Industrial Engineering - Some Important Concepts - A Presentation

 1.

Industrial Engineering - Simple Definition

IE is System Efficiency Engineering

Enterprise - System- Process - Operation - Element

IISE Definition

Interesting.

Systems Engineering Efficiency.

Falko Firl, 

Head of Fighter Radar Engineering at HENSOLDT,

https://www.linkedin.com/pulse/systems-engineering-efficiency-falko-firl/

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2.

Industrial Engineering

Productivity (and other results areas) Engineering Related to Design and Redesign of Products, Systems, Facilities, and Processes.

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3.

Industrial Engineering

Significant value to be added through cost reduction based  on Productivity Improvement (Time reduction - machine time - man time)

Cost reduction can lead to lower prices, revenue growth and profit increase.

There can be direct increase in profit due to cost reduction.

IE sustains and grows business.

What is the value your are adding as a department?

Value Creation for the Organization by Industrial Engineers - Productivity Engineering Potential.

Propose and get approvals for Productivity Projects. Implement them and realize the RoI.

Lesson 13. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

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

We start with a MS Industrial Engineer earning $12,000 per month. He is expected to have 6 BS industrial engineers under him. Each BS industrial engineer is earning a salary of $6000 per month.

Let us take a team of one  BS industrial engineer + Supervision by MSIE + staff support totaling $10,000 per month. which is equal to $120,000 per year.

This team is expected to generate a saving of $600,000 per year in 50 IE projects. That means each project has to save 12,000 dollars on average.

Let us assume each project is on an operator earning $3000 per month. The total cost of the work center can be taken as $30,000 per month. Which means $360,000 per year. Industrial engineers have to find $12,000 savings out of that expenditure every year assuming that a BSIE is responsible for work of 50 operators . Operation Analysis is used on One Machine + Operator combination. It is possible that multiple machines are operated by one operator in which case we may think of one machine + part operator.  Maynard and Stegemerten authored a full book on operation analysis and Niebel explained it well in a chapter in his book on Motion and Time Study.

The IE department's expenditure per month is $60,000 ((1 MSIE + 5 BSIEs + Staff)). They have to find savings of $300,000 per month. $3,600,000 per year on $100,000,000 cost of production per year.

Breakup of Productivity Benefit  - Sharing Scheme

Savings of $300,000 per month

Benefit break up:

IE department staff: $60,000
Investment in projects: $60,000
Increase in benefits to other employees:$60,000
Benefit to customers: $60,000
Increase in profits of the company: $60,000

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4. 

Product Industrial Engineering

Value Analysis and Engineering

DFMA

Productivity Engineering I - Product Industrial Engineering.

Lesson 9. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2012/09/product-design-industrial-engineering.html

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5.

Facilities Industrial Engineering

Machine Study - Machine selection - Need for modification - Maintenance Policies - Replacement

Accessories Study - Tools Study

Work station layout

Plant Layout

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6. System Industrial Engineering

A system is used by many processes

Stores system

Materials purchase system

Production Planning System

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7. Process Industrial Engineering

A process has operations.

1. Eliminate Operations

2. Examine dividing or combining operations

3. Change the sequence of operations

4. Simplify operations

Productivity Engineering II. Process Industrial Engineering. 

Lesson 10. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2017/02/process-industrial-engineering.html

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8. Simplify Operation Through Operation Analysis

Operation Analysis Sheet

Operation Data Sheet

Machine Effort Study - Machine study - Machine work or operation study

Human Effort Study - Study of Humans - Anatomy - physiology - Human work study - Motion study - Ergonomics

Industry - meaning - effort

Machine Work Study.

Taylor's Industrial Engineering - Machine Work Study. The first focus of industrial engineering.

Productivity Improvement of Machines in Machine Shop.

Lesson 17 . Industrial Engineering ONLINE Course  #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2020/05/productivity-improvement-in-machine.html

Taylor's Industrial Engineering - Human Work Study - Productivity Improvement and Development of Science in Mechanic Arts - F.W. Taylor. 

Lesson 18 . Industrial Engineering ONLINE Course  #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2013/08/development-of-science-in-mechanic-arts.html

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Human Motions (Motion Study) - Part 1  

Lesson 21.  Industrial Engineering ONLINE Course #IndustrialEngineering #Productivity #CostReduction #HumanEffort #Operator #Mechanic

https://nraoiekc.blogspot.com/2015/08/motion-study-frank-b-gilbreth-part-1.html

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9.Productivity Science

Science based Productivity Engineering and Productivity Engineering.

Productivity Science  Principle of Industrial Engineering. Develop a science for each element of a man - machine system's work related to efficiency and productivity.

Lesson 8. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2017/06/productivity-science-principle-of.html

Taylor - Productivity Science and Art of Metal Cutting - Important Points  #IndustrialEngineering #Productivity #CostReduction

Lesson 14. Industrial Engineering ONLINE Course 

https://nraoiekc.blogspot.com/2019/06/taylor-art-of-metal-cutting-important.html

Productivity Science Module - Lessons.

https://nraoiekc.blogspot.com/2021/05/productivity-science-module-lessons.html

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10. Productivity Engineering

Engineering to utilize benefits indicated by Productivity Science

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11. Productivity Management - Management of IE Department and its activities

Planning IE studies.

Managing IE studies.

Planning IE Projects

Implementing IE Projects

Behavior Management - Self, Associates, Suppliers, Customers

Harrington Emerson - A Pioneer Industrial Engineer -  12 Principles of Efficiency - Principles of Productivity Management.

Lesson 29 - Industrial Engineering ONLINE Course #IndustrialEngineering #Productivity #CostReduction #Planning

https://nraoiekc.blogspot.com/2012/02/harrington-emerson-pioneer-industrial.html

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12. Toyota Style Industrial Engineering - IE in Toyota Motors and Japan

Ohno - Mentions only Industrial Engineering in his books.

TPS is output of application of IE.

TPS description only outlines what is special in TPS. TPS used full IE principles and practices.

Managementt drives IE in Toyota. IE connected to Management.

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13. Lean Manufacturing - Lean Thinking - Concept

Lean Mfg.  - Mfg. system with less inventory (compared to bulk manufacturing in batches).

Further extended - Lean Mfg. -With less resources (No muda - No excess resources)

Lean Thinking - Value - Value stream - Flow - Pull - Perfection.

                       Product - Process  - Facilities - Quantity Planning - Improvement

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14. Productivity Planning - Productivity Budgeting

Planning for Productivity Improvement by Technique/Technology (Say based on IoT)

Planning for Productivity Improvement by Period (Next year planning)

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15. Hoshin Kanri - Deployment of Productivity Planning

Now the world admires Japanese practice

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16. Knowledge Management for IE

IE is a knowledge intensive task.

For each process, Industrial engineers have to collect lot of information on external developments apart from internal data.

Information on new technologies, new products, machines, devices - new offerings from subcontractors, consultants

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17. Work Allocation in IE Departments.

Identification of processes in the organization.

Allocation of processes in the organization.

Identification of products  in the organization.

Allocation of products  in the organization.

Identification of facilities  in the organization.

Allocation of facilities  in the organization.

Identification of systems   in the organization.

Allocation of systems   in the organization.

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18. Applied Industrial Engineering - Industrial Engineering Applications .

I strongly feel that industrial engineering applications have to progress parallel to progress in each branch in basic engineering. Every invention that is commercialised requires applied industrial engineering of the product and process on a continuous basis throughout its life cycle. These IE applications gives rise to improved engineering elements some of which can be even patented. 

I am trying to develop course materials that describe and give examples of this IE practice.

Industrial Engineering FREE ONLINE Course. 

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

19. New Wave of Technology - Smart Manufacturing - Industrial Engineering 4.0 - Industrial Engineering 5,0

20.

I. Define Vision, Mission, and Scope

II. Strategic Alignment

III. Product, Process, Facility and System Improvement and Optimization. - IE  Methodologies

IV. Applied Industrial Engineering - New Technology Integration

V. Talent Development and Culture

VI. Performance Measurement and Reporting

VII. Collaboration and Communication

VIII. Continuous Improvement of the IE Department Itself

ud. 23.7.2025, 17.7.2025

Pub. 5.7.2025