Thursday, April 16, 2026

Management Module for Industrial Engineering

 


Management Module for IE

IE as a function and as a department needs to be managed. IE studies and projects are to be managed. Hence IEs need management inputs in their educational programs. Presently in IE programs a well developed management module appropriate to creating management expertise in industrial engineers is not there.

Mikell Groover in his  Book - Work Systems and the Methods, Measurement, and Management of Work specially includes management of work in the title.

He gave the following chapters under management of work in third edition of the book.

Ch.27 Work organization
Ch. 28 Worker Motivation and Social Organization of Work
Ch. 29 Job Evaluation and Performance Appraisal
Ch. 30 Compensation Systems

Industrial Engineering Projects - Formulation, Communication and Implementation
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Tuesday, April 14, 2026

L.D. Miles - Value Engineering - Product Industrial Engineering - Low Cost Products and Processes for IE

 


Value Analysis Techniques


Miles provided 13 ideas as value analysis techniques (Each technique linked to a video).
 
  1. Avoid generalities
  2. Get all available costs
  3. Use information from the best source
  4. Blast create and refine
  5. Use real creativity
  6. Identify and overcome roadblocks
  7. Use industry experts to extend specialized knowledge
  8. Get a dollar sign on key tolerances
  9. Utilize vendors’ available functional products
  10. Utilize and pay for vendors’ skills and knowledge
  11. Utilize specialty processes
  12. Utilize applicable standards
  13. Use the criterion, “would I spend my money this way?”
Blast create and refine and Utilize specialty processes are related to low cost products or parts and low cost processes.


Brief Explanation of the VE Analytical Techniques 

Blast, Create and Refine

Blast
To do blast activity, the basic functions to be accomplished by a product or a component are given the focus and alternative products, materials and processes are brought into the picture. These alternatives need not entirely accomplish all the basic functions completely. These alternatives need to qualify on the basis of accomplishing some important part of the function or functions in a very economical manner. The alternatives are in the consideration list even if they can accomplish important part of the function based on some modifications. During this activity, the amount of the function which would be accomplished by the suggested or identified alternatives and the cost involved are ascertained.

Create
Use real creativity to generate alternatives to improve the ideas of blast stage, to accomplish large part of the required function with accompanying increase in cost. Increase in functions obtained needs to be accounted by increase in cost.

Refine
The solution obtained in create stage is further sifted and refined by adding features which provide further functions and fully accomplish the desired function. Miles stated that this blast, create and refine technique delivered the total function with the same reliability but at a cost of one-half to one-tenth of the original for many components and products.


Utilize specialty processes and special tools


Miles defines specialty process as an applicable process which would reliably accomplish the needed function for significantly lower cost and which either exists or could, and would be developed by some one who leads in the technology involved if he understood the need for it.

Miles gave the opinion that even persons engaged in value work take time to recognize specialty processes. In 1961, he gave the delay as three years. Other engineers take around 10 years to recognize specialty processes. The purpose of identifying and emphasizing this point in the list of VE techniques is to reduce this time lag.

Special tools also provide value opportunities. Value engineers have to be on the lookout for appearance of special tools.




Low-cost additive manufacturing materials are primarily driven by thermoplastic filaments for FDM/FFF printers, with PLA (Polylactic Acid) being the most affordable ($20–$30/kg) and beginner-friendly option. Other low-cost, versatile, or specialized materials include ABS, PETG, TPU for flexible parts, and PLA-based composites for increased rigidity or aesthetic properties. 

Top Low-Cost Materials (FDM/FFF)
PLA (Polylactic Acid): Excellent for prototypes and beginner projects due to its low cost ($20–$30/kg), ease of printing, and availability.
ABS (Acrylonitrile Butadiene Styrene): Durable and heat-resistant, often used for functional prototypes, though it requires higher temperatures and a heated chamber.
PETG (Polyethylene Terephthalate Glycol): Combines ease of use (like PLA) with higher strength and chemical resistance (like ABS).
TPU (Thermoplastic Polyurethane): Flexible and resilient material used for creating dampeners, toys, and phone cases.
PLA Composites (Wood/Metal filled): These are PLA blends containing wood fibers or metal powder (copper, bronze), offering unique textures and aesthetics, often at a similar price point to standard PLA. 

Low-Cost Specialized Approaches
Electrochemical Additive Manufacturing (ECAM): A highly cost-effective, low-energy approach to metal 3D printing that uses electrochemical deposition rather than expensive lasers or powder beds.
Pellet Additive Manufacturing (PAM): Uses, cheaper pelletized polymer feedstock instead of specialized filaments, significantly reducing raw material costs for larger prints.
Recycled Filaments: Using recycled materials can lower costs and increase environmental sustainability. 

Key Considerations for Cost Saving
Material Cost: PLA remains the most cost-effective option.
Waste Management: Using methods like PAM (Pellet Additive Manufacturing) or recycling systems minimizes material waste, decreasing the overall production cost.

How Much Does 3D Printing Cost? 2026 Ultimate Guide
Updated
Aug 22, 2025


Cost Factor            FDM (Filament)          Resin (SLA/LCD)
Standard Material    $20–$30 / kg           $40–$80 / kg




https://protomont.com/what-are-the-most-affordable-3d-printer-filaments-on-the-market-2/


HardwareX
Volume 11, April 2022, e00292
HardwareX
Low cost 3D printing of metals using filled polymer pellets
































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Monday, April 13, 2026

Knowledge Management for Industrial Engineering

 


System Industrial Engineering requires knowledge.


Process Industrial Engineering requires knowledge.


Operation Industrial Engineering requires knowledge.


Element Industrial Engineering requires knowledge.


Product Industrial Engineering requires knowledge.


Knowledge has external and internal components.


External Objective knowledge may be available for sale. But somebody has to identify and purchase and them make it available to many persons in the company.


Internal knowledge has also objective knowledge and informal or knowledge which is only with the people who did a project and service. An internal knowledge system must accumulate knowledge and make it available to many in the organization.


Four Components of Knowledge Management


The four important components of knowledge management are people, process, content/IT, and strategy. Regardless of the industry, size, or knowledge needs of your organization, you always need people to lead, sponsor, and support knowledge sharing. You need defined processes to manage and measure knowledge flows. You need knowledge content and IT tools that connect the right people to the right content at the right time. And finally, you need a clear and documented strategy for using KM to meet the most important and urgent needs of the business.

What are the Best Four Components of Knowledge Management? | APQC


Knowledge Management Software Reviews and Ratings 

Best Knowledge Management (KM) Software Reviews 2026 | Gartner Peer Insights


What Is Knowledge Management? | IBM










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Automation - Examples and Case Studies

 


Webinar TMF - Automating the production of mineral insulated temperature sensors


The Machines Factory


 1 Apr 2026

During this short session we will introduce TMF and present our latest developments aimed at automating key steps in the production process of mineral insulated temperature sensors.


Topics we will cover:

• Introduction to The Machines Factory and its vision for sensor production automation

• Overview of our currently available machines, including the CS-1100 straightening and cutting machine and SH-600 spool holder

• Presentation of our latest developments: the laser grooving unit

• Concept of the sorting carousel for automated handling of cut parts

• Live demonstration of the CS-1100 machine

• Q&A session

https://www.youtube.com/watch?v=TSyl7xHsZ0g




Association for Advancing Automation

900 Victors Way, Suite 140, Ann Arbor, Michigan, USA 48108 

Automated Inspection of Electronic Assemblies

01/28/2025


Our advanced camera system provides a fully automated solution for inspecting various connector geometries, enabling precise and efficient quality assurance.


Application and Solution

In the production of electronic assemblies, our camera system was integrated to perform a comprehensive set of inspections, including:

Pin Inspection: Verifying the presence, alignment, and integrity of connector pins

Coding Inspection: Ensuring correct coding for compatibility and proper assembly

Pluggability Inspection: Validating connectors for proper fit and alignment

Label Content Inspection: Verifying label data, including OCR (Optical Character Recognition), OCV (Optical Character Verification), and DM (Data Matrix) code grading

Multiple cameras were deployed in the system, strategically positioned to capture high-resolution images of critical components. The system processes images in real-time to identify defects or inconsistencies, ensuring production quality.


Performance Highlights

Speed and Efficiency: Achieved a maximum image processing and evaluation time of 1.5 seconds per inspection

Precision: Delivered position accuracy of ± 0.01 mm for traversing axes

Font Size Testing: Inspected text as small as 1 mm font size, ensuring readability and compliance with labeling standards

https://www.automate.org/vision/case-studies/automated-inspection-of-electronic-assemblies

A supplier.

senswork Vision Systems

senswork is an expert in machine vision systems and specializes in optical inspection, industrial image processing and testing equipment manufacturing. Our ready-to-use camera technologies for automation and quality assurance are used every day by our renowned customers in numerous industries.







Top 6 Factories in Korea that use Automation


First factory shown manufactures vacuum cleaner

_____________________


https://www.youtube.com/watch?v=RZ-M_nX4qXA

______________________


Hand Pallet Trucks - Mass Production


______________________

https://www.youtube.com/watch?v=kSMwrOMK1bQ

______________________






Ud. 13.4.2026, 2.2.2025

Pub. 21.7.2023



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Saturday, April 11, 2026

Job Shop Industrial Engineering - Job Shop Lean - Shahrukh Irani

 Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems Hardcover – 18 May 2020

by Shahrukh A. Irani (Author)

https://www.amazon.in/Job-Shop-Lean-Implementing-Low/dp/0367472252




https://www.iise.org/uploadedFiles/Webcasts/Public/Adapting-Lean-HMLV.pdf

Houston's manufacturers can utilize services of Dr. Shahrukh through the internship assignments of IE students.


Shahrukh Irani

A GUIDE TO ISE (Industrial & Systems Engineering) PROGRAMS TO IMPROVE THE PERFORMANCE OF HOUSTON'S MANUFACTURERS


Calling all manufacturers in Houston regardless of your size, type of manufacturing you do, etc. As the saying goes "From little acorns grow mighty oaks!" Well, in this case, the little acorn is to simply host me for a 1/2 day visit to tour your factory floor. But, prior to my visit, you will need to complete and return to me a questionnaire that helps me to prep for any such factory visit.


After the visit is over, I will send you a Trip Report that contains my observations, diagnostics and recommendations for actions you can take to improve factory operations. At this point, you can decide to not have any further dealings with me. HOWEVER, if you desire to benefit from the numerous industry outreach programs that the Department of Industrial & Systems Engineering at UH has to offer Houston's Manufacturers, you could start either by (1) hiring our students as interns or by (2) hosting one or both my courses on Lean and Job Shop Lean. 


If you do either or both the above, you would have laid the foundations for reaping the benefits of partnering with my department as has McWane Plant & Industrial Inc. They hired Sultan Ahmed Mohammed and Ujwal Rayala, CLSSGB as interns in Summer 2024. At that time, they did about $600K per month in revenue. Today, they do anywhere between $1 million and $1.2 million, thanks in main to the stellar work of Sultan who is currently a full-time Senior Manufacturing Engineer with MPI.

If you are in shock at the prospect of reading a 300-page document, please rest easy! Just submit this guide to your favorite LLM, say ChatGPT or Claude, and have it summarize any section that appears in the Table Of Contents. In fact, I could send you the summary that I generated! :-) :-) :-)

If you are interested, or even have questions, please dm me at your convenience.

Thank you.

Dr. Shahrukh Irani

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_ise-outreach-programs-to-benefit-houstons-ugcPost-7445875160324304896-s48H








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Friday, April 10, 2026

Innovations by Industrial Engineers - Recent LinkedIn Posts on Innovations

 

Industrial engineers have to innovate. They have to identify and implement new engineering ideas and products in their processes and operations. They have to use creativity to maximize the output from engineering ideas currently in use in the company as well as new ideas that are now adopted.

What are some of the recent posts on innovation on LinkedIn




Steve Wozniak, co-founder of Apple and a pioneer of the personal computer revolution, shares candid perspectives on innovation, intellectual property, leadership, and collaboration, shaped by real successes, failures, and bold ideas.


His personal stories and practical insights offer a fresh perspective on how innovation comes to life, not just as ideas, but through the way we develop, protect, and scale them.

https://www.linkedin.com/feed/update/urn:li:activity:7447663848331079681/


Innovation is a team effort. 

Here, engineers from countries around the world come together to brainstorm new ideas, create boundary-pushing solutions and redefine industry standards. See Chief Engineer Lena’s thoughts on being part of an international engineering team and explore engineering here



Defining INNOVATION 

Innovation is not just a new idea.

It is a valuable idea.

Barbara Salopek makes a powerful distinction:

Not all ideas are innovation.
Not even all patents are innovation.

Innovation happens when an idea:
• Creates real value
• Solves a meaningful problem
• Works in the real world
• Generates impact (and often revenue)

Innovation is not about the idea.  It is about the value it creates.

Watch a presentation here:



The culture shift that fuels innovation at work





Interesting Picture Presentation
Exploring the journey of innovation through New Product Development and Re-engineering—where ideas evolve into impactful solutions and continuous improvement drives success.


Mette Storvestre

PhD Corporate Entrepreneurship



Yes, Incremental Innovation Matters

In my PhD research, one insight kept resurfacing: In mature organisations, incremental innovation, not only what Jens Stoltenberg once called a “moon landing,” that truly moves the needle.

McKinsey’s 2022 data is clear:
82%+ of revenue growth come from everyday improvements
12%+ from adjacent innovation (new markets, new tech)
6%+ from radical innovation

How to build a real competitive advantage?
Embracing the human side of innovation by including all innovation modes and building a culture where continuous improvements from the many are recognised and valued. That’s where a substantial growth opportunity lies, and where everyday work becomes more meaningful for more people.

References
Bellis, P., Dell'Era, C., & Verganti, R. (2026). Reframing Through New Minds: How External Experts Unlock Problem Reframing Through Reasoning Logics. Journal of Product Innovation Management.
McKinsey & Company (2022, 7th July). Choosing to grow: The Leader's blueprint.













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Education System - School - College - Univeristy - Improvement Science and Practice

 Q Manage Health Care

Vol. 22, No. 3, pp. 170–186

C 2013 Wolters Kluwer Health | Lippincott Williams & Wilkins

Seven Propositions of the Science of Improvement: Exploring Foundations

Rocco J. Perla, EdD; Lloyd P. Provost, MS; Gareth J. Parry, PhD

https://qi.elft.nhs.uk/wp-content/uploads/2015/06/seven-propositions-of-the-science-of-improvement.pdf


Lloyd Provost

‪Lloyd Provost‬ - ‪Google Scholar‬



John A. Dues

Chief Learning Officer, United Schools Network

Columbus, Ohio, United States 


Author, accomplished education systems leader, and improvement science scholar-practitioner; has served on the founding teams of seven school and nonprofit organizations with more than two decades experience in the sector.


ServicesServices

Educational Consulting • Management Consulting • Non-profit Consulting


https://www.linkedin.com/in/johnadues/



Kata in the Classroom

A simple pattern that helps you teach scientific thinking


Kata = a way of practicing a skill.

Kata in the Classroom (KiC) is a simple overlay that helps educators turn almost any activity or assignment into effective practice of scientific thinking. Repeatedly utilizing KiC helps students develop scientific thinking as a practical life skill and mindset.





Ud. 10.4.2026

Pub 30,1,2024








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Thursday, April 9, 2026

Health Aspects of Industrial Engineering

 


The Sri Lankan Corporate Health & Productivity Awards (SLCHPA) and the Global Healthy Workplace Awards are two prominent health and productivity awards that recognize organizations for their commitment to employee well-being and workplace sustainability. The SLCHPA, launched by the Chamber of Lankan Entrepreneurs (COYLE) in collaboration with the Japan External Trade Organisation (JETRO), aims to inspire organizations to take proactive steps towards better workplace health and holistic productivity. The awards also support COYLE's broader mission to foster a better employment environment in Sri Lanka, ensuring that companies place people at the heart of their growth strategies. 

Sri Lankan Corporate Heath & Productivity Awards 2025


The Global Healthy Workplace Awards celebrate organizations that have shown extraordinary leadership, innovation, and measurable impact in advancing workplace health, safety, and wellbeing. 

 

The Global Centre for Healthy Workplaces is proud to announce the finalists for the 2025 Global Healthy Workplace Awards. This year, we honour six exceptional organisations that have shown extraordinary leadership, innovation, and measurable impact in advancing workplace health, safety, and wellbeing.


Large Enterprise Finalists


Bayer India (India)


Hamad Medical Corporation (Qatar)


Tata Motors (India)


Multinational Enterprise Finalists


Allianz (Germany)


Sanofi (France)


Wipro (India)


These outstanding finalists will showcase their pioneering workplace health programmes at the 13th Global Healthy Workplace Awards and Summit, taking place 20th – 21st November at Godrej One, Mumbai, India, in collaboration with the Arogya World Healthy Workplace conference and hosted by our strategic partner Godrej Industries Group. Each organisation will compete for the distinguished title of the world’s healthiest workplace.

Global Healthy Workplace Awards Reveal 2025 Finalists Ahead of Mumbai Summit – Global Centre for Healthy Workplaces | Good Health is Good Business | Workplace Health Awards & Summit


Both awards provide a platform for organizations to demonstrate their commitment to employee well-being and productivity excellence, contributing to a healthier and more productive workforce.




Hitachi Energy Japan Recognized as a 2026 Health & Productivity Management Outstanding Organization (Large Enterprise Category)

Press Release | Tokyo, Japan | 16.03.2026 | 


okyo, March 16, 2026 - Hitachi Energy Japan Ltd. has been recognized as a 2026 Health & Productivity Management Outstanding Organization (Large Enterprise Category) under the recognition program, jointly administered by Japan’s Ministry of Economy, Trade and Industry (METI) and Nippon Kenko Kaigi (Japan Health Council).


Since 2023, the company has been recognized in the Small and Medium‑Sized Enterprise Category for three consecutive years. In 2026, Hitachi Energy in Japan was recognized for the first time in the Large Enterprise Category, reflecting its workforce growth. Organizations certified in this category are expected to lead by example, extending health and productivity management beyond their own operations to group companies, business partners, local communities, customers, and employees’ families.


People‑Centric HSE as a Foundation for the Energy Transition


At Hitachi Energy, we promote “Health and Productivity Management”—activities designed to maintain and enhance employee health—guided by the Hitachi Group Safety and Health Policy, whose core principle is that safety and health always come first, and our global HSE*1 policy, which focuses on improving health and well‑being in the workplace.

*1 Health, Safety, and Environment.


With people at the heart of everything we do, Hitachi Energy views health and productivity management as a management foundation that underpins corporate value and social trust. By fostering a safe and healthy work environment through shared responsibility and continuous improvement, the company reinforces its role in advancing the energy transition and shaping a sustainable energy future for all.


 


About the Health & Productivity Management Outstanding Organization Recognition Program


The Health & Productivity Management Outstanding Organization Recognition Program is a program established by Japan’s Ministry of Economy, Trade and Industry (METI) in fiscal year 2016. The program highlights large enterprises and small and medium‑sized enterprises that are implementing particularly excellent health and productivity management, and aims to develop an environment in which such organizations can gain enhanced recognition from employees, job seekers, related companies, and financial institutions. Marking its 10th year, the 2026 program recognized 3,765 organizations in the Large Enterprise Category and 23,085 organizations in the Small and Medium‑Sized Enterprise Category.


Hitachi Energy Japan Recognized as a 2026 Health & Productivity Management Outstanding Organization (Large Enterprise Category)


Investment in Health

English - ACTION！健康経営｜ポータルサイト（健康経営優良法人認定制度）




Contact us


Regarding the "Health and Productivity Management Excellent Organization Certification" and "Health Scoring Report" conducted by the Japan Health Council, there is a dedicated secretariat and contact information for system design and data processing operations.

For details and contents of the system, please refer to the relevant websites, etc., and contact the following contact.



Matters related to "Certification as an Excellent Health and Productivity Management Organization"


■Health and Productivity Management Excellent Organization Certification Secretariat (Nikkei Shimbun)

Contact: Nikkei Research Co., Ltd.

Tel: 03-5296-5172

(Inquiry hours: Weekdays 10 a.m. ~ 5:30 p.m.)

E-mail address:

About the Large Corporation Division health_survey* nikkei-r.co.jp

(Please correct * to @)

About the Small and Medium-sized Corporation Division kenkoujimu*nikkei-r.co.jp

(Please correct * to @)


■Ministry of Economy, Trade and Industry, Commerce and Service Group, Healthcare Industry Division

Phone: 03-3501-1790 (Reception hours: weekdays 10 a.m. ~ 6 p.m.)

E-mail address: healthcare*meti.go.jp

(Please change * to @ and send it)

Japan Health Conference 2025

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Wednesday, April 8, 2026

Goals of Industrial Engineering - Statements of Pioneers and Later Scholars

 

F.W. Taylor

Work/Operation/Process/Task element science development, engineering and management

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

The advantages of this system of management are:

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

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

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

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

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




Frank Gilbreth



The aim of motion study is to find and perpetuate the scheme of perfection. There are three stages in this study:

1. Discovering and classifying the best practice.

2. Deducing the laws.

3. Applying the laws to standardize practice, either for the purpose of increasing output or decreasing hours of  labor, or both.

Standardizing the trades is the world's most important work to-day, and motion study is the first factor in that  work.

In presenting this material I have attempted to show the necessity for Motion Study and the savings that are possible by the application of its underlying principles.


While Professor Shaler's book was right, and while the waste from the soil washing to the sea is a slow but sure national calamity, it is negligible compared with the loss each year due to wasteful motions made by the workers of our country. In fact, if the workers of this country were taught the possible economies of motion study, there would be a saving in labor beside which the cost of building and operating tremendous settling basins, and the transporting of this fertile soil back to the land from whence it came, would be insignificant. Besides, there would still be a surplus of labor more than large enough to develop every water power in the country, and build and maintain enough wind engines to supply the heat, light, and power wants of mankind.

There is no waste of any kind in the world that equals the waste from needless, ill-directed, and ineffective motions.

By motion study the earning capacity of the workman can surely be more than doubled. Wherever motion study has been applied, the workman's output has been doubled.

Our duty is to study the motions and to reduce them as rapidly as possible to standard sets of least in number, least in fatigue, yet most effective motions.

PLACE OF MOTION STUDY IN SCIENTIFIC MANAGEMENT

Motion study as herein shown has a definite place in the evolution of scientific management not wholly appreciated by the casual reader.

Its value in cost reducing cannot be overestimated

Its value as a permanent element for standardizing work and its important place in scientific management have been appreciated only since observing its standing among the laws of management given to the world by Mr. Frederick W. Taylor, that great conservator of scientific investigation, who has done more than all others toward reducing the problem of management to an exact science.




Harrington Emerson


THE TWELVE PRINCIPLES OF EFFICIENCY
SIXTH Edition
NEWYORK
THE ENGINEERING MAGAZINE CO.
1924

The Twentieth Century dawns with the as yet unaccomplished task of conservation, of eliminating wastes wanton and wicked wastes of all kinds, wastes that make our civic governments a by-word, our destruction of natural resources a world scandal, our complacent industrial inefficiency a peculiarly national disgrace, since, of all nations, we Americans ought to know better. (p9)

It is this national inefficiency, this national wastefulness, this national squandering of cur rent and future material, human and machine resources, that can be remedied, if we but believe and practice the plainest teachings of recent history, which are an appropriate introduction to a statement of efficiency principles
and organization. (p10)

American sympathies were with Japan, but scarcely was the war over before the industrial organization of Japan, as much superior in principle to ours as were her army and navy to those of Russia, began to make us cry out in cowardly fear. (p20)   (This is an interesting statement by Harrington Emerson)

Efficiency, like hygiene, is a state, an ideal, not a method; but in America we have sought our salvation in methods. 

American industrial organization, even when it has good methods, cannot use them, because the organization, inherited from antiquated British models, is so defective in theory as to make an application of the principles as well as of good methods impossible. (p24)























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Tuesday, April 7, 2026

Flow Analysis and Improvement Industrial Engineering

 


In the types of process charts, flow process in an important chart. It shows the complete process involved in the producing a part and assembling all the parts into the final product. There is an operation process chart which focuses on the value adding operation and inspection of it. Flow analysis is always a part of industrial engineering.

Ford Motors developed flow production of assembly of automobiles and established assembly lines as an important production layout or a production system. Assembly line balancing became an important technique in industrial engineering.

Toyota Motors executive Taiichi Ohno came to the conclusion that Toyota Motors cannot use the batch quantities recommended by the economic batch quantity (EOQ) formula and thinking on the issue he came out with the idea of making efforts to reduce setup time. Efforts to reduce setup times was an industrial engineering task before Ohno also. Maynard clearly identifies it. But Ohno used to dramatically reduce setup time in collaboration with an industrial engineering Shigeo Shingo. Initially it was reduced to 30 minutes from many hours. Batch quantities on the presses dropped significantly and total inventory cost came down. Shigeo developed a procedure for doing SMED and the method was extended to many machines. Ohno also tried a change in material receipt procedures. He initiated a system of direct delivery of materials from various suppliers to assembly line. So the warehouses disappeared and the obstacles to flow were gone. In Toyota Production System one can see many new policies and procedures that were adopted to increase flow by removing opportunities for creating stocks.

So industrial engineers now have a new area to focus on - Flow Analysis and Improvement Industrial Engineering

In Toyota Motors, a chart named material and information flow chart is used to identify inventories and make efforts to reduce them.


Post included in

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Modern Industrial Engineering - LinkedIn Newsletter - Archive

 

Latest Issue on Top.


Modern Industrial Engineering Newsletter April 2026 Issue - Product Industrial Engineering - Contribution of L.D. Miles - Value Engineering.



March  2026 - Taylor Month of IE - Contribution of F.W. Taylor to Industrial Engineering and Productivity Management.

https://www.linkedin.com/pulse/march-2026-issue-taylor-month-ie-contribution-fw-industrial-kvss-71nlc

975+ reads

February 2026 - Innovation

https://www.linkedin.com/pulse/february-2026-innovation-industrial-engineering-department-kvss-gb7nc/

700+ reads

January 2026 - Improvement

https://www.linkedin.com/pulse/january-2026-issue-improvement-management-performance-kvss-dfb2c/




2026 Issues Themes


Jan - Improvement

Feb - Innovation

March - F.W. Taylor

April - Product Industrial EngineeringA to Z of Industrial Engineering

May - Principles of Industrial Engineering - Productivity Science - Productivity Improvement and Engineering -  Productivity  Management 

June - Machine and Machine Effort Industrial Engineering - Science of Metal Cutting - Nakajima - TPM - OEE

July - Gilbreth - Human Effort IE - Modern IE

August - Emerson - Productivity Improvement and Management - Cost Reduction -  Waste Elimination

September - Toyota Production System - Delivery Focus -Inventory Reduction - Waste Elimination - Lean Systems 

October - Productivity Engineering - Operation Analysis - Maynard - Barnes

November - Supply Chain Industrial Engineering

December - News 




October 2025

Celebrating the birthdays of famous second generation industrial engineers - Ralph M. Barnes and H.B. Maynard.  Birthday Barnes - 17 October, Birthday Maynard - 18 October.

Modern Industrial Engineering - October 2025 Barnes - Maynard Months - Human Effort - Machine Effort Industrial Engineering.

https://www.linkedin.com/pulse/modern-industrial-engineering-october-2025-barnes-maynard-kvss-8vbjc




July 2025 Issue of Modern Industrial Engineering - LinkedIn Newsletter.
Theme - 21st Century Industrial Engineering - Industrial Engineering  New Framework.


Cost of Ignorance is Square of Cost Quality. - Narayana Rao.

July 2025 - IEKC Industrial Engineering Self-study Online Course Lessons
https://www.linkedin.com/pulse/july-2025-iekc-industrial-engineering-self-study-online-kvss-0filc
#IndustrialEngineering #Productivity #CostReduction



 

Modern Industrial Engineering - Summary Explanation.

Modern Industrial Engineering - LinkedIn Newsletter - April 2025 Issue.

https://www.linkedin.com/pulse/modern-industrial-engineering-summary-explanation-april-kvss-8hiyc

#IndustrialEngineering #Productivity #CostReduction

1350+ readers








Starting from Issue 1

450+ readers

March - F.W. Taylor Month of Industrial Engineering and Productivity Management
"Let us Industrial Engineer a Better World together with Creative Ideas, Engineering and Management."
March 2025 - Issue 2

850+ readers
 

Modern Industrial Engineering - Summary Explanation.

Modern Industrial Engineering - LinkedIn Newsletter - April 2025 Issue.

https://www.linkedin.com/pulse/modern-industrial-engineering-summary-explanation-april-kvss-8hiyc

1350+ readers

May 2025

1050+ readers

July 2025 Issue of Modern Industrial Engineering - LinkedIn Newsletter.
Theme - 21st Century Industrial Engineering - Industrial Engineering  New Framework.

850+ readers


Ud. 21.10.2025
Pub. 1.7.2025
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Industrial Engineering Encyclopedia - A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

Industrial Engineering is System Efficiency Engineering. - Narayana Rao K.V.S.S.


To make the system efficient, its components also have to be efficient, and adjustments to the component parameters have to be done to ensure maximum performance from the system.

F.W. Taylor hailed as the Father of Industrial Engineering advocates that designs and processes have to be improved at element level in processes and systems.



Modern Industrial Engineering - Summary Explanation.

https://www.linkedin.com/pulse/modern-industrial-engineering-summary-explanation-april-kvss-8hiyc

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

New. Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  

FREE Download.

In top 2% on Academia.edu. 12,000+ Downloads so far. (Total 14,500+)

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0




Online Free Access Handbook of Industrial Engineering includes all modules of IE Online Course Notes.


Industrial Engineering Methods and Techniques - YouTube Videos

Principles of Industrial Engineering
_______________

_______________

Industrial Engineering - Principles, Methods and Techniques - YouTube Videos Playlist

https://www.youtube.com/watch?v=pU8CdWfZZdU&list=PL6W3qaSriFEjxHCNr9K_w7Bs6JskncWmq
_______________

Industrial Engineering Encyclopedia 

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

A


Analysis - Productivity Analysis of New Technology - Applied Industrial Engineering
Applied Industrial Engineering - Process Steps

B












IE Course 


1. Industrial Engineering - Introduction
http://nraomtr.blogspot.com/2011/12/industrial-engineering-introduction.html


4. Productivity Science of Machine - Machining - F.W. Taylor

5. Productivity Science of Human Effort - F.W. Gilbreth

6. Product Industrial Engineering


8. Operations Research - An Efficiency Improvement Tool for Industrial Engineers

9. Industrial Engineering Statistics - Application of Statistics in Industrial Engineering Practice

10. Industrial Engineering Economic Analysis: Engineering Economy or Engineering Economics: Economic Decision Making by Engineers

11. Human Effort Industrial Engineering

12. Industrial Engineering Measurements
Cost Measurement - Essential Activity of Industrial Engineering



Industrial Engineering Practice in Top Global Manufacturing Companies

Articles Created for A to Z Challenge 2020

1. Apple  - Former Chairman industrial engineer - Current CEO industrial engineer

2. BMW

3. CISCO, Coca-Cola, Continental

Old article: Productivity Success Story - Coca Cola

4. DowDuPont  - Now split into Dow, Dupont and Coverta

Old article:  We have to innovate and We have to be productive - Ellen Kullman - CEO Dupont

5. Enel - Eni

6. Ford - Fujitsu

7. GlaxoSmithKline - GE - General Motors

8. Honda - Hyundai

9. Intel

10. Johnson & Johnson - Jardine Matheson

Old article:  Design To Value - Design For Value (DTV) at Johnson & Johnson

11. Kia Motors

12. Lockheed Martin

13. Mitsubishi - Mitsui

14. Novartis 

15. Otis Elevators

16. Procter & Gamble 

17. Qualcomm

18. Renault

19. Saint-Gobain 

20. Toyota

21. United Technologies

22. Volkswagen

23. Wilmar International

24. Xiaomi Corporation

25. Yamaha Motors

26. ZF Friedrichshafen








K



Kaizen -  Articles 

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


Knowledge Required for Value Engineering Application and Practice

L


Leadership and Productivity

Levels of  Industrial Engineering in an Enterprise -   Enterprise Level to Engineering Element Level Industrial Engineering

Industrial Engineering Strategy - Enterprise Level Industrial Engineering

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

Facilities Industrial Engineering

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

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

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

Operation Industrial Engineering.

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

Element Level Analysis in Industrial Engineering

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



M


Machine Based Industrial Engineering - Japanese Practice - Karakuri Kaizen

Productivity Science - Determinants of Productivity
Productivity Science of Machining I - Industrial Engineering Research by Taylor Part 1.
For every basic production process we need productivity science.


Process Improvement - Process Industrial Engineering - Methods and Techniques













Processes - Examples and Illustrations


Q


Quality Improvement - Poka Yoke in Software - Information Systems

R


Research Papers - Industrial Engineering

S


Seven Wastes Model
Simulation and Forecasting - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)

Six Sigma





Taylor Society Bulletin on Industrial Engineering - Taylor's Way




Techniques of Value Analysis and Engineering by L.D. Miles, Book Information, Review and Summary



Videos on Industrial Engineering

Engineering in Industrial Engineering - Product/Process Industrial Engineering

Principles of Industrial Engineering - Taylor - Narayana Rao - IISE 2017 Pittsburgh Conference Paper



W



Water Productivity - Why Waste Water? - Eliminate The Water Waste
Work Simplification Education and Training to All - Principle of Industrial Engineering






This blog post is made on 26 June 2018.
On this day, this blog attained the

Global Number 1 Industrial Engineering Blog rank in Google search 

for the term  "Industrial Engineering" Blog.

Updated on  2.4.2026
First posted on 26 June 2018




2026 A to Z Blogging April Challenge - Theme Reveal Post


Important dates for 2026:
March 9 - 14 Theme Reveal
March 23 - April 4 Sign-up
May 4 - 9 Reflections
May 11 - Road Trip opens
------------------

If you are a blogger join the challenge.


You can reveal your theme.
Visit  


#AtoZChallenge

Topics for 2026

Applied IE - Agentic AI

Behavioral Aspects in  IE

Cost Reduction and Cost Management by Industrial Engineers

Decision Making in IE

Effectiveness of IE

Flow Analysis and Improvement IE

Goals of IE

Health Aspects of IE

Innovations by IEs

Job Shop IE - Shahrukh Irani

Knowledge Management for IE

Low Cost Products and Processes for IE

Management Module for IE

New Technologies Adoption by IE in Processes Under Their Productivity Management

Operations Management and IE

Production and Industrial Engineering - A Popular Branch of Engineering

Quality Related Interventions by IEs

Respect for People and Personal Relations - Assertion by F.W. Taylor

Society Prosperity - Industrial Engineering Effectiveness

Total Industrial Engineering

Understanding Processes

Value Addition by IEs

What is New in  IE in 2025-2026?

X-Platform - Industrial Engineers' Participation

YouTube - Industrial Engineering Videos by Narayana Rao

Zeal for Industrial Engineering - Productivity - Cost Reduction



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


2025

Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."

I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.


Supporting Information.

Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.

Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.

The prime contribution of IE has to be cost reduction through productivity improvement.

https://nraoiekc.blogspot.com/2025/07/effective-industrial-engineering-some.html





2023 Year - Blogging Statistics
https://bloggingwizard.com/blogging-statistics/   - 10,000 visitors per month is a good performance for a blog.

Blog posts for the 2023 Challenge


Date
April          Post



4                 Courses - Industrial Engineering

5                 Dissertations - Industrial Engineering



8                  Goals of  Industrial Engineering

10                Human Effort Industrial Engineering


12               Journals of  Industrial Engineering

13                Knowledge Management for Industrial Engineering    

 


18.               Organizing Industrial Engineering Department    











30.                 Zenith of Industrial Engineering                                  


This year it is my theme reveal post for 2023. The theme is "A to Z of Industrial Engineering."

In industrial engineering, this blog is global number one. Industrial engineering helps the world by helping producers to manufacture or produce more of the goods and services desired by the society with the same resources.

The main components of industrial engineering are machine effort industrial engineering and human effort industrial engineering.

I am going to write 26 new blog articles starting from 1 April 2023 as per the requirements of A to Z Challenge. 

2023

Happy. This year this blog registered 2 million cumulative page views in blogger statistics. Thank you readers. You motivate me to keep updating the blog.

2 Million Page Views in Blogger Statistics - 20 March 2023 - Industrial Engineering Knowledge Center Blog.
2 Million Page View Registered by Industrial Engineering Knowledge Center Blog on 20 March 2023.

10.3.2024
Very happy to notice that in the last year Industrial Engineering Knowledge Center Blog  got  0.276 million page views in blog statistics.





Interest in this article was rekindled by a LinkedIn Post.
https://www.linkedin.com/posts/mercadokorina_industrialengineering-konnectkonsult-technology-activity-7152157739765354497-w1ZZ  by Korina “Kon” MercadoKorina “Kon” Mercado. Continuous Improvement @Amazon - Industrial Engineer  @KonnectKonsult @OptimizeLifeSeries 


Suggested for inclusion

Assignment

"Assignment"
It is taught in Operations Research Course as part of Linear Programming. Proper assignment of jobs to operators in a shop will reduce the time taken to complete all the jobs and thus increase productivity. It is part of production planning and control at shop level.


Benchmarking, Bonus

Benchmarking.

IEs have to monitor and benchmark with productivity improvements of others.
Applied Industrial Engineering. Industry 4.0 Technologies. List of Industry 4.0 Light Houses - WEF - McKinsey - Have You Benchmarked with the Best in Industry 4.0 Implementation?

Comfort Survey, Cutting Parameters Analysis,

Defects Analysis,

Elementary Rate Fixing

Fatigue Study, Flow Process Chart, Flow Diagram

Goal Setting for Operators

Incentives

Job Evaluation


Method Study, MTM, Methods Engineering, Motion Study

Operation Analysis

Process Charts

Synthetic Time Determination

Therblig Analysis, Time Study

Work Simplification, Work Study



New Writing Project

Industrial Engineering: Productivity Improvement of Systems and Processes - Book by Narayana Rao K.V.S.S.


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