Thursday, May 29, 2025

Industrial Engineering 5.0 - IE 5.0 - IE in Industry 5.0 - Human Effort Industrial Engineering

 




Update on 29.5.2024

A search for the key word "Industrial engineering 5.0" did not reveal any document.

So still developments in Industry 5.0 are only available as online documents. Any development on the topic "Industrial engineering 5.0" has to initially track developments in industry 5.0


Positioning Industrial Engineering in the Era of Industry 4.0, 5.0, and Beyond: Pathways to Innovation and Sustainability


45 Pages Posted: 23 Jan 2025 Last revised: 16 Jan 2025

Ocident Bongomin

Moi University; Africa Centre of Excellence II in Phytochemical, Textile and Renewable Energy (ACE II-PTRE); Ain Shams University; National Crops Resources Research Institute; Ndejje University; Pabplek Advanced Simulation and Modeling Solutions


Date Written: January 14, 2025


Abstract

Industrial Engineering (IE) has continually evolved to optimize systems and processes, addressing the demands of an ever-changing industrial landscape. From its historical roots in work organization to its current role in Industry 4.0 and the emerging Industry 5.0 paradigm, IE has remained central to fostering innovation, efficiency, and sustainability.  Industry 5.0 shifts the focus to human-centric, ethical, and sustainable practices, leveraging advanced technologies such as cognitive digital twins, collaborative robots, and resilient systems to enhance human-machine collaboration and environmental responsibility. This  highlights strategies for advancing the IE profession and academic programs, ensuring their relevance in the digital era. Additionally, it identifies six future research directions, including Human-AI collaboration, Adaptive and resilient systems design, advanced sustainability models, ethical and inclusive systems design, digital twin integration, and quantum computing, as key enablers for driving innovation and achieving global sustainability goals. By bridging the technological advancements of Industry 4.0 with the human-centric and sustainable objectives of Industry 5.0, IE is positioned to lead the transformation of industrial systems, fostering a resilient, inclusive, and sustainable future.



Open Access
Pillars of the Industry 5.0 Used in Industrial Engineering
Florin-Daniel Edutanu, Mariana Ciorap  and Dragos-Florin Chitariu  
Nov 21, 2024
Bulletin of the Polytechnic Institute of Iași. Machine constructions Section
VOLUME 70 (2024): ISSUE 1 (MARCH 2024)

This paper examines the perspective through the lens of the three principles proposed by I5.0: human-centric, sustainability and resilience, which outline these new manufacturing technologies used to improve production processes in most fields, including industrial engineering. The pillars of the I5.0 concept identified in this paper will describe the amplification of this digital transformation and the more meaningful and effective collaboration between humans and machines and systems in their digital ecosystem.  These pillars underpin a new industrial revolution and define a new level of organisation and control over the future entire product life cycle value chain.


--------------------------

Pub. 29.4.2023

Update on 29.5.2025,  24.1.2024

Less than one hundred Scopus-indexed articles mention the 5th industrial revolution (5IR) in their titles or abstracts starting from 2016. Also, many works can be found in Google Scholar. So, what is the difference between the 4th and the 5th industrial revolutions?


Rundle (2017) describes the 5IR as being faster, more scalable, and affecting more people through the nature of the technology at their disposal than previous ones. The European Economic and Social Committee (2018) describes the 5IR as "…focused on combining human beings' creativity and craftsmanship with the speed, productivity and consistency of robots" (EESC, 2018).


The Fifth Industrial Revolution, 5IR, is the idea of people and machines working together harmoniously, emphasizing the well-being of multiple stakeholders ― society, businesses, workers and customers. It thus paves the way for an (r)evolution in thinking about and harnessing human-machine collaboration for greater societal well-being (Noble, 2022).




The European Economic and Social Committee (2018) describes the 5IR as "…focused on combining human beings' creativity and craftsmanship with the speed, productivity and consistency of robots" (EESC, 2018).

We can see one focus of IE 5.0 "combining human beings' creativity and craftsmanship with the speed, productivity and consistency of robots". This is the human effort industrial engineering focus in IE 5.0. In IE 4.0 the focus is on understanding connected machines, devices and using them in processes to increase productivity.

Blog Book - Industrial Engineering 4.0 - IE in the Era of Industry 4.0

IE 4.0: IoT Adoption, Improvement, Maturity, Productivity, Innovation and Connected Products



What is Industry 5.0?
European industry is a key driver in the economic and societal transitions that we are currently undergoing.

In order to remain the engine of prosperity, industry must lead the digital and green transitions.

This approach provides a vison of industry that aims beyond efficiency and productivity as the sole goals, and reinforces the role and the contribution of industry to society.

It places the wellbeing of the worker at the centre of the production process and uses new technologies to provide prosperity beyond jobs and growth while respecting the production limits of the planet.

It complements the existing "Industry 4.0" approach by specifically putting research and innovation at the service of the transition to a sustainable, human-centric and resilient European industry.

Why Industry 5.0?
Industries can play an active role in providing solutions to challenges for society including the preservation of resources, climate change and social stability. 

The Industry of the Future approach brings benefits for industry, for workers and for society.

It empowers workers, as well as addresses the evolving skills and training needs of employees. It increases the competitiveness of industry and helps attract the best talents.

It is good for our planet as it favours circular production models and support technologies that make the use of natural resources more efficient.

Revising existing value chains and energy consumption practices can also make industries more resilient against external shocks, such as Covid-19 crisis.

How to make it happen?
This approach to industry contributes to 3 of the Commission’s priorities: "An economy that works for people", "European Green Deal" and "Europe fit for the digital age".

Elements related to the future of industry are already part of major Commission policy initiatives

adopting a human-centric approach for digital technologies including artificial intelligence (Proposal for AI regulation)
up-skilling and re-skilling European workers, particularly digital skills (Skills Agenda and Digital Education Action plan)
modern, resource-efficient and sustainable industries and transition to a circular economy (Green Deal)
a globally competitive and world-leading industry, speeding up investment in research and innovation (Industrial Strategy)
These are just some examples that demonstrate the strong links between the industrial transition and other societal developments.

Experts from research and technology organisations as well as funding agencies discussed the Industry 5.0 concept during 2 virtual workshops on 2 and 9 July 2020.

ESIR a high-level expert group advising the Commission on how to develop a forward-looking and transformative research and innovation policy, are currently developing a new policy brief on industry. It will provide concrete policy recommendations and actions for attaining Industry of the Future goals and will provide an important basis for advancing European and national-level policy initiatives and making sure the development is in line with the Commission's political priorities.




2 November 2023

INDUSTRY 5.0 GLOBAL OUTLOOK 2024 - 2025

Michael Rada

874 views  Premiered on 3 Nov 2023
Recorded on
 November 2, 2023
The growing number of companies, businesses organizations, and governments referring to INDUSTRY 5.0 and calling it "THE FUTURE STRATEGY results in the need to prepare and share the outline of INDUSTRY 5.0 global development for the next two years.
I hope it will help you to understand and to see your role in the global transformative journey that turns the EARTH from a global landfill to BLUE MARBLE again
If any questions, feel free to ask and please do not hesitate to contact me, the best way is on LINKEDIN which from the very beginning serves as the main communication platform and tool. Here is my profile  

 / michaelrada  


Article to be developed.


A FRAMEWORK FOR DESIGNING WORK SYSTEMS IN 
INDUSTRY 4.0.
INTERNATIONAL CONFERENCE ON ENGINEERING DESIGN, ICED19 
5-8 AUGUST 2019, DELFT, THE NETHERLANDS 
ICED19. 


Exploring the status of the human operator in Industry 4.0: A systematic review.
Liliana Cunha, Daniel Silva and Sarah Maggioli. 
SYSTEMATIC REVIEW article
Front. Psychol., 20 September 2022
Sec. Organizational Psychology
Volume 13 - 2022 | https://doi.org/10.3389/fpsyg.2022.889129










Ud. 25.1.2024,  16.1.2024, 7.5.2023
Pub. 29.4.2023

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering






TPS is Industrial Engineering System of Toyota Motors.

 Taiichi Ohno on Industrial Engineering 





Taiichi Ohno in Toyota Production System: Beyond Large Scale Production,

Advocating Profit-Making Industrial Engineering  



After World War II, the United States influenced Japan greatly in many ways.

Aggressive Japanese businesses imported and adopted America's high-level production and manufacturing technology. In academia and business, a great number of American business management techniques were also studied and discussed. For example, Japanese businesses carefully studied industrial engineering (IE), a company-wide manufacturing technology directly tied to management that was developed and applied in the United States.

Defining industrial engineering seems to be fairly difficult. When first introduced, it was pointed out that the Toyota production system was method engineering (ME), not IE. Don't be confused over the meanings.

To me, IE is not a partial production technology but rather a total manufacturing technology reaching the whole business organization. In other words, IE is a system and the Toyota production system may be regarded as Toyota style IE.

What is the difference between traditional IE and the Toyota system? In brief, Toyota style IE is mekeru or profitmaking IE, known as MIE. 

Unless IE results in cost reductions and profit increases, I think it is meaningless.

There are various definitions of IE. A former head of the American Steel Workers' Union defined its function as that of entering a plant to improve methods and procedures and to reduce costs. And this is exactly so.

"IE is the use of techniques and systems to improve the method of manufacturing. In scope it: ranges from work simplification to large-scale capital investment plans."'

"IE has two meanings. One aims at improving work methods in the plant or in a particular work activity. The other one means the specialized study of time and action. However, this is the work of a technician. Essentially, an industrial engineer studies systematic approaches to improvements. "

I would like to add a definition from the Society for Advancement of Management (SAM), an organization that succeeded the Taylor Society:

Industrial engineering applies engineering knowledge and techniques for the study, improvement, planning, and iniplementation of the following:

1. method and system,
2. qualitative and quantitative planning and various standards including the various procedures in the organization of work,
3. measuring actual results under the standards and taking suitable actions.

This is all done to exercise better management with special consideration for employee welfare, and it does not restrict business to lowering the cost of improved products and services.'

I have listed various IE definitions, each saying good things, because they are useful references. However, in private business, implementing IE effectively is not easy.

The reason I call Toyota's industrial engineering profitmaking IE is my wish that the Toyota production system born and raised at Toyota Motor Company be comparable or superior to the American IE's business management and manufacturing system.

We are very happy that the Toyota production system has become, as I intended, a company-wide manufacturing technology directly tied to management. And, fortunately, it is extending to the outside cooperating firms as well.



Quotes from Above.


Japanese businesses carefully studied industrial engineering (IE), a company-wide manufacturing technology directly tied to management that was developed and applied in the United States.


When first introduced, it was pointed out that the Toyota production system was method engineering (ME), not IE.


TPS is Industrial Engineering System of Toyota Motors.

IE is a system and the Toyota production system may be regarded as Toyota style IE.


Toyota style IE is mekeru or profitmaking IE, known as MIE. 
Unless IE results in cost reductions and profit increases, I think it is meaningless.


Essentially, an industrial engineer studies systematic approaches to improvements.


It is my wish that the Toyota production system born and raised at Toyota Motor Company be comparable or superior to the American IE's business management and manufacturing system.


Industrial engineering (IE), a company-wide manufacturing technology directly tied to management that was developed and applied in the United States.

We are very happy that the Toyota production system has become, as I intended, a company-wide manufacturing technology directly tied to management.



------------------------

Taiichi Ohno repeats what Taylor said. Improve every element of an operation/process.


Improve machining processes,  install autonomous systems, improve tools,  rearrange machines,  improve  transportation methods. Examine available resources and  the materials at hand for manufacturing. optimize their use.

Prevent the recurrence of defective products, operational mistakes, and accidents, and by incorporate  workers' ideas."  


Toyota Industrial Engineering that is Ohno's Industrial Engineering is improving every element of the process and reducing every delay, defect and machine breakdown (Naryana Rao)


Toyota style Industrial Engineering - Ohno


"We have eliminated waste by examining available resources, rearranging machines, improving machining processes, installing autonomous systems, improving tools, analyzing transportation methods and optimizing the materials at hand for manufacturing. High production efficiency has also been maintained by preventing the recurrence of defective products, operational mistakes, and accidents, and by incorporating workers' ideas." Taiichi Ohno (P. 21)

Source: Taiichi Ohno, Toyota Production System: Beyond Large Scale Production, pp. 21-22.


------------------------

Japanese businesses carefully studied industrial engineering (IE), a company wide manufacturing technology improvement discipline that is directly tied to management.

The success of Toyota in cost reduction, productivity improvement, and international competitiveness and its celebrated Toyota Production System, fulfilled the dream of Yoichi Ueno (that Japan can guide US in improved practices of efficiency improvement). The success of #Toyota and the World Class #TPS was  built on the sustained efforts many Japanese persons who understood Taylor and Gilbreth's writings and improvised them in implementing them in Japanese companies.


Summarized from Taiichi Ohno's Book - Toyota Production System: Beyond Large Scale Production,

IE is not a partial technology improvement discipline but it is a total manufacturing technology improvement discipline reaching the whole organization. Toyota production system utilizes Toyota-style IE.


                    Jun. 17, 2020. Toyota Launches New Model Harrier in Japan                       

What is Toyota style Industrial Engineering?


Toyota style industrial engineering is mokeru or profit-making industrial engineerng (MIE). Unless IE results in cost reductions and profit increases, I (Taiichi Ohno) think it is meaningless.

A former head of the American Steel Workers' Union defined IE's function as that of entering a plant to improve methods and procedures and to reduce costs.

"IE is the use of techniques and systems to improve the method of manufacturing. In scope it ranges from work simplifications to large-scale capital investment plans"

IE aims at improving work methods in the plant or in a particular work activity. An industrial engineer studies systematic approaches to improvements.

Definition of IE according to Society for Advancement of Management (Successor to Taylor Society)


Industrial engineering applies engineering knowledge and techniques for the study, improvement, planning and implementation of the following:

1. Method and system
2. Qualitative and quantitative planning and various standards including the various procedures in the organization of work.
3. Measuring actual results under the standards and taking suitable actions.

This is all done to exercise better management with special consideration for employee welfare, and it does not restrict business to lowering the cost of improved products and services.

Ohno said he included various definitions as each is good description. But he indicated that implementing IE effectively is not easy.

Ohno made a wish that IE as used in Toyota will be superior to the IE used in American Business.

Toyota style Industrial Engineering - Ohno


"We have eliminated waste by examining available resources, rearranging machines, improving machining processes, installing autonomous systems, improving tools, analyzing transportation methods and optimizing the materials at hand for manufacturing. High production efficiency has also been maintained by preventing the recurrence of defective products, operational mistakes, and accidents, and by incorporating workers' ideas." Taiichi Ohno (P. 21)

Source: Taiichi Ohno, Toyota Production System: Beyond Large Scale Production, pp. 71-72.

Japanese Leaders in Efficiency - Productivity Movement - Industrial Engineering.
#IndustrialEngineering #Productivity #CostReduction  #Japanese


Yoichi Ueno - Japanese Leader in Efficiency - Productivity Movement

Rear Admiral Takuo Godo - Productivity Promoter in Japan


Shigeo Shingo - The Japanese Industrial Engineer - Contribution to Industrial Engineering

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering


Takeshi Kawase - Industrial Engineering - Definition. IE  deals  with the efficiency of systems that include humans.






Updated on 28.5.2025,  10.7.2024, 26 June 2020, 12 November 2013









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

Case Study 42 - Seco Jetstream Tooling - Benefit - Case Study

Taylor's Industrial Engineering in New Framework - Narayana Rao



Industrial Engineering - Definition
Principles of Industrial Engineering
Functions of Industrial Engineering - Productivity Science - Productivity Engineering - Productivity Management.
Focus Areas of Industrial Engineering
Machine Work Study
Toyota Style Industrial Engineering
Industrial Engineering 4.0
Industrial Engineering 5.0

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING  

Pdf File. Free Download.
by Narayana Rao Kvss.

Industrial Engineering - Definition


Industrial Engineering is System Efficiency Engineering.
It includes Machine Effort and Human Effort Industrial Engineering.

Industrial Engineering is concerned with efficiency design or productivity design during initial product or process design and productivity improvement on a continuous basis during the life of the product and process. Industrial engineers participate in the installation of processes and process improvement projects and take full responsibility to make their designs or design modifications actual implementations and results generators.

Engineers and design and produce.

Value Creation for the Organization by Industrial Engineers


Industrial engineering learners have to understand the potential for value creation by them in the companies. The compensation or income received is always related to the value created by a professional. Hence for industrial engineering students as well as professionals, understanding value creation potential is extremely important. A model is presented in this essay on value creation (2020). 

Value Creation for the Organization by Industrial Engineers - Productivity Engineering Potential
Lesson 13. Industrial Engineering ONLINE Course 



Principles of Industrial Engineering


Taylor - Narayana Rao Principles of Industrial Engineering
http://nraoiekc.blogspot.com/2017/06/taylor-narayana-rao-principles-of.html


21. Cost measurement

Taylor - Narayana Rao Principles of Industrial Engineering Video Presentation

_______________



_______________

Functions of Industrial Engineering

Productivity Science - Productivity Engineering - Productivity Management

_______________

_______________

Focus Areas of Industrial Engineering


_______________

_______________

Functions and Focus Areas of Industrial Engineering
https://nraoiekc.blogspot.com/2017/07/functions-of-industrial-engineering.html


Focus Areas of Industrial Engineering

Productivity Science

Facilities Industrial Engineering

Product Industrial Engineering

Process Industrial Engineering

Industrial Engineering Optimization

Industrial Engineering Statistics

Industrial Engineering Economics

Human Effort Industrial Engineering

Productivity Measurement

Productivity Management

Industrial Engineering  Knowledge Management and Other Information Systems (New)

Applied Industrial Engineering

Important Focus Areas of Industrial Engineering

Facilities Industrial Engineering
Product Industrial Engineering
Process Industrial Engineering
Human Effort Industrial Engineering


Product Industrial Engineering


______________

______________


Process Industrial Engineering


______________

_______________


Human Effort Industrial Engineering

MAYNARD's HUMAN EFFORT INDUSTRIAL ENGINEERING - Methods Time Measurement (MTM) - Introduction  
Lesson 34 - Industrial Engineering ONLINE Course

_______________

_______________

Machine Work Study

H.B. Maynard - MACHINE EFFORT INDUSTRIAL ENGINEERING - Operation Analysis - Machine Work Study
Lesson  33. - Industrial Engineering ONLINE Course 

_______________

_______________


_______________

_______________

Industrial Engineering 4.0

11 July 2021
VERY HAPPY. Blog Book accessed 1000 times. 
Industrial Engineering 4.0 - IE in the Era of Industry 4.0 - Blog Book by K.V.S.S. Narayana Rao

_______________


_______________
_______________

_______________

Taylor's Industrial Engineering and Productivity Improvement Described by Taylor  in His 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


Updated on 12.7.2023, 12 July 2022,  12 July 2021,  4 August 2019, 6 July 2019

Industrial Engineering ONLINE Course Notes - Industrial Engineering Knowledge Center

Industrial Engineering for Society Prosperity.


"I went so many years without people really knowing what I had to say." - Deming

I may add, "I do not know for years what it is." Let me explain with my best effort.


Industrial Engineering ONLINE FREE Course - Industrial Engineering Knowledge Center Online Course

365 Lessons - Social Media Sharing 1 June to 31 May.
2025-2026 - Sixth Year of Offering - Starts on 1 June 2025.

This Year communicated through LinkedIn News Letter

Open Access Industrial Engineering ONLINE FREE Course Lessons - Industrial Engineering Knowledge Center Online Course - Toyota Style Industrial Engineering.
June 2025 Issue of Modern Industrial Engineering - LinkedIn Newsletter. Please share to current learners of industrial engineering. Thank you.




Bookmark the Page - Visit Every Day - Read a new lesson. 
Subscribe to the blog to get email notifications.  

You can download index - list of lessons as pdf file.
O-Book - Modern Industrial Engineering - A Book of Online Readings.
365+ Lessons and articles and 100+ Case Studies on Industrial Engineering. 
Based on Principles of Industrial Engineering (2017) - Functions and Focus Areas of Industrial Engineering (2016).



INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING.  10000+ Downloads/Reads.  In Top 0.5%  of E-Books on Academia-Edu. Free Download EBook (122 pages). Download from:

The E-Book has detailed materials on the lessons of the first two modules of the course.

Online Handbook of Industrial Engineering



Principles of Industrial Engineering

_____________


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

9570+ Views so far.

Industrial Engineering - Result oriented engineering. Productivity orientation.  Engineering for enhancement of results.


Engineering analysis and design, to specify, predict, and evaluate the results to be obtained from engineering systems.
Industrial Engineering - IISE Definition - Components of Industrial Engineering.
_____________

Industrial Engineering Online Course - Areas & Modules  

(Click on the link to access module lessons) -Access  365 Lessons & 75+ Case Studies.



Please give your suggestion and feedback through comments on course pages. 
Please share and inform your friends and colleagues.



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

Author of Principles of Industrial EngineeringFunctions of Industrial Engineering and Focus Areas of Industrial Engineering.






Industrial Engineering Course Lessons - Module 1

List and Links


Day 1 (Fith Year of the Course  Started on 1 June  2024)

Introduction to Industrial Engineering - Module 1


Day 1 - Lesson 1

Taylor - Narayana Rao Principles of Industrial Engineering - Extended List


Day 6

Functions and Focus Areas of Industrial Engineering

Value Engineering - Paddy Transplanter - Case Study

Day 7

Industrial Engineering of Belting - 1893

Ford - Industrial Engineering Activities and Jobs

Day 8

Productivity Science

GE going strong on Lean & Kaizen
GlaxoSmithKline - GE - Industrial Engineering Activities and Jobs

Day 9

Product Industrial Engineering

Value Analysis and Engineering - Examples by L.D. Miles - Part 1

Day 10

Process Industrial Engineering

Process Industrial Engineering - Illustration: Process Industrial Engineering Using Robo Cylinder

Day 11

Industrial Engineering Economic Analysis

Honda - Industrial Engineering Activities and Jobs

Day 12

IE Measurements

Milling - Estimation of Machining Time

Day 13

Value Creation for the Organization by Industrial Engineers - Productivity Engineering

Process Industrial Engineering - Illustration:  Gear Machining Productivity


Module  2 - List and Links

Contribution of Taylor, Gilbreth, Emerson, Maynard, Barnes, Lehrer, Shigeo Shingo

Day 14

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

Process Industrial Engineering - Illustration:    Cryogenic Machining Adoption - Productivity Improvement at Lockheed Martin


15

Taylor's Industrial Engineering - First Proposal 1895

Process Industrial Engineering - Illustration - Investment in Sliding-Head Lathe with Chipbreaking Feature

16

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

Process Industrial Engineering - Illustration - Process Improvement via Toolholder Change

17

Productivity Improvement in Machine Shop - F.W. Taylor

Tool Wear and Temperature Analysis for Process Improvement

18

Development of Science in Mechanic Arts - F.W. Taylor

Dynamic Control of Circulatory Pumps for Heating Systems Saves 20% of Energy Cost

19

Time Study for Process Time Reduction - F.W. Taylor

Process Industrial Engineering - Illustration - Additive Manufacturing of Fixtures - Productivity Benefits

20

Taylor on Quality, Human Relations and Management

Process Industrial Engineering - Illustration -Alternative Lubricants and Productivity - Case Study

21

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

Illustration of Human Effort Productivity Improvement - Bricklaying Improvement by Gilbreth

22

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

Illustration of Human Effort Productivity Improvement - Pig Iron Handling by Taylor

23

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

Illustration of Human Effort Productivity Improvement - Bicycle Balls Inspection Example - Taylor

24

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

Case Study - Method Study - Cast Iron Housing Loading and Unloading 2014

25

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

Case Study - Method Study - Welding Fixture Redesign - Productivity Improvement 2002

26

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

Case Study: Method and Motion Study in a Printing Company - 2019

27

Process Charts - Gilbreths - 1921

Case Study - Examining All Operations in a Process

28

It is important that industrial engineers have to recognize that scientific management was evaluated by Lilian Gilbreth, a psychologist from a human behavior  perspective and a positive opinion was given. Industrial engineering, appeared as a part of the system of management and engineering developed to reduce cost of products made using engineering processes and methods.

Psychology Evaluation of Scientific Management by Lilian Gilbreth - 1914

Implementing Standard Work - Issues

29

After discussing the contribution of Taylor and Gilbreth in more detail, the contribution of many other industrial engineering researchers, professionals, consultants and authors are provided in a series of notes to introduce more industrial engineering concepts. These concepts and their applications will be discussed in more detail in various focus area modules of the course.

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

Case Study: New Scheduling Algorithm Substantially Improves Foundry Productivity - 2017

30

Prof. Hugo Diemer - Taylor's Industrial Engineering

Industrial Engineering Exercise: Productivity Analysis of a Newly Introduced Machine

31

Industrial Engineering - The Concept - Developed by Going in 1911

Productivity Improvement Using Alternative Boring Heads

32

Taylor Society Bulletin

Information for IE: Productivity Improvement Technology in Grinding - 2020

33


Operation Analysis and Improvement: Application of Tribos Toolholder for Productivity

34

H.B. Maynard - HUMAN EFFORT INDUSTRIAL ENGINEERING - Methods Time Measurement (MTM) - Introduction
H.B. Maynard - Methods Time Measurement (MTM) - Introduction (Revised)

Operation Improvement:   Rego-Fix ER Collets for Tools - Productivity Improvement Case

35

Operator Industrial Engineering - Kaizen - Work Simplification - Alan Mogensen
Work Simplification - Alan Mogensen (Revised)

Operation Improvement: Productivity Improvement Through Tool and Toolholder Change - Corogrip

36

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

Collet for Corochuck 930 with Mechanical Locking - Productivity Improvement Use Case


37

Product Industrial Engineering for Cost Reduction - L.D. Miles

Value Analysis and Engineering - Examples by L.D. Miles - Part 2

38

L.D. Miles - 13 Techniques of Value Analysis

Unless special effort to know is made, engineers take 10 years to know engineering developments and implement them in their company processes - L.D. MILES.
Prime Turning (TM) - New Turning Process with High Productivity
RE-INVENTING TURNING, SANDVIK COROMANT TECHNICAL PAPER, 2018
https://nraoiekc.blogspot.com/2020/06/sandvik-coromant-cutting-tools.html

39

Yoichi Ueno - Japanese Leader in Efficiency - Productivity Movement

Sandvik PrimeTurning™ Increases Productivity - Case Studies

40

Toyota style Industrial Engineering - Waste Elimination - Ohno

"We have eliminated waste by examining available resources, rearranging machines, improving machining processes, installing autonomous systems, improving tools, analyzing transportation methods and optimizing the materials at hand for manufacturing. High production efficiency has also been maintained by preventing the recurrence of defective products, operational mistakes, and accidents, and by incorporating workers' ideas." Taiichi Ohno (P. 21)

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

Productivity Improvement Using Through-Tool High Pressure Coolant

41

Industrial Engineering - Foundation of Toyota Production System

3D Printing Multiple Numbers as a Vertical Stack - Significant Productivity Improvement

42

Taylor's Industrial Engineering in New Framework - Narayana Rao

Seco Jetstream Tooling - Benefit - Case Study

43

Review of Module 1 - Industrial Engineering ONLINE Course

Industrial Engineering Concepts - Industrial Engineering ONLINE Course Module 2 - Review

Third Module - Process Industrial Engineering 


44

Introduction to Process Industrial Engineering Module

45

IE Research by Taylor Part 1 - Productivity of Machining


Visit for Module 3 Process Industrial Engineering for Further Lessons





Blog  Industrial Engineering Knowledge Center - Industrial Engineering ONLINE Course.


First year of course offering. 19 May 2020 to May 2021.
(You can start any time and read the lessons.  You can choose modules and lessons of your immediate need. You can always read earlier lessons as needed).

Since 19 May 2020: 1815 visits, 1619 Unique visitors, 862 entrances - direct to the page.

Second Round course revision and social media sharing from  1 June 2021 

Present module under circulation
(In the first year 1000 learners accessed the course page. So far 1690 unique learners accessed this page.)


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

Reading Performance of Learners of the course Since 1 June 2021.

Target. 50 readers for each of the 300 lessons.


7 Feb 2022

132nd Ranked post - 50 readers

Design Thinking and Industrial Engineering

http://nraoiekc.blogspot.com/2017/05/design-thinking-and-industrial.html

221st ranked post - 34 readers
Industrial Engineering through Process Mining

297th ranked post - 24 readers

300th Ranked post - 23 readers  
News - Information for Inspection Activities Productivity Improvement. 




The Course Page First posted on 19 May 2020

Updated on 26.6.2024,  1.6.2024,  13.10.2023, 11.5.2022,  23.4.2022, 12.4.2022,  8.2.2022,  7.1.2022,  29.10.2021, 16 July 2021, 5 July 2021,  30 May 2021,  6 July 2020

Wednesday, May 28, 2025

Seven Flows of Manufacturing - Toyota Production System Industrial Engineering

TPS is Industrial Engineering System of Toyota Motors.


IE is a system and the Toyota production system may be regarded as Toyota style IE.

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

https://nraoiekc.blogspot.com/2013/11/taiichi-ohno-on-industrial-engineering.html

 




Toyota Production System has a system or process design component and system and process improvement component. The Jidoka pillar of TPS describes these activities. The other pillar JIT deals with quantities of material flowing in the system. JIT is a small batch quantity production system.


Seven flows are important in process design and process improvement.


They are:


The flow of raw material

The flow of work-in-process

The flow of finished goods

The flow of operators

The flow of machines

The flow of information

The flow of engineering

Industrial engineers must first observe each of these flows to gain full understanding. Based on observation, they have to take notes and sketch out the seven flows. 

https://www.reliableplant.com/Read/19651/underst-implement-7-flows-of-manufacturing



OCTOBER 21, 2007 BY MARK

The Seventh Flow - The flow of engineering

http://theleanthinker.com/2007/10/21/the-seventh-flow/


Understand and implement the 7 flows of manufacturing.

Published on February 5, 2016

https://www.linkedin.com/pulse/understand-implement-7-flows-manufacturing-graham-chick/


Nakao-san and Shingijutsu-Kaizen

August 4, 2014 by Bob Emiliani

https://bobemiliani.com/nakao-san-and-shingijutsu-kaizen/


A kaizen method like no other!


Shingijutsu-Kaizen: The Art of Discovery and Learning describes how, for more than three decades, Kaizen consultants from Shingijutsu USA Corporation have been helping manufacturing and service organizations improve processes by teaching people the methods and tools of flow production.

https://bobemiliani.com/book/shingijutsu-kaizen/


http://www.shingijutsuusa.com/


Chihiro Nakao - Taiichi Ohno’s best student from outside of Toyota proper.

The Most Dangerous Idea in the World

By Jon Miller • Published: June 22nd, 2015

https://blog.gembaacademy.com/2015/06/22/the-most-dangerous-idea-in-the-world/


Nakao was in charge of development activities in a supplier company.

https://books.google.co.in/books?id=cNs_CQAAQBAJ&pg=PA13#v=onepage&q&f=false

Flow Analysis is part of Toyota Kaizen Course in 1968


Improving Flow - Lee Candy


Document or Map the process - Process Chart, Value Stream Map

Identify and log all problems the process owners/managers/engineers/operators experience

Identify all waste in the current process

Develop ideas for  improvement opportunities

Do engineering of improvement ideas

Develop Process Chart or Map of the Revised Process 

Develop an action plan to install the revised process

Actively monitor the new processes put into place to assure improvement expected.

Create performance measures for control in the operations

https://online.kettering.edu/news/2016/07/07/understanding-principle-flow-lean-manufacturing


A Toyota Leader on Misunderstandings About the Toyota Production System

By Mark Graban On Apr 24, 2019

It's a talk given by Nampachi Hayashi at the “Building on Success 2018 Conference.”

Mr. Hayashi says the name “should have been TPS = Toyota Process Development System.”

Built-in quality and improved flow leading to lower cost… as a result. Cost reduction isn't the primary lever that's pulled (as we see attempted in so many Western companies, including hospitals)… it's a result. Simple cost-cutting might not lead to better quality and flow (it's often quite the opposite that happens). But better flow and better quality always leads to lower cost, in my experience. Productivity is also a forward activity. It focuses on fully utilizing the machine and man to do a job with less resources. This it results in lower cost.



Discussion in LinkedIn Topic  https://www.linkedin.com/feed/update/urn:li:activity:6866080389295874048

When you talk about Flow - what else can be added to the information below!



Sivakumar Shanmugasundaram
https://www.linkedin.com/in/sivakumar-shanmugasundaram-84b9665a/

Operator flow .....

Are the operators knowledgeable about the process ?

Have the operators acquired the required skills to execute the work?

Is their fatigue level is same throughout the operating hours ?

Are they able to identify the defects ?

Are they able to identify the abnormalities in the machine ?

Are they able to measure and adjust the machine to produce zero defects ?


Material flow....

Is the material flow visible throughout the value stream ?

Is the material defect free ?

Is the material easy to handle ?

Information flow...

Does the right information reach the right person at the right time ?

What is the mode of information flow ?
verbal, hardcopies, or electronic

Has the receiver able to understand the information and execute effectively?



Ud 16.11.2021
Pub 3.5.2021













TPS - Toyota Industrial Engineering - The Story

TPS is Industrial Engineering System of Toyota Motors.


IE is a system and the Toyota production system may be regarded as Toyota style IE.

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

https://nraoiekc.blogspot.com/2013/11/taiichi-ohno-on-industrial-engineering.html

 





The success of Toyota in cost reduction, productivity improvement, and international competitiveness and its celebrated Toyota Production System, fulfilled the dream of Yoichi Ueno (that Japan can guide US in improved practices of efficiency improvement). The success of #Toyota and the World Class #TPS was  built on the sustained efforts many Japanese persons who understood Taylor and Gilbreth's writings and improvised them in implementing them in Japanese companies.



TPS - the ancestors

Sakichi Toyoda - Toyoda Loom Works -  invented an automatic power loom, Jikoda (autonomous automation), 5 Whys

Kiichiro Toyoda - dreamed of branching into automobiles, started in 1933.
Frustrated by difficulties in engine casting, begins process study.
1936 - creates Kaizen improvement teams
Resigned 1948 due to poor sales.

Department of War TWI program -
1950 - Deming visits Japan. at request of Japanese Union of Scientists and Engineers, June-August 1950, trains 100s of engineers, managers and scholars in statistical process control and quality.

JUSE - > Genichi Taguchi - consults with Toyota

In 1957 cousin Eiji Toyoda takes over. Visits Ford. Implements Ford mass production standards.

Frederick Taylor's PSM -> Shigeo Shingo

Toyota Production System

Many folks may think that Japan achieved market dominance through robots, or being workaholics. Not so.

Taiichii Ohno - graduated from Nagoya Technical High School, joined Toyota in 1943 -
Shigeo Shingo - late 50s to 60s - consulting with Toyota
Eiji Toyoda..
Started in 1948 - based on work of Deming

muri - inconsistency
mura - overburden
muda - waste

design out mura - be able to meet required results smoothly - Tai Chi
decrease muri - increase flexibility without stress - Yoga
eliminate muda - eliminate waste - Shaolin Kung-Fu
Perfection is achieved, not when there is nothing left to add, but when there is nothing left to remove. - Saint-Exupery

Unable to eliminate bottlenecks in production
EOQ - Economic Lot Size - calculation of best use of line, production must be high enough to meet demand for different models

different model = different parts, different dies, different procedures, different tools

high downtime for line changeover = high economic lot size
high economic lot size = high stock  of parts inventory
high stock of inventory = investment of $$$, land costs in Japan are expensive, high cost for big warranty
lesser diversity of models

First - rework factory and models to make use of standard parts, tools, and processes.

Next goal is SMED
biggest component of changeover is die exchange
examine process -
die weighs many tons
use crane to remove old and install new
requires minute measurement to put into place
done by hand and by eye
tested by making test stampings, wasting time and resources
process took 12 hours to 3 days

improve
invest in precision measurement devices
record necessary measurements for each die
install according to measurements rather than by hand and eye - changeover to 90 minutes

FRS - fixed repeating schedule
die changes in standard sequence
scheduling tool changeovers as the new product moved through factory
scheduling use of cranes

SMED achieved
Single Minute Exchange of Die
<10 minutes to change die.
EOQ = 1 vehicle.
Just in time manufacturing

intangible benefits
stockless production
reduction of process footprint = free floor space
productivity increased
ability to changeover more
elimination of defects
improved quality of each product
improved quality from
increased safety due to simpler setup
simplified housekeeping
lower expense of setup
operator preferred = better worker satisfaction
lower skill requirements
elimination of waste
goods are not lost due to deterioration in inventory
new attitudes on work process among staff

Source:
TPS by Ken Harris
http://knol.google.com/ k/ken-harris/tps/ 6p1yn013rxws/2

Posted under creative commons 3.0 attribution license




Full List of Articles on Kaizen

Kaizen eno Yon Dankai - Improvement in 4 Steps - History of Kaizen in Japan

Rules for Successful Kaizen Management


Kaizen - Engaging Front-Line Staff in Continuous Improvements - Industrial Engineering

Leading and Managing Kaizen Events

Agile Kaizen

Kaizen - The Japanese Style Productivity Improvement Methodology

Industrial Engineering is Kaizen in Engineering

Kobetsu Kaizen - Focused Improvement of Machine and Machine Work in TPM

Front Line Kaizen for Product and Process Industrial Engineering


Gadget-based improvement is widespread as improvement activities that can not only eliminate losses but also inspire the workplace.

Karakuri Kaizen - Introduction

Industrial Engineering is Kaizen Engineering

Toyota Kaizen Methods: Six Steps to Improvement - 2010 - Book Information

Kaizens - Production Improvement Ideas Implemented - India - Kaizen Eye

Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line - Book Information

Kaikaku: The Power and Magic of Lean : a Study in Knowledge Transfer - 2004 - Norman Bodek - Book Information

Kaizen Costing and Kaizen Cost Management







Pub. 20.3.2012   Ud. 12.11.2024