various engineering improvements to increase productivity of machines. The improvements include use of cutting fluids, higher power in the machines for increasing feed, development of high speed steel, development of tool life equation and many more improvements. Taylor estimated the time required for taking each cut and reduced the time taken by improvement in cutting speed, feed and depth of cut.

Taylor also advocated production control systems that allowed managers to know more precisely what was happening on the shop floor, piece-rate systems that encouraged workers to follow orders and instructions, and various related measures. Taylor developed time study of elements to measure time taken by machines and men to perform various tasks done by operators. Data collected from multiple machines and multiple operators were used to identify ways of working that gave minimum times. 


Frederick Taylor established the first department in factory doing industrial engineering work of process improvement for increase in productivity and cost reduction in 1885. The name he gave it to the department is "Elementary Rate Fixing."  Its function is to breakdown the process into elements and find the best way of doing each  by observing number of persons doing the same element and finding the best way through time study. The next step is to find science behind the way of doing the elements. Then from the best ways of doing each element, a new process is developed and the operators are trained in it. The final step of rate fixing refers to specifying the time required to do each element and the piece rate for it. The Piece rate of a component is fixed by first developing the detail at element level. The operators are provided the instruction sheet at the element level so that they know the time specified for each element and make effort to do it in that time. Taylor stated that operators are motivated to do well when they know the goal clearly and receive feedback quickly. The elementary rate fixing department has the responsibility to develop productivity science, do productivity engineering and do productivity management.

Based on the statements of Taylor, we can say elementary rate fixing department was established in 1885 by Taylor (https://nraoiekc.blogspot.com/2021/11/frederick-taylors-industrial.html).


In 1895, he employed a colleague, Sanford E. Thompson, to help him determine the optimum time to perform industrial tasks; their goal was to compute, by rigorous study of the worker’s movements and the timing of those movements with stopwatches, standards for skilled occupations that could be published and sold to employers.

Between 1898 and 1901, as a consultant to the Bethlehem Iron Company, Taylor introduced all of his systems and vigorously pursued his research on the operations of metal-cutting tools.  Taylor’s discovery of high-speed steel in 1900, which improved the performance of metal-cutting tools, assured his fame as an inventor. In his effort to introduce systematic methods in many areas of the company’s operations, Taylor developed an integrated view of managerial innovation and a broader conception of the shop/production manager’s role.  In 1901, when he left Bethlehem, Taylor resolved to devote his time and ample fortune to promoting his new conception of industrial management. In the paper, Shop Management ( 1903),  he portrayed an integrated complex of systematic management methods and also productivity improvement of machine shops. 

In the following years,  he began to rely more heavily on anecdotes from his career to emphasize the links between improved management and greater productivity.   Second, Taylor tried to generalize his management principles to more areas of work. Between 1907 and 1909, with the aid of a close associate, Morris L. Cooke, he wrote a sequel to Shop Management that became The Principles of Scientific Management (1911).   Taylor came out with four principles and  relied on colorful stories from his experience and language to illuminate “principles” of management. To suggest the integrated character and broad applicability of scientific management, he equated it to a “complete mental revolution.”

 Taylor had fashioned scientific management from systematic management. The two approaches were intimately related. Systematic and scientific management had common roots, attracted the same kinds of people, and had the same business objectives. Yet in retrospect the differences stand out. Systematic management was diffuse and utilitarian, a series of isolated measures that did not add up to a larger whole or have recognizable implications beyond day-to-day industrial operations. Scientific management added significant detail and a larger view.

The Principles extended the potential of scientific management to nonbusiness endeavors and made Taylor a central figure in the efficiency movement of the 1910s.  To engineers and nonengineers alike, he created order from the diverse prescriptions of a generation of technical writers. By the mid-l910s, he had achieved wide recognition in American engineering circles and had attracted a devoted following in France, Germany, Russia, and Japan. Pennsylvania State College introduced the first industrial engineering major in 1907 and promoted the thinking of Taylor.

Taylor's  insistence that the proper introduction of management methods required the services of an expert intermediary helped in the emergence of  industrial engineering independent consultants and accelerated the rise of a new profession.

Initially, the spread of systematic management occurred largely through the work of independent consultants, a few of whom, such as the accountant J. Newton Gunn, achieved prominence by the end of the nineteenth century. By 1900, Taylor overshadowed the others; by 1910, he had devised a promotional strategy that relied on a close-knit corps of consultants to install his techniques, train the client’s employees, and instill a new outlook and spirit of cooperation. The expert was to ensure that the spirit and mechanism of scientific management went hand in hand. This activity of Taylor produced a number of successful consulting firms and the largest single cluster of professional consultants devoted to industrial management.

Between 1901 and 1915, Taylor’s immediate associates introduced scientific management in nearly two hundred American businesses, 80 percent of which were factories  Some of the plants were large and modern, like the Pullman and Remington Typewriter works.  Approximately one-third of the total were large-volume producers for mass markets. A majority fell into one of two broad categories. First were those whose activities required the movement of large quantities of materials between numerous workstations (textile mills, railroad repair shops, automobile plants). Their managers sought to reduce delays and bottlenecks and increase throughput.

The records available suggest that the consultants provided valuable services to many managers. They typically devoted most of their time to machine operations, tools and materials, production schedules, routing plans, and cost and other record systems. Apart from installing features of systematic management, their most notable activity was to introduce elaborate production-control mechanisms (bulletin boards and graphs, for example) that permitted managers to monitor operations


Between 1910 and 1920, industrial engineering spread rapidly. Large firms introduced staff departments devoted to production planning, time study, and other industrial-engineering activities and consulting firms also developed further. By 1915, the year of Taylor’s death,  professional organization,  the Taylor Society founded in 1910 was active. Western Efficiency Society was founded in 1912.  The Society of Industrial Engineers was founded in 1917. These societies provided forums for the discussion of techniques and the development of personal contacts. Financial success and professional recognition increasingly depended on entrepreneurial and communications skills rather than technical expertise alone. A new generation of practitioners, including many university professors developed successful consulting practices.


Contributions of Gilbreth, Emerson and Bedaux


Competition for clients and recognition, especially after the recession of 1920-21 made executives more cost-conscious-produced other changes. Some industrial engineering consultants began to seek clients outside manufacturing. Spurred by the growing corps of academicians who argued that the principles of factory management applied to all businesses, they reorganized offices, stores, banks, and other service organizations. A Society of Industrial Engineers survey of leading consulting firms in 1925 reported that many confined their work to plant design, accounting systems, machinery, or marketing . A third trend was an increasing preoccupation with labor issues and time study. This emphasis reflected several postwar developments, most notably and ominously the increasing popularity of consultants who devoted their attention to cost cutting through the aggressive use of time study.

By the early 1920s, industrial engineers  had divided into two separate and increasingly antagonistic camps. One  influential group of industrial engineers, centered in the Taylor Society, embraced personnel management and combined it with orthodox industrial engineering to form a revised and updated version of scientific management. A handful of Taylor Society activists, Richard Feiss of Joseph & Feiss, Henry S. Dennison of Dennison Manufacturing, Morris E. Leeds of Leeds & Northrup, and a few others, mostly owner-managers, implemented the new synthesis. They introduced personnel management and more controversial measures such as profit sharing, company unionism, and unemployment insurance that attacked customary distinctions between white- and blue-collar employees and enlisted the latter, however modestly, in the management of the firm.

A larger group emphasized the potential of incentive plans based on time and motion study and disregarded or deemphasized the technical improvement.  Their more limited approach reflected the competition for clients, the trend toward specialization, and the continuing attraction of rate cutting. Indicative of this tendency was the work of two of the most successful consultants of the post- 1915 years, Harrington Emerson and Charles E. Bedaux. This led to the development of a major weakness in Industrial Engineering. Industrial engineers got the description of "Time Study Men."

Harrington Emerson

Emerson (1853-1931) was a creative personality. Attracted to Taylor at the turn of the century, he briefly worked as an orthodox practitioner and played an influential role in Taylor’s promotional work. He soon became a respected accounting theorist and a successful reorganizer of railroad repair facilities. As his reputation grew, however, he broke with Taylor and set up a competing business with a large staff of engineers and consultants. Between 1907 and 1925, he had over two hundred clients  He also published best-selling books and promoted a mail-order personal efficiency course. He was probably the best-known industrial engineer of the late 1910s and early 1920s.’ Emerson’s entrepreneurial instincts defined his career. An able technician, he was capable of overseeing the changes associated with orthodox scientific management. He also recruited competent assistants, such as Frederick Parkhurst and C. E. Knoeppel, who later had distinguished consulting careers, and E. K. Wunnerlund, who became the head of industrial engineering at General Motors. But Emerson always viewed his work as a business and.tailored his services to this customer’s interests. In practice, this meant that his employees spent most of their time conducting time studies and installing incentive wage systems. By the mid-1920s, General Motors, Westinghouse, the Baltimore & Ohio Railroad, Aluminum Company of America, American Radiator, and many other large and medium-sized industrial firms had introduced the Emerson system and in many cases an industrial engineering department staffed by former Emerson employees.

Bedaux (1886-1944) was a French immigrant who was a clerk at a St. Louis chemical company. In 1910 when an expert arrived to conduct time studies, Bedaux quickly grasped the essentials of time study and replaced the outsider. Then he found other clients. The turning point in his career came in 1912, when he accompanied several Emerson engineers to France as an interpreter. In Paris he struck out on his own, reorganized several factories, and studied the writings of Taylor and Emerson. Returning to the United States during World War I, he launched the Bedaux Company and began to cultivate clients.  He relied on a simple, compelling promise: he would save more money than he charged. Although Bedaux employed able engineers and usually made some effort to reorganize the plant, his specialty was the incentive wage. His men worked quickly, used time studies to identify bottlenecks and set production standards, installed a wage system similar to Emerson’s.  Bedaux’s clients included General Electric, B. F. Goodrich, Standard Oil of New Jersey, Dow Chemical, Eastman Kodak, and more than two hundred other American firms by the mid-1930s. His European offices were even more successful.

Whereas Taylor and his followers opposed wage cutting and “speed-up” efforts, Emerson was more flexible, and Bedaux made a career of forcing workers to do more for less. One notable result was a resurgence of strikes and union protests. By the 1930s, Bedaux had become infamous on both sides of the Atlantic. In response to his notoriety, he revised his incentive plan to increase the worker’s share and dropped much of his colorful terminology, including the famous B unit. Bedaux’s business survived, though neither he nor his firm regained the position they had enjoyed in the late 1920s and early 1930s.

Bedaux’s legacy was a substantial burden for other industrial engineers. The growth of labor unrest in the 1930s and the frequent appearance of the “Be-do” plan on grievance lists revived the association of industrial engineering with labor turmoil. Regardless of their association with Bedaux and his tactics, industrial engineers became the targets of union leaders and their allies. In industries such as autos and tires, worker protests paralyzed the operations of industrial engineering departments and led to the curtailment or abandonment of many activities.


Diffusion of Industrial Engineering

There are at least three partial measures of the diffusion of industrial engineering.  First, the many references to cost accounting, centralized production planning and scheduling, systematic maintenance procedures, time study, and employment management in the trade press and in the records of industrial corporations indicate that these activities were no longer novel or unfamiliar to executives. The promotional work of the consultants, the “efficiency craze,” and the growth of management education in universities had made the rudiments of industrial engineering widely available; only the oldest or most isolated executives were unaware of them. The critical issue was no longer the desirability of the new management; it was the particular combination of techniques suitable for a given firm or plant, the role of the outside consultant, if any, and the authority of the staff experts.

Second, the information on industrial wage systems that the National Industrial Conference Board assiduously collected in the 1920s and 1930s documents widespread acceptance of incentive wage plans, particularly among large corporations. In 1928, for example, 6 percent of the smallest companies (1-50 employees) had incentive wage plans, while 56 percent of the largest firms (more than 3,500 employees) had such plans. In earlier years, small firms devoted to industrial reform had been among the most vigorous proponents of industrial engineering. But their ranks did not grow, and they were soon overshadowed by large corporations, which found in industrial engineering an effective answer to the problems that often prevented large, expensive factories from achieving their potential. Incentive wage plans were an indicator of this trend.  Feiss, Dennison, and others hoped to transform the character of industrial work through the use of incentives and personnel programs; judging from the information that survives, big business managers had more modest goals. Their principal objective was to make the best use of existing technology and organization by enlisting the workers’ interest in a higher wage. In the early 1930s, many managers were attracted to the “work simplification” movement that grew out of the Gilbreths’ activities, but the effects were apparently negligible, at least until the World War II mobilization effort. To most manufacturers, industrial engineering provided useful answers to a range of shop-floor problems; it was a valuable resource but neither a stimulus to radical change nor a step toward a larger goal.

A third source, contemporary surveys of the industrial engineering work of large corporations, provides additional support for this conclusion.   A 1928 survey by the Special Conference Committee, an elite group of large industrial firms, emphasized related problem. It reported wide differences in the practice of time study, in the duties of time-study technicians, and in the degree of commitment to time study as an instrument for refining and improving the worker’s activities. At Western Electric, which had one of the largest industrial engineering staffs, a manufacturing planning department was responsible for machinery and methods; the time-study expert was simply a rate setter. At Westinghouse, which also had a large industrial engineering department, time-study technicians were responsible for methods and rates. However, a report from the company’s Mansfield, Ohio, plant indicated that the time-study engineer could propose changes in manufacturing methods “in cooperation with the foremen.” Most companies had similar policies. The time-study expert was expected to suggest beneficial changes to his superiors, often after consulting the foreman, but had no independent authority to introduce them. Essentially, the “expert” was a rate setter. In most plants, industrial engineering focused on detail, seldom threatened the supervisors or workers, and even more rarely produced radical changes in methods.

Experience at Du Pont

A recent, detailed examination of industrial engineering at E. I. Du Pont de Nemours & Company, a Special Conference Committee member, suggests the range of possibilities that could exist in a single firm (Rumm 1992, 175-204). Du Pont executives created an Efficiency Division in 1911 after the company’s general manager read The Principles. Rather than employ an outside consultant, they appointed two veteran managers to run the division. These men conducted time and motion studies, “determined standard times and methods for tasks, set standard speeds for machinery, and made suggestions for rearranging the flow of work, improving tools, and installing labor-saving equipment.” Yet they encountered a variety of difficulties; their proposals were only advisory, they clashed with the new employment department when they proposed to study fatigue and the matching of workers and jobs, and they found that many executives were indifferent to their work. Worst of all, they could not show that their activities led to large savings. In 1914, after the introduction of functional supervision in the dynamite-mixing department apparently caused several serious accidents, the company disbanded the Efficiency Division.

Although some Du Pont plants introduced time-study departments in the following years, the company did nothing until 1928, when it created a small Industrial Engineering Division within the larger Engineering Department. The IED was to undertake a “continuous struggle to reduce operating costs.” That battle was comparatively unimportant until the Depression underlined the importance of cost savings. In the 1930s, the IED grew rapidly, from twenty eight engineers in 1930 to over two hundred in 1940. It examined “every aspect of production,” conducted job analyses, and introduced incentive wage plans.  IED engineers began with surveys of existing operations. They then “consolidated processes, rearranged the layout of work areas, installed materials-handling equipment, and trimmed work crews.” To create “standard times” for particular jobs, they used conventional stopwatch time study as well as the elaborate photographic techniques the Gilbreths had developed. By 1938, they had introduced incentive wage plans in thirty plants; one-quarter of all Du Pont employees were affected.

Du Pont introduced a variety of incentive plans. Three plants employed the Bedaux Company to install its incentive system. Other managers turned to less expensive consultants, and others, the majority, developed their own “in-house” versions of these plans. Some executives, and workers, became enthusiastic supporters of incentive wages; others were more critical. Despite the work of the aggressive and ever-expanding IED, many workers found ways to take advantage of the incentive plans to increase their wages beyond the anticipated ranges. Wage inflation ultimately led the company to curtail the incentive plans. Time and motion study, however, remained hallmarks of Du Pont industrial engineering.

During the depression of the 1930s, when they developed a new sensitivity to the value of industrial engineering, they defined it as a way to cut factory costs.  One reason for this perspective was bureaucratic: Du Pont had developed an extensive personnel operation in the 1910s and 1920s, which had authority over employee training, welfare programs, and labor negotiations. Equally important was the apparent assumption that industrial engineering only pertained to the details of manufacturing activities, especially the work of machine operators. Despite mounting pressures to reduce costs, the company’s offices, laboratories, and large white-collar labor force remained off-limits to the IED. Despite these handicaps, the IED had a significant impact because rapid technological change in the industry created numerous opportunities for organizational change and Du Pont avoided relations with powerful unions.

Du Pont executives were receptive to the “principles” of industrial engineering but focused on the particulars, which they assessed in terms of their potential for improving short-term economic performance. As a result there was little consistency in their activities until the 1940s; even then, industrial engineering was restricted to the company’s manufacturing operations. This approach, fragmentary and idiosyncratic by the standards of Taylor or Dennison, was logical and appropriate to executives whose primary objective was to fine-tune a largely successful organization.

During the first third of the twentieth century, industrial engineers successfully argued that internal management was as important to the health of the enterprise as technology, marketing, and other traditional concerns. Their message had its greatest impact in the 1910s and 1920s, when their “principles” won wide acceptance and time study and other techniques became common-place. Managers whose operations depended on carefully planned and coordinated activities and reformers attracted to the prospect of social harmony were particularly receptive. By the 1930s, the engineers’ central premise, that internal coordination required self-conscious effort and formal managerial systems, had become the acknowledged basis of industrial management.

(See
https://books.google.co.in/books?id=LyQOQWC66usC&pg=PA44#v=onepage&q&f=false
https://books.google.co.in/books?id=w-Wm_PrFB5IC&pg=PA552#v=onepage&q&f=false)


1930s

Allan Mogensen's Common Sense Applied to Motion and Time Study (1932)

Ralph Barnes's Indus­trial Engineering and Management: Problems and Policies (1931).

Steward M. Lowry, Harold B. Maynard, and G. J. Stegmerten's widely used Time and Motion Study and Formulas for Wage Incentives. - The 1927 edition treated motion study only briefly and insubstantially, while devoting many chapters to stopwatch methods and rate setting formulas. In 1932, the authors approached Lillian Gilbreth and her research group for more detailed information on their methods. By 1940 Lowry, Maynard, and Stegmerten had reduced their treatment of wage incentive formulas from nine chapters to three, and increased the number of chapters devoted to motion study to seven.

IE History - Some Recollections
Andrew Shultz
https://www.informs.org/Resource-Center/Video-Library/H-T-Videos/Andrew-Schultz-on-AIIE-ORSA-and-Cornell-s-ORIE




2017
Principles, Functions and Focus Areas of Industrial Engineering - Narayana Rao

_______________

_______________


Industrial engineering is carried out at various levels in an organization. The following are the important levels of IE.

Industrial Engineering Strategy - Enterprise Level Industrial Engineering

Policy Decisions by Top Management: Starting and Expanding IE Department, Approval of Productivity Improvement Project Portfolio as part of Capital Budgeting of the Company, Approving Productivity Policy, Setting Productivity and Cost Reduction Goals. Setting Employee related comfort, health and safety goals. Incentive income policy making.

https://nraoiekc.blogspot.com/2014/11/industrial-engineering-strategy.html


Facilities Industrial Engineering

Facilities are used by processes. Facilities are common to processes. Taylor clearly mentioned in his "Piece Rates - Elementary Rate Fixing System" paper that he has to make modifications to all machines to increase productivity of his machine shop. Toyota even today carries out gradual improvements to the machines in the direction of autonomation. Machines are continuously improved. Period layout studies and readjustments are another example of facilities industrial engineering. 5S that demands upkeep of facilities is another example of facilities IE when it is implemented for the first time and proposed and initiated by the IE department. Thereafter it becomes the activity of operations management.

https://nraoiekc.blogspot.com/2020/05/facilities-industrial-engineering.html



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

Process industrial engineering is the popular method of industrial engineering. But, the process chart method was promoted by Motion Study books. The machine effort industrial engineering, that is improvement of machine effort, that was done by Taylor primarily to increase productivity got neglected in the evolution of industrial engineering. It is a weakness to be corrected to make IE a strong discipline.

https://nraoiekc.blogspot.com/2021/11/process-industrial-engineering-process.html


Operation Industrial Engineering.

Process chart is a condensed version that show the entire process of producing a full product and the production of each part. The process chart is composed by symbols representing 5 operations. Operation - Inspection - Transport - Temporary Delay (WIP) - Permanent Storage (controlled store). Using process chart, the sequence of operations can be investigated and changed for more benefit. But each operation needs to be improved. It is termed simplification in process chart analysis. To do simplification information on each operation has to be collected in operation information sheets and they have to be analyzed in operation analysis sheets (Stegemerten and Maynard)

https://nraoiekc.blogspot.com/2013/11/approach-to-operation-analysis-as-step.html


Element Level Analysis in Industrial Engineering

Elements are in Operations - We can understand the term "element" from the subject "Design of Machine Elements". Each engineering product has elements. Similarly each operation, that is part of a process has elements. Some are related to machines and tools used in the process. Some are related to human operators. Some are related to working conditions. Some are related to the work being done. Taylor first named the productivity department as "Elementary Rate Fixing Department." It has to improve each and every element in task and determine the output possible for unit time in the work element. The time allowed for that element for a piece or batch is determined through these elementary standard times or allowed times.

Taylor's Industrial Engineering System - First Proposal 1895 - Productivity Improvement of Each Element of the Process








Contributions of Industrial Engineering Pioneers, Researchers and Scholars in Chronological Order


Taylor - Machine - Engineering Based Productivity Improvement

Taylor - Productivity Science and Art of Metal Cutting - Important Points

Taylor's Industrial Engineering - First Proposal 1895

Industrial Engineering Described in Shop Management by F.W. Taylor

Productivity Improvement in Machine Shop - F.W. Taylor

Development of Science in Mechanic Arts - F.W. Taylor (Human work)

Time Study for Process Time Reduction - F.W. Taylor  (Human work)

Taylor on Quality, Human Relations and Management



Gilbreth - Human Effort Focus

Gilbreth's Human Effort Industrial Engineering Motion Study - Part 1

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 2

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 3

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 4

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Variables Affecting of Motion Time.
ACCELERATION - AUTOMATICITY - COMBINATION WITH OTHER MOTIONS, AND SEQUENCE - COST - DIRECTION AND USE OF GRAVITY - EFFECTIVENESS - FOOT-POUNDS OF WORK ACCOMPLISHED - INERTIA AND MOMENTUM OVERCOME - LENGTH

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Future Scope

Process Charts - Gilbreths - 1921


Psychology Evaluation of Scientific Management by Lilian Gilbreth - 1914

Harrington Emerson - A Pioneer Industrial Engineer - His Principles and Practices


Prof. Hugo Diemer - Taylor's Industrial Engineering

Industrial Engineering - The Concept - Developed by Going in 1911

Taylor Society Bulletin


H.B. Maynard - Operation Analysis - Introduction

H.B. Maynard - Methods Time Measurement (MTM) - Introduction

Work Simplification - Alan Mogensen

Method Study - Ralph M. Barnes - Important Points of Various Chapters

Product Industrial Engineering

L.D. Miles - Value Analysis and Engineering - Introduction

L.D. Miles - 13 Techniques of Value Analysis



Japanese Contribution

Yoichi Ueno - Japanese Leader in Efficiency - Productivity Movement

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

Industrial Engineering - Foundation of Toyota Production System


2017
Taylor's Industrial Engineering in New Framework - Narayana Rao



Sources

http://www.nber.org/chapters/c8748.pdf


Bibliography

Westinghouse manual of time study procedure. © Aug. 10, 1945, AA 4994.94.

Westinghouse operation analysis. © Aug. 10, 1945, AA 49,493. Westminster press ...
1945

2005
Georgia Tech Fall 2005 Engineering Enterprise Issue has an article on History of IE at Georgia


#IISE75 (1948 - 2023) - 75  Productive Years of IISE (Institute of Industrial and Systems Engineers) 


Wyllys Stanton. Inside his Columbus, Ohio home on Jan. 12, 1948 (75 years ago), he and a dozen others met to discuss “the problems, methods and potentialities of a new organization specializing in the problems and interests of industrial engineers.”
That’s a direct quote from a blurb Stanton himself penned. It’s included in “Origins of Industrial Engineering: The Early Years of a Profession,” by Howard P. Emerson and Douglas C.E. Naehring.
The fateful discussion inside Stanton’s home included talks on prospective membership requirements, ways such an organization could be useful, scopes of activities and plans for the path ahead.
“There seemed to be no question in the founders' minds of the desirability of such an organization,” Stanton wrote. “They believed that industrial engineering was an important branch of engineering and just as much in need of an organization devoted to its exclusive representation as civil, mechanical, or electrical engineers.”
Invites were sent out to all known industrial engineers in the Columbus area to attend the American Institute of Industrial Engineers’ first-ever meeting. The name would later change multiple times to reflect the organization’s international presence as well as the scope of professions included in what is now the Institute of Industrial and Systems Engineers. For more: iise.org/75

https://www.linkedin.com/posts/narayana-rao-kvss-b608007_tbt-iise75-activity-7021336008017227776-Mspl


AIIE Journal of Industrial Engineering - Interesting on Archive - Org - Collection



Industrial Engineering in Academic Institutions


Prof. Diemer's 1908 Proposal - 4-Year Industrial Engineering Course

Prof. Diemer started the first two year specialization and the first four-year course in industrial engineering in the Pennsylvania State College. Now it is Penn State University.

Histories of Industrial Engineering Departments and Institutes - USA





Lesson 2. Industrial Engineering - Definition and Explanation 

Updated on 23.9.2023, 18.1.2023, 1 June 2022,  2 January 2022,  8.11.2021, 1 June 2021,  1 April 2021,  19 May 2020,  9 April 2020, 10 November 2019, 22 December 2014

The updates to this post are examples of industrial engineering - continuous improvement based on periodic reviews as well as when a relevant information becomes available or an idea comes to mind.

The first creation of the post is the example of basic engineering - product design as well as process design. The updates made show that there will be opportunities for improvement. Similarly in engineering systems, there is opportunity for industrial engineering, periodic and continuous improvement.