Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort IE. 10.7 Million Page View Blog. 200,000+ visitors. (36,000+ pv, 25,500+ visitors in 2025.)------------------ Blog Provides Industrial Engineering Knowledge: Articles, Books, Case Studies, Course Pages and Materials, Lecture Notes, Project Reviews, Research Papers Study Materials, and Video Lectures.
Tuesday, January 13, 2026
Industrial Engineering Challenges and Field Levels Barriers - Issues for Debate and Resolution
Saturday, November 29, 2025
Manufacturing Managers Questions - Topic-Wise - Industrial Engineering and Manufacturing Cost Management
# How industrial engineering concept can be integrated with product design?
# How to convince a team of people (with interest and without interest) for a change of betterment?
# Can't we run a manufacturing unit in a better way without industrial engineering support? For example, most of the small/medium scale units run without industrial engineer.
# If any product is running with minimum cost and the rejection rate as well as warranty claims are well within the target then how to progress further in value analysis/value engineering ensuring proper quality of the product.
# How to increase productivity even after reaching all the maximum target values in any production line? Optimum cycle time/man power
# How to improve efficiency of operations?
# How to improve inventory and process lead time?
# How can we achieve best efficiency from the work force without any additional remunerations?
# What are the tools to achieve cost effectiveness even at the highest market price?
# With this versatile market demand, how to manage and maintain optimum inventory levels?
# Ways for increasing productivity
While deciding the time study, how much factor to be taken in starting?
# How to study time-motion of a process effectively?
How to reduce cost of product without cutting quality level?
While deciding the time study, how much factor to be taken in starting?
Is there any standard criteria between product cost, labour cost and manufacturing cost?
Quality Management vs Industrial engineering
Significance of allowances provided
How can JIT be applied ini mass production unit?
Process variation
Productivity Improvement
What the specific tools that can be used to increase efficiency of manufacturing operations?
How to relate motion study for a manual job?
How to increase productivity for the same machine where the cycle time remain constant.
• Significance of industrial engineering in organisations business?
• Every Industry takes a target of cost reduction in every year. At the same time they need upgradation of quality every year. To what extend it is logical
• Cost optimization in manufacturing process.
• Basic roles of Industrial Engineer to access a manufacturing process.
• How Quality of a product has been taken care by Industrial Engineer.
How to minimize repetitive Human errors?
• How to you control the human behavior when it comes to making costly errors?
• What are the basics of Industrial Engineering? How to improve the Industrial Relationship?
• The parameters to be focused for Productivity for meticulous performance?
# How manufacturing cost can be measured at each stage of production?
# What are the common/special considerations in working out manufacturing cost?
# How to calculate the manufacturing cost?
# How to calculate break even cost?
# How depreciation cost is calculated?
# Is there an ideal ratio of fixed and variable cost?
# Steps to be taken to meet the budgeted mfg. cost. even at less production volume compared to budgeted volume.
# What are different ways to control cost of product?
How to manage cost without compromising the basic standard of shop floor?
How to control manufacturing cost of a product?
• What is the benefit of Manufacturing Cost Management?
• Whether cost management talks only or cost Reduction?
----------------------------
# Understanding lean manufacturing and implementation procedure.
# Importance of outsourcing in manufacturing and control needed.
# Quality management - Comparing with competitors.
---------------------------
# Managing critical situation like one side despatch urgency - otherside quality abrasion.
# In the manufacturing sector, will the low cost automation serve long term benefit?
----------------------------
------------------------------
# What is manufacturing management and how can it help in our daily life as well as in our industry?
# Format for calculating different types of output
# Relation between demand and manufacturing department activities
# How to develop engineering skills in the operators?
-------------------
--------------------
# What are tools to utilise resources at the optimum during the lean period without hampering the employee expectations?
--------------------------------
----------------------------
# Explain inventory control in manufacturing.
# What are best practices in manufacturing?
----------------------------
----------------------------
# Cell concept of manufacturing
Up to how much level of cost cutting we can go so that our product can sustain in the market?
What is D.O.E.?
-------------------------
How to manage manufacturing where product life cycle is shrinking and market dynamics are changing?
How to manage manufacturing in global market scenario?
How to tackle new competitors entry with cost benefits?
How to manage wide product gamut and supply chain challenges?
------------------------
Role of automation
How to handle IR where process is varying?
-------------------------
What are various aspects of manufacturing management?
------------------------
Product cost control
Outsourcing - quality issues
Automation requirements - Why?
---------------------
Reduction in Operating cost
Control over Outsourcing
How to increase production, since there are fixed norms for production
How to motivate people for problem solving (improvement)?
Reduction in waste in case of random patterns
-----------------
How do you get productivity measures in maintenance field?
----------------
How to address less availability of manpower in QA functions for inspection activities?
Automation will it really lead to reduction of manpower when an organization is bound by trade unions.
In Indian industries, normally the shopfloor does not abide through 7 QC tools and sometimes ti gets impractical. How to make it effectie on the floor, apart from training.
Eximbank business excellence model or Manufacturing Business Excellence
How to estimate risk involved in any improvement implemented in shop floor through a statistical
model?
-----------------
What are the latest best practices going on in the industy?
What impact is there for cost of quality?
Different methods of calculating cost of quality.
11.11.2014
• Frequent change of manufacturing plan – How we can accommodation.
• Conversion cost remain recharges with compare to last year though the other costs are variable.
• How to accommodate with customers’ requirement (time base samples).
• How to increase the skills throughout out operation as well as surprises.
--------------
• How is the managerial effectiveness measured?
• Leader is born or made! It made, how attribute of leadership are inculcated into the individual?
• Do amenity measures leave input on customer delist and satisfactions and hence, overall business substance in long run.
• Inputting management or sells/marketing management or financial management or all three – plays significant role in business growth & enhancement of bio on line when market wide remains the same or in the force of economic down worldwide?
----------------------------------
• How do you evaluate the effectiveness of this type of programme?
• Every industry takes a target to expand business in every year for a substantial %, How much it is realistic?
•
• In every Industry, salary of workmen get revised after every 3 years based on chartered demand. It is very difficult for manufacturing unit those who are long time player. How do you analyse this?
• Many Industries go for diversification on product with much having background. How do you justify?
--------------------------------
• What are the basic role of a manager for manufacturing excellence.
• How personality related to manufacturing management.
------------------------------
• What is the best way to bring people to same skill levels?
• What is the threshold point for cost reduction?
• How to handle other department heads who are fairly new do the company and may be working towards achieving their own short term goals?
---------------------
• What is the course detail?
• What does it mean by Manufacturing Management?
• Faculty Background?
• What is the benefit of Manufacturing Management?
-----------------
• How to manage the Manufacturing Process by the person who has not been trained preciously by experience or Study or by skill?
• How the Manufacturing cost optimized for healthy competition in the Market?
• Cost or Price of a product : How these are guided by the Manufacturing Management?
-----------------
# How to manage cost without compromising the basic standard of shop floor?
-----------------
# How to manage costs during lean periods of market demand without having IR issues?
-----------------
These questions were asked in a programme conducted for manufacturing managers in 2014.
Course coordinated by dr. K.V.S.S. NRao
Updated 29.11.2025, 7 Apr 2016
Pub.11.11.-14
Manufacturing Managers - Questions on Industrial Engineering and Cost Management - 2014
# How industrial engineering concept can be integrated with product design?
# How manufacturing cost can be measured at each stage of production?
----------------------------
# Understanding lean manufacturing and implementation procedure.
# Importance of outsourcing in manufacturing and control needed.
# Quality management - Comparing with competitors.
---------------------------
# Managing critical situation like one side despatch urgency - otherside quality abrasion.
# How to convince a team of people (with interest and without interest) for a change of betterment?
# What are the common/special considerations in working out manufacturing cost?
# Can't we run a manufacturing unit in a better way without industrial engineering support? For example, most of the small/medium scale units run without industrial engineer.
# In the manufacturing sector, will the low cost automation serve long term benefit?
----------------------------
# If any product is running with minimum cost and the rejection rate as well as warranty claims are well within the target then how to progress further in value analysis/value engineering ensuring proper quality of the product.
# How to increase productivity even after reaching all the maximum target values in any production line? Optimum cycle time/man power
------------------------------
# What is manufacturing management and how can it help in our daily life as well as in our industry?
# Format for calculating different types of output
# Relation between demand and manufacturing department activities
# How to develop engineering skills in the operators?
-------------------
# With this versatile market demand, how to manage and maintain optimum inventory levels?
# How to improve efficiency of operations?
# How to improve inventory and process lead time?
--------------------
# How can we achieve best efficiency from the work force without any additional remunerations?
# What are the tools to achieve cost effectiveness even at the highest market price?
# What are tools to utilise resources at the optimum during the lean period without hampering the employee expectations?
--------------------------------
# How to calculate the manufacturing cost?
# How to calculate break even cost?
# How depreciation cost is calculated?
# Is there an ideal ratio of fixed and variable cost?
# Steps to be taken to meet the budgeted mfg. cost. even at less production volume compared to budgeted volume.
----------------------------
# Explain inventory control in manufacturing.
# What are best practices in manufacturing?
# What are different ways to control cost of product?
# Ways for increasing productivity
----------------------------
# How to study time-motion of a process effectively?
How to reduce cost of product without cutting quality level?
----------------------------
# Cell concept of manufacturing
While deciding the time study, how much factor to be taken in starting?
Up to how much level of cost cutting we can go so that our product can sustain in the market?
What is D.O.E.?
Is there any standard criteria between product cost, labour cost and manufacturing cost?
How to manage cost without compromising the basic standard of shop floor?
-------------------------
How to manage manufacturing where product life cycle is shrinking and market dynamics are changing?
How to manage manufacturing in global market scenario?
How to tackle new competitors entry with cost benefits?
How to manage wide product gamut and supply chain challenges?
------------------------
Role of automation
How to handle IR where process is varying?
Quality Management vs Industrial engineering
Significance of allowances provided
-------------------------
What are various aspects of manufacturing management?
How to control manufacturing cost of a product?
How can JIT be applied ini mass production unit?
------------------------
Process variation
Product cost control
Productivity Improvement
Outsourcing - quality issues
Automation requirements - Why?
---------------------
Reduction in Operating cost
Control over Outsourcing
How to increase production, since there are fixed norms for production
How to motivate people for problem solving (improvement)?
Reduction in waste in case of random patterns
-----------------
How do you get productivity measures in maintenance field?
----------------
How to address less availability of manpower in QA functions for inspection activities?
Automation will it really lead to reduction of manpower when an organization is bound by tradeunions.
In Indian industries, normally the shopfloor does not abide through 7 QC tools and sometimes ti gets impractical. How to make it effectie on the floor, apart from training.
Eximbank business excellence model or Manufacturing Business Excellence
How to estimate risk involved in any improvement implemented in shop floor through a statistical
model?
-----------------
What the specific tools that can be used to increase efficiency of manufacturing operations?
What are the latest best practices going on in the industy?
How to relate motion study for a manual job?
What impact is there for cost of quality?
Different methods of calculating cost of quality.
11.11.2014
• Frequent change of manufacturing plan – How we can accommodation.
• Conversion cost remain recharges with compare to last year though the other costs are variable.
• How to increase productivity for the same machine where the cycle time remain constant.
• How to accommodate with customers’ requirement (time base samples).
• How to increase the skills throughout out operation as well as surprises.
--------------
• Significance of industrial engineering in organisations business?
• How is the managerial effectiveness measured?
• Leader is born or made! It made, how attribute of leadership are inculcated into the individual?
• Do amenity measures leave input on customer delist and satisfactions and hence, overall business substance in long run.
• Inputting management or sells/marketing management or financial management or all three – plays significant role in business growth & enhancement of bio on line when market wide remains the same or in the force of economic down worldwide?
----------------------------------
• How do you evaluate the effectiveness of this type of programme?
• Every industry takes a target to expand business in every year for a substantial %, How much it is realistic?
• Every Industry takes a target of cost reduction in every year. At the same time they need upgradation of quality every year. To what extend it is logical
• In every Industry, salary of workmen get revised after every 3 years based on chartered demand. It is very difficult for manufacturing unit those who are long time player. How do you analyse this?
• Many Industries go for diversification on product with much having background. How do you justify?
--------------------------------
• What are the basic role of a mange for manufacturing excellence.
• Cost optimization in manufacturing process.
• Basic roles of Industrial Engineer to access a manufacturing process.
• How personality related to manufacturing management.
• How Quality of a product has been taken care by Industrial Engineer.
------------------------------
• How to minimize repetitive Human errors?
• What is the best way to bring people to same skill levels?
• What is the threshold point for cost reduction?
• How to you control the human behavior when it comes to making costly errors?
• How to handle other department heads who are fairly new do the company and may be working towards achieving their own short term goals?
---------------------
• What is the course detail?
• What does it mean by Manufacturing Management?
• Faculty Background?
• What is the benefit of Manufacturing Management?
• What is the benefit of Manufacturing Cost Management?
-----------------
• How to manage the Manufacturing Process by the person who has not been trained preciously by experience or Study or by skill?
• What are the basics of Industrial Engineering? How to improve the Industrial Relationship?
• The parameters to be focused for Productivity for meticulous performance?
• Whether cost management talks only or cost Reduction?
• How the Manufacturing cost optimized for healthy competition in the Market?
• Cost or Price of a product : How these are guided by the Manufacturing Management?
-----------------
# How to manage cost without compromising the basic standard of shop floor?
-----------------
# How to manage costs during lean periods of market demand without having IR issues?
-----------------
Ud, 29.11.2025
Pub. 11.11.2014
Tuesday, April 22, 2025
Industrial Engineering of Systems - System Industrial Engineering
First published in this blog. Saturday, September 22, 2012
Industrial Engineering of Systems - System Industrial Engineering
Industrial engineers work on functional designs created by various engineers and managers and make them more efficient by improving resource use efficiency. Industrial engineers are to be associated with systems design or engineering process to make systems more efficient right from the first design stage. Presentation at a Global Conference on the topic (made in 2010 in Tokyo) is included in the article.
Author: Narayana Rao
All Rights Reserved
Last edited Version 8: 05 Aug 2010 on Knol
Original URL: http://knol.google.com/k/-/-/ 2utb2lsm2k7a/ 2037
Have you industrial engineered your systems?
The Toyota man, Ohno said industrial engineering is profit engineering. If you have not industrial engineered your systems, you are leaving potential profit on the table. Industrial engineering is a set of techniques to evaluate your systems' functional designs for efficiency. Wherever there is scope, IE will improve the system's efficiency. What is efficiency? Efficiency or productivity is output/input. A functionally designed system is expected to achieve certain output. Actually the system is designed for a specific installed capacity. Industrial engineers work on this functional design and reduce resource input.
What is Industrial Engineering?
"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved."
Industrial engineers make special efforts to confirm that no quality deterioration takes due to increasing output from machine-man combinations. They demonstrate that same quality is produced after increase in productivity and reduction in cost of production and product.
The definition emphasizes human effort engineering and system efficiency engineering.
What are techniques of Industrial Engineering?
Human Effort Industrial Engineering - Techniques
1. Principles of Motion Economy
2. Motion Study
4. Application of Ergonomics and Biomechanics
5. Fatigue Studies
6. Productivity/Safety/Comfort Device Design
8. Operator training
9. Incentive Systems
10. Job Evaluation
11. Learning effect capture
System (Engineering) Efficiency Improvement Techniques of Industrial Engineering
1. Process Productivity Analysis - Machine Work Study - Human Work Study
3. Time study for Process Cost Reduction
5. Statistical quality control
6. Statistical inventory control and ABC Classification Based Inventory Systems
7. Six sigma
8. Operations research
9. Variety reduction
10. Standardization
11. Incentive schemes
12. Waste reduction or elimination
13. Activity based management
14. Business process improvement
15. Fatigue analysis and reduction
16. Industrial Engineering Economy Analysis
17. Learning effect capture and continuous improvement (Kaizen, Quality circles and suggestion schemes)
18. Standard costing
19. 5S
20. SMED
21. IoT Implementation
22. Digital Twin Implementation
23. Automation - Autonomation
References
Industrial Engineering - Knols of Narayana Rao K V S S
I made presentation on the topic in the GloGift 2010 conference organized at the Keio University, Yokohama City, Tokyo. The presentation is given below.
Presentation made by Prof K.V.S.S. Narayana Rao, Professor, National Institute of Industrial Engineering, Mumbai at GloGift Conference, July 2010, Keio University, Tokyo, Japan
https://docs.google.com/presentation/d/1KeBZffFfZGqid6hVDja1qmR9nWSl3nQ_PV7lgO-5l_A/embed?slide=id.i0
Industrial engineering is redesign of engineering system both products and production system to make them productive and economical. Industrial engineering improves efficiency and reduces cost of production and products. Reduction in costs permits companies to sell products at lower prices and increase sales. Thus industrial engineering provides growth to companies and thus in aggregate provides growth to economy.
The redesign is done immediately after the original designers come out with the design and also many times later during the operation of the production system or production life cycle of the product.
Industrial engineering methods can be classified in these categories
1. Product Design Efficiency Engineering
2. Methods Efficiency Engineering - Production Methods Efficiency Engineering, Inspection Methods Efficiency Engineering, Maintenance Methods Efficiency Engineering, Business Processes Efficiency Engineering, Management Methods Efficiency Engineering
All resources used in methods are analysed for efficient usage. Man, Material, Money, Management, Motive Power, Machine,
3. Industrial Engineering Optimization - Engineering system problems are expressed as mathematical functions and maximum or minimum values as appropriate are ascertained to use as design values.
4. Industrial Engineering Statistics - Issues related to variability in engineering systems are decided using statistical methods - Ex. Statistical quality control, Six sigma methodology to improve process capability to determine the target central value and minimise variation of the process.
5. Industrial Engineering Economics - Use of engineering economics methodology to decide the productivity of capital used in engineering systems
6.Human Effort Engineering - Principles of Motion Economy, Motion Study to improve human effort efficiency, Ergonomics, Job Evaluation and Wage Incentives
7. Work Measurement, Cost Measurement, and Productivity Measurement
8. Management of IE studies, projects and departments
Application Areas for Industrial Engineering in an Organization
1. Production Industrial Engineering
2. Inspection Industrial Engineering
3. Maintenance Industrial Engineering
4. Transportation Industrial Engineering
5. Supply Chain Industrial Engineering
6. Marketing System Industrial Engineering
7. Information System Industrial Engineering
Engineering and Industry Sectors for Industrial Engineering Application
Aeroplane production
Automobile Production
Coal Mining
Electrical Equipment Manufacturing
Electronic Equipment Manufacturing
Thermal Power
Ud. 22.4.2025
Pub. 11.9.2021
Thursday, December 26, 2024
My Comments on Industrial Engineering Issues in Social Media Forums
Nigel Thurlow 🇺🇸🇺🇦🇬🇧
14.6.2022 - Shahrukh Irani
14.6.2022 - Osamu Higo
14 May 2016
People, processes and technology - I explain it as human effort engineering and system efficiency engineering. Industrial engineering have to improve technology/engineering processes using both technology and managerial knowledge. I feel two engineering subjects "product productivity engineering and "Engineering processes productivity engineering" have to be made important subjects in IE curriculums to bring out clearly the engineering foundation of IE. Similarly a subject discussing waste being created by managerial processes/actions in technical processes has to be studied to bring out the role of managerial actions in reducing or improving productivity.
In FaceBook discussion
https://www.facebook.com/groups/IIEnet/permalink/10156787029820562/
January 2016
Narayana Rao Kvss: Engineering knowledge is the primary requirement. Industrial engineers have to keep updating their engineering knowledge to improve the products and processes. Lean thinking is industrial engineering only with new emphasis on reduction of inventory.
http://www.iienet2.org/IndustrialEngineer/printerfriendly.aspx?id=41092
27 Feb 2015
IE in Supply Chain Activities
IE is applied to technical processes, business processes, and managerial processes.
Supply or purchasing as well as distribution are more of a business processes. IE can be applied to improve them. But under the philosophy or line of thinking that assumes that suppliers are your partners and you should do every thing to improve their processes to improve the whole supply chain IE applied to mfg processes within a company can be applied in Supplier's company also. So IE of mfg also is applicable in SC activity.
I'll like to know how does Industrial Engineering integrate /connect/relate to supply chain and logistics, I understand it better from the quality and operations/production point of view
Linkedin - Industrial Engineering Network Group
Beatrice Khoete
Industrial Engineering Intern
https://www.linkedin.com/groupItem?view=&gid=49280&type=member&item=5970981505470603264&commentID=5976802885567078400&report%2Esuccess=8ULbKyXO6NDvmoK7o030UNOYGZKrvdhBhypZ_w8EpQrrQI-BBjkmxwkEOwBjLE28YyDIxcyEO7_TA_giuRN#commentID_5976802885567078400
I strongly advocate that industrial engineering's main focus is productivity improvement of technical processes. The successful improvement of productivity in technical processes can be extended to the business processes and managerial processes. Industrial engineering itself is a managerial process. Industrial engineering went into a decline all over the world and lost its reputation as it lost its focus on technology and has not made any productivity improvements to any technology in the last so many years. It is only in Japan, that some companies led by Toyota at the top implemented IE in technology and became world class. But still IE profession refused to see the success of productivity improvement of tech processes and we have many other discipline people trying to push their discipline ahead under various names citing Japanese success.
Linkedin - Industrial Engineering Network
Towards the Configuration of an Industrial Engineering Education Field in Colombia from the Critical Didactics Pedagogy
Lexie Scirp
Editor at Scientific Research Publishing
https://www.linkedin.com/groupItem?view=&gid=49280&type=member&item=5972531657633185794&commentID=5976798831579328512&report%2Esuccess=8ULbKyXO6NDvmoK7o030UNOYGZKrvdhBhypZ_w8EpQrrQI-BBjkmxwkEOwBjLE28YyDIxcyEO7_TA_giuRN#commentID_5976798831579328512
Monday, December 25, 2023
What is lacking in Industrial Engineering? - A LinkedIn Survey
9.12.2023
What is lacking in Industrial Engineering?
Strategy
Engineering
Management
Research/Science
What is lacking in Industrial Engineering? 40 Votes in 2 weeks - Percentages
Strategy 48%
Engineering 13%
Management 13%
Research/Science 28%
------------------------------
Industrial Engineering Departments have to prepare strategy document and implement it.
Industrial Engineering Strategy - Enterprise Level Industrial Engineering
https://nraoiekc.blogspot.com/2014/11/industrial-engineering-strategy.html
Ud. 25.12.2023
Pub. 9.12.2023
Saturday, November 25, 2023
Economically Efficient Design of Products and Production Processes - Presentation Transcript
Economically Efficient Design of Products and Production Processes
Economic Decision Making and Design and Process Changes by EngineersDr. K.V.S.S. Narayana Rao
Professor, NITE, MumbaiIndustrial Engineering Knowledge Center
http://nraoiekc.blogspot.com
Engineering Economics, John M.Watts, Jr., and Robert E. Chapman http://fire.nist.gov/bfrlpubs/build02/PDF/b02155.pdf
KVSSNRao - Social Media Ids
https://twitter.com/knoltweet/http://in.linkedin.com/pub/narayana-rao-kvss/7/800/b60
https://www.facebook.com/kvssnrao
A Poem
Engineers design engines
Engineers produce engines
Engineers maintain engines
Engineers redesign engines
Engines work
Engineers make buck
Engines sell in millions
Engineers make billions
To sell in millions
Engineers use economics
Demand curves give price
Engineers keep it in eyes
Engineers strain
stretch their brain
mix and fix
materials and processes
They achieve the cost
that gives them most
profit at last
and makes them best
Technology makes one good engineer
Economy makes him rich engineer
http://nraopoems.blogspot.com/2012/02/poem-collection-theme-engineer.html
Good Engineer and Rich Engineer
Tasks and Activities of Engineering Designer
The main task of engineering designer is to apply their scientific and engineering knowledge to the solution of technical problems, and then to optimize those solutions within the requirements and constraints set by material, technological, economic, legal, environmental, and human-related considerations Source: Engineering Design: A Systematic Approach Ken Wallace, Luciënne Blessing Springer, 06-Aug-2007 - Technology & Engineering - 639 pages Page 1Design Intent and Alternative Ways of Implementing It
The design intent can be achieved in a variety of ways.Material type, part features, tolerances, finishes and fit requirements can often be modified without jeopardizing the part, assembly or component function.
This has been demonstrated for discrete parts used in the aerospace, automotive, and precision parts industries
Large fraction of costs can be influenced though economic analysis of design-manufacturing combinations.
Source: Vijay A. Tipnis, Design and Analysis of Integrated Manufacturing Systems ( 1988 )
http://www.nap.edu/openbook.php?record_id=1100&page=93
Engineering Phases or Steps
SynthesisAnalysis
Improvement and Optimization
Engineering Economy: An Explanation
An engineering economy study involves technical considerations and it is a comparison between technical alternatives in which the differences between the alternatives are expressed so far as practicable in money terms .(Grant and Ireson, 1960).
"Will it pay?"
Every engineering decision must be subjected to the question "Will it pay?"General John J.Carty,
Chief Engineer of the New York Telephone Company,asked three questions
1. Why do this at all?
2. Why do it now?
3. Why do it this way?
1. Why do this at all?
The first question makes an enquiry regarding profit.In business you do a thing because it is profitable to do so.
2. Why do it now?
The second asks whether the person proposing the investment or expenditure has considered the time alternatives.Can we postpone the investment/expenditure and make more profit?
3. Why do it this way?
Have you considered all other alternatives to the issue at hand and do you certify that the solution proposed is the most profitable proposal.Have you done profit improvement analysis of alternative that you are suggesting?
Economic Decision Making
Every dollar an executive proposes to spend or proposes not to spend has to be subjected to economic decision making.Executives are Unprepared for Economic Decision Making
George A. Taylor, in his text book, Managerial and Engineering Economy .Most of the executives seldom justify their actions and the resulting expenditure by adequate economic criteria.
Too many executives do not a feel a true responsibility for the costs they create or the costs they protect by maintaining the status quo.
Design Engineer – Cost Responsibility
Designers create costs due to selection of alternatives for design.But they feel costs are the responsibility of the company or somebody else in the company.
Proper reflection will make them conclude that costs that result from design are in their sphere of management and hence are their responsibility, because they and not somebody else selected the proposed design from all the possible alternative designs.
Engineering Efficiency versus Financial Efficiency
O.B. Goldman, Book - Financial Engineering, 1923The primary duty of the engineer is to consider costs in order to obtain real economy.
To get the most power, for example, not from the least number of pounds of steam, but from the least possible number of dollars and cents: to get the best financial efficiency.”
Goal of Equipment Selection
The goal of equipment selection in a business system is acceptable financial efficiency, not engineering efficiency.Searching for Low Engineering Efficiency Alternatives
If the final choice is based on financial efficiency alone, the search for alternatives must be conducted on either side of current engineering efficiency.Search for higher financial efficiency is not necessarily a search for higher engineering efficiency.
Finance - Capital
Finance is the money resources of a business organization.Money resources of an organization consist of equity capital contributed by owners of the firm and loans (short-term as well as long-term) given by various other banks, firms and individuals.
Rate of Return on Capital (Finance)
All the entities who provide finance to a firm expect to get back the principal and additional return on principal.The business operations of a firm need have the ability to generate that return or more than that return to acquire capital or finance in the first place and then generate the return to satisfy the expectations afterward.
This idea gives rise to cost of capital.
Cost of Capital
The user of capital must satisfy the profit motive of the supplier of capital.This obligation of the user of capital is termed as the cost for using capital or cost of capital.
Hence all expenditure proposals need to include an evaluation mechanism that considers the cost of capital for the capital required to implement the proposal.
Engineering Economy Study
The process of engineering economy study will included data gathering and data analysis.Analysis requires analytical methods
The analytical techniques express the alternatives in comparable measures of money with respect to their cost, revenue or return on capital.
Estimation
Data gathering will include some current estimates made by engineers by combining the technical information and costs/prices relevant to the materials and processes used to provide goods or services.The data gathering effort cannot be a one time effort and systems are to be put in place to record appropriate data as and when it first appears.
Accounting
For this purpose accounting sections or departments (financial, cost and management accounting) and technical departments have to jointly work out the need for future engineering economy studies and install appropriate recording systems.Economic Skills
Contributing to data collectionSupport to accounting function
Cost estimating
Economic analysis
Economic Analysis Concepts
Time value of moneyCompound interest calculation
Present worth calculation
Net present value = Present worth of cash inflows minus present worth of cash outflows
Internal Rate of Return – Can be compared with cost of capital
Engineering Economics is part of Industrial Engineering Tool Kit
Engineering Economics - Articles
http://nraomtr.blogspot.com/2011/11/engineering-economy-or-engineering.html
http://nraomtr.blogspot.com/2011/12/engineering-economics-is-efficiency.html
Industrial Engineering – Engineering Systems Efficiency
Industrial Engineering (IE) is Human Effort Engineering and System Efficiency Engineering.Two tasks of IE of interest to our topic of discussion
Efficiency Engineering of Product Design
Efficiency Engineering of Manufacturing Processes
Efficiency Engineering of Product Design
Economic Material SelectionEconomic Tolerance Selection
Value Engineering
Basic Steps of value Analysis
1. Identify the function. 2. Evaluate the function by comparison 3. Cause value alternatives to be developed.VA aim – Answers to Questions
1. What is the item? 2. What does it cost? 3. What does it do? 4. What else would do the job? 5. What would that alternative cost?Alternatives have to cost less. VA provides a direction for it.
Value Analysis Techniques
Miles provided 13 ideas as value analysis techniques.Avoid generalities
Get all available costs
Use information from the best source
Blast create and refine
Use real creativity
Identify and overcome roadblocks
Use industry experts to extend specialized knowledge
Get a dollar sign on key tolerances
Utilize vendors’ available functional products
Utilize and pay for vendors’ skills and knowledge
Utilize specialty processes
Utilize applicable standards
Use the criterion, “would I spend my money this way?”
Value Engineering Articles
Article by L.D. Mileshttp://nraomtr.blogspot.com/2011/12/value-engineering-introduction.html
Book by L.D. Miles
Download from above link
Value Engineering – Recent Examples, Cases and Benefits
http://nraoiekc.blogspot.in/2012/03/value-engineering-examples-cases-and.html
Efficiency Engineering of Manufacturing Processes
Process AnalysisOperation Analysis
Motion Analysis
Process Analysis for Process Economic Efficiency
After Process Synthesis do Process AnalysisRationalize each operation
Why is it required? What happens if it is not done?
Rationalize Division into operations
Is further division required or will combination give better economy?
Rationalize the sequence of operations
Will any change in sequence give more economic benefits?
Simplify Operation (Operation analysis)
Operation Analysis for Operation Economic Efficiency
After Operation SynthesisSubject every resource used in the operation to questioning to find lower cost alternatives.
Uses Operations Research and Statistical Methods (Six Sigma) to optimize the parameters.
Motion Analysis
Operator activity is subjected to principles of motion economy and ergonomicsThank You
Thank YouReady for Comments, Suggestions and Questions.
Case Studies
Economically Efficient Design of Solar Reflector 2009
http://www.maths-in-industry.org/miis/396/1/ESGI70_8.pdf
Wednesday, April 19, 2023
Production Industrial Engineering - Scope
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
Basic Production Processes and Technologies and Industrial Engineering
Production/Manufacturing Processes
1. Casting
2. Rolling
3. Forging
4. Sheet Metal Work
5. Machining
6. Welding
7. Assembling
8. Wood Working
Industrial Engineering Focus Areas
1. Productivity Science
2. Production Process Industrial Engineering
3. Product Industrial Engineering
Concepts, Research Papers and Case Studies in Production Industrial Engineering
1. Productivity Science
2. Production Process Industrial Engineering
(Equipment/Machine, Power Transmission, Production Instructions/Information, Utilities, Working Conditions, Layout, Production Processes)Casting
H.W. Perry, (1950) "An Improved Casting Process with Resin‐Sand Moulds: Some Details of a New Method Evolved by the Bakelite Corporation from the Johannes Croning System", Aircraft Engineering and Aerospace Technology, Vol. 22 Issue: 12, pp.371-374, https://doi.org/10.1108/eb031978
Process improvements in sand casting over the past 60 years (part 1)
https://www.haworthcastings.co.uk/news/process-improvements-in-sand-casting-over-the-past-60-years-part-1
Process improvements in sand casting over the past 60 years (part 2)
https://www.haworthcastings.co.uk/news/process-improvements-in-sand-casting-over-the-past-60-years-part-2
Innovative Ideas for Improving Foundry Productivity and Quality
http://www.foundryinfo-india.org/images/pdf/Innovative_Ideas_for_Improving_Foundry_Productivity_and_Casting_Quality.pdf
OVERALL PRODUCTIVITY IMPROVEMENT IN CASTING AND FASTENING INDUSTRY
International Journal of Mechanical and Production Engineering
Volume-1, Issue-1, July-2013
http://iraj.in/journal/journal_file/journal_pdf/2-12-139383136143-48.pdf
Rolling
Improving Hot Rolling Quality and Maximizing Mill Throughput
Level 2 Automation for Mill Reheating Furnaces
http://www.automationtatasteel.com/brochures/fce.pdf
PRODUCTIVITY AND QUALITY IMPROVEMENT THROUGH SETTING PARAMETER IN HOT ROLLING MILL-A REVIEW.
2018
http://www.journalijar.com/article/23102/productivity-and-quality-improvement-through-setting-parameter-in-hot-rolling-mill-a-review/
Analysing quality and productivity improvement in steel rolling industry in central India
International Conference on Advances in Engineering & Technology – 2014 (ICAET-2014)
http://www.iosrjournals.org/iosr-jmce/papers/ICAET-2014/me/volume-7/2.pdf
Forging
Improvement in forging processes and steels1993
http://www.eurekanetwork.org/project/id/720
New Developments in Forging Technology
To help forgers meet the demands of automobile manufacturers, this equipment manufacturer has developed new equipment for pre-forming, automation of hammer forging, new drive concepts, and a new generation of control systems.
May 13, 2005
https://www.forgingmagazine.com/feature/new-developments-forging-technology
STUDY OF PROCESS PARAMETERS TOWARDS IMPROVING EFFICIENCY OF CLOSED DIE HOT FORGING PROCESS
2014
http://ethesis.nitrkl.ac.in/5909/1/E-87.pdf
Productivity Improvement in Forging Industry Using Industrial Engineering Techniques
Conference Paper · October 2016
https://www.researchgate.net/publication/312316702_Productivity_Improvement_in_Forging_Industry_Using_Industrial_Engineering_Techniques
Sheet Metal Work
Improvement of Productivity in Metal Stamping Process of Ethiopian Industries Through Introducing CAD/CAM Based Press Tools
2017
http://article.sciencepublishinggroup.com/pdf/10.11648.j.ijimse.20170203.11.pdf
“Yield Improvement in Press Shop”
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
Volume 6 Issue IV, April 2018- Available at www.ijraset.com
https://www.ijraset.com/fileserve.php?FID=16098
Automotive Stamping Solutions
Combine PLM software with Siemens production equipment to transform design, manufacture and production efficiency
https://www.industry.siemens.com/verticals/global/en/automotive-manufacturing/Documents/PDF/AE_Automotive-Stamping-Solutions.pdf
Case study: Production and OEE improvement for an 800 tons stamping press
Master thesis work
https://www.diva-portal.org/smash/get/diva2:699942/FULLTEXT01.pdf
Machining
Welding
IMPROVEMENT OF PRODUCTIVITY IN AL WELDING
6th International DAAAM Baltic Conference
INDUSTRIAL ENGINEERING
24-26 April 2008, Tallinn, Estonia
http://innomet.ttu.ee/daaam08/Online/Engineering%20Management/Stepanov.pdf
CURRENT TRENDS IN WELDING PROCESSES AND MATERIALS: IMPROVE IN EFFECTIVENESS
RAMS, 2012
http://www.ipme.ru/e-journals/RAMS/no_23012/08_kah.pdf
Improving Weld Productivity and Quality by means of Intelligent Real-Time CloseLooped Adaptive Welding Process Control through Integrated Optical Sensors
2017
https://www.energy.gov/sites/prod/files/2015/12/f27/7%20-%20Improving%20Weld%20Productivity%20and%20Quality%20by%20means%20of%20Intelligent%20Real-Time%20Close-Looped%20Adaptive%20Welding%20Process%20Control.pdf
Assembling
How to Optimize Your Assembly Operations
http://www13.boschrexroth-us.com/Catalogs/OPTIMIZE%20ASSEMBLY%20OPERATIONS.pdf
BODY ASSEMBLY PROCESS IMPROVEMENT FOR AUTOMOTIVE INDUSTRY
MOHD NAJMI BIN MOHAMAD
2008
http://umpir.ump.edu.my/id/eprint/248/1/Mohd_Najmi_Bin_Mohamad.pdf
DEVELOPMENT OF SIMPLE GUIDELINES TO IMPROVE ASSEMBLY INSTRUCTIONS AND
OPERATOR PERFORMANCE
C. Söderberg, A. Johansson & S. Mattsson
Chalmers University of Technology, Division of Production Systems
Assembly instructions is an important means for supporting operator performance in final assembly. This paper describes an experiment that shows that assembly instructions can increase operator
performance and presents nine simple guidelines. The Importance of including the operator view is stressed and how the guidelines should be implemented in practice is discussed.
http://publications.lib.chalmers.se/records/fulltext/202981/local_202981.pdf
Woodworking
Chapter 1:5 1900 and Before -- Technological Development:The Woodworking Industry's Shift From the Handicraft System to the Factory System
Revised 07-24-2012
http://www.woodworkinghistory.com/chapter_1-5_technological_development.htm
DESIGN AND DEVELOPMENT OF WOOD CUTTING AND DRILLING MECHANISM USING SEWING MACHINE
5th National Conference RDME 2016, 10-11th, March 2016. 39 Page
http://www.iosrjournals.org/iosr-jmce/papers/Conf15008/Vol-3/39-42.pdf
3. Product Industrial Engineering
How to Improve Your Sand Casting Design, 5 General Tips
http://www.metals-china.com/how-to-improve-your-sand-casting-design-5-general-tips.html
Assembly
Introduction to Design for (Cost Effective) Assembly and Manufacturinghttp://me.gatech.edu/files/capstone/L071ME4182DFA
Optimization of Sand Casting Process Parameter Using Taguchi Method in Foundry
International Journal of Engineering Research & Technology (IJERT)
Vol. 1 Issue 7, September - 2012
https://www.ijert.org/research/optimization-of-sand-casting-process-parameter-using-taguchi-method-in-foundry-IJERTV1IS7476.pdf
OPTIMIZATION IN GREEN SAND CASTING PROCESS FOR EFFICIENT, ECONOMICAL AND QUALITY CASTING
Int J Adv Engg Tech/Vol. V/Issue I/Jan.-March,2014/25-29
http://www.technicaljournalsonline.com/ijeat/VOL%20V/IJAET%20VOL%20V%20ISSUE%20I%20JANUARY%20MARCH%202014/IJAETVol%20V%20Issue%20I%20Article%206.pdf
Application of Six Sigma Method to Reduce Defects in Green Sand Casting Process: A Case Study
International Journal on Recent Technologies in Mechanical and Electrical Engineering (IJRMEE)
Volume: 2 Issue: 6 , June 2015
http://www.ijrmee.org/download/application-of-six-sigma-method-to-reduce-defects-in-green-sand-casting-process--a-case-study-1434089168.pdf
Welding
Process Improvement in the Manufacture of Metro Car Side Wall by Optimization of Welding Parameters – A Case Study
http://qcin.org/nbqp/DLShah-Award/pdf/2014/Art-8-09-BEML-Metro%20Car%20(87-92).pdf
7. Human Effort Industrial Engineering
Woodworking
Occupational Health
http://www.ilocis.org/documents/chpt86e.htm
8. Industrial Engineering Measurement
Productivity Measurement
Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting
http://web.mit.edu/skd/www/casting/casting-v2.pdf
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1. Jigs and Fixtures Design
2. SMED
3. Poka Yoke
4. Automation and Autonomation - Productivity Impact Analysis of Recent Developments in Automation and Autonomation Field. Engineering Economic Analysis of Latest CIM Developments.
5. High Speed Machining for Productivity
6. Engineering Economic Analysis of Robots
7. Energy Conservation in Production Processes
8. Work Station Design
9. Design for Manufacturing
10. Design for Assembly
11. Gravity Chutes Design to Reduce Handling Time for Input Materials and Components and Completed Components and Assemblies.
12. Competency Mapping for Production Trades and Jobs
13. Manufacturing Cost Analysis and Reduction
14. Manufacturing Information Systems Rationalization
15. Work in Process Inventory Rationalization
Recommended Books
Shigeo Shingo - A Study of Toyota Production System from Industrial Engineering Point of View,
Shigeo Shingo - SMED, Revolution in Manufacturing
Shigeo Shingo - Poka Yoke, Zero Quality Control.
David A. Stephenson and John S. Agapiou, Metal Cutting Theory and Practice, CRC, 2006
Chapters: Machining Optimization and Economics, High Throughput Machining, Design for Machining.
R. Venkata Rao, Advanced Modeling and Optimization of Manufacturing Processes, Springer- Verlag London Limited 2011 (archive org)
Richard B. Chase, F. Robert Jacobs, Operations and Supply Management, 12th Edition,
Chapter: Operations Technology (Supplement B), McGraw Hill
L.V. Ottinger, "Robotics for the IE: Terminology, Types of Robots," Industrial Engineering, November 1981, P.30
Appropriate research papers and case study examples can be added by the faculty.
Related Article
Methods Efficiency Engineering - Operation Analysis Approach - Knol Book
Updated: 19.4.2023, 15.3.2023, 27.8.2022, 8.4.2022, 22 Dec 2021, 29 Sep 2021, 29 Jan 2019
11 April 2015, 3 April 2015, 1 April 2015
First Posted on 20 March 2015 at NIT, Trichy

