Showing posts with label IE - Issues for debate. Show all posts
Showing posts with label IE - Issues for debate. Show all posts

Tuesday, January 13, 2026

Industrial Engineering Challenges and Field Levels Barriers - Issues for Debate and Resolution

Industrial Engineering Challenges and Field Levels Barriers - Information Needs.

Hello, This year I am focusing on maintaining Industrial Engineering Bulletin Board - Industrial Engineering Knowledge Center https://nraoiekc.blogspot.com/2016/06/industrial-engineering-bulletin-board.html  on a regular basis to collect what is happening in industrial engineering theory and practice. Once such a collection is there for some months, we know the current trends and issues,

I am trying to write articles in the LinkedIn Newsletter. January 2026 Issue -  MODERN INDUSTRIAL ENGINEERING Newsletter - Improvement Management of Performance Areas - Safety, Quality, Delivery, Cost and Productivity
https://www.linkedin.com/pulse/january-2026-issue-improvement-management-performance-kvss-dfb2c/


The other thing I would like to do is collect challenges and barriers that  industrial engineers are facing in the field. The idea is to search for solutions in the published materials are ask some senior industrial engineers and faculty to gives us some guidance.
Industrial Engineering Challenges and Field Levels Barriers - Issues for Debate and Resolution  https://nraoiekc.blogspot.com/2012/04/industrial-engineering-issues-for.html

Through this I hope some useful content for industrial engineering effectiveness can be created for use.

I request you to please respond with your ideas in this regard.

Thank You, NRao.
 
 
January 2009

"We need to be focused on the word engineering." 
 
"I really have a problem with this whole message of, "We don't make things. We just make things better." We make things, too, and we need to be recognized for that."
 
Four IIE presidents expressed their opinions on issues related to IE in an article in Industrial Engineer magazine "A meeting of IIE's leadership minds", (January 2009, pp. 56-58).
 
Louis Martin Vega, North Carolina State University
 
We need to be focused on the word engineering. We need to play a strong role in the world of bio-, nano- and information technology.
 
He also added, "I really have a problem with this whole message of, "We don't make things. We just make things better." We make things, too, and we need to be recognized for that."
 
Authors comment: Yes industrial engineers can make things. Then can invent various devices in the field of human effort engineering. They can invent devices or artifacts that improve efficiency of systems. Gantt chart is an example. Gantt charts made planning efficient. There is nothing wrong in division of labor to take up a profession that concentrates on improving existing systems or systems designed by some functional specialists from efficiency perspective.
 
Marlin Thomas
 
It's very difficult to expect that you can go forward and take the leadership roles we think we should take in the future without a basic understanding of the science backgrounds. To determine what is a failure in nanotechnology, you need some knowledge that isn't available in our current core. I think our greatest challenge is going to be to alter that if we want leadership role in new sciences and technologies
 
Authors comment: As new domains or sectors in economy and sciences emerge, industrial engineers who want to contribute in that sector have to learn the basics of that sector. Some industrial engineering institutes have to take the lead and incorporate a basic subject in that sector in their curriculum
 
Allen Soyster
 
I think industrial engineering needs a clear vision that people can attach to and believe in.
I've always been jealous of (other professional groups) and have had these pangs of envy as to how they can have these visions and IEs can't.
 
 
Original knol - http://knol.google.com/k/narayana-rao/industrial-engineering-issues-for/   2utb2lsm2k7a/ 2170



Ud. 13.1.2026
{ub. 8.4.2012

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

3. Workstation Design

4. Application of Ergonomics and Biomechanics

5. Fatigue Studies

6. Productivity/Safety/Comfort Device Design

7. Standardization of  Methods

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

2. Operation Analysis 

3. Time study for Process Cost Reduction

4. Value engineering

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

24. Seven Wastes Model

 

 

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



Presentation at
GLOGIFT 2010
Tenth Global Conference on Flexible Systems Management
26th to 28th July, 2010
Venue: Graduate School of System Design and Management
Collaboration Complex, Hiyoshi
Keio University, Japan

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

Objective of the paper

To advocate that industrial engineering has a role in systems engineering/design process.
The role is to be recognized and highlighted in systems engineering activity description and books.

Industrial Engineering (IE) – Definition by NRao

“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.”



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


26.12.2024
The constructive work of Time Study in Industrial Engineering.

The Time Study of work elements reveals defective conditions surrounding and accompanying the work are defective.  Examples are improper tools, 
machines requiring modifacations for perfecting, bad sanitary conditions, etc. This correcitve actions leads frequently to the improvement and standardization of tools and conditions and to the invention of superior methods (processes) and machines.
Industrial Engineering - Bulletin Board - Industrial Engineering Knowledge Center.
#industrialengineering #productivity #costreduction








16 July 2022
Comment by Shahrukh Irani
 
I help any high-mix low-volume (HMLV) manufacturer customize their implementation of Lean

Narayana Rao KVSS   What you are doing is a shot in the arm for our profession. But we cannot promote our profession if we trumpet about the pioneers from the 20th century. Toyota, Lean Enterprise Institute, Shingo Institute ---- they have harmed our profession by promoting their "stuff" as Industrial Engineering. Your postings are unbiased, well researched, honest ---- just do it except please promote the modern day IE stalwarts. Just my two cents opinion.

https://www.linkedin.com/feed/update/urn%3Ali%3Aactivity%3A6953341870781382656/?commentUrn=urn%3Ali%3Acomment%3A%28groupPost%3A49280%2D6953341870127087616%2C6953358788527632384%29&dashCommentUrn=urn%3Ali%3Afsd%5Fcomment%3A%286953358788527632384%2Curn%3Ali%3AgroupPost%3A49280%2D6953341870127087616%29&replyUrn=urn%3Ali%3Acomment%3A%28groupPost%3A49280%2D6953341870127087616%2C6953539385556430848%29&dashReplyUrn=urn%3Ali%3Afsd%5Fcomment%3A%286953539385556430848%2Curn%3Ali%3AgroupPost%3A49280%2D6953341870127087616%29

https://www.linkedin.com/feed/update/urn:li:activity:6953341870781382656      

----------------
A comment: In US many companies don't know what an IE is or does and the academy lost its way


Reply by Narayana Rao: Possible. I am once again reading development of IE from 1949 through some journal articles. "What is IE?" was examined number of times. Still, the world is not clear about IE. I also made the attempt. I feel explaining IE as system efficiency engineering is better. Basic engineering and management are involved in designing "engineering systems" with effectiveness and acceptable efficiency. IEs are focused on increasing the efficiency of "engineering systems" on a continuous basis. No doubt you can increase effectiveness, matching customer requirements also on a continuous basis.

Do it. It is Real Engineering. Industrial Engineering is Engineering Primarily.
Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use for industrial engineering. 
Best Practices in #IndustrialEngineering 
https://www.linkedin.com/feed/update/urn:li:activity:6946216164469420032

-----

Nigel Thurlow 🇺🇸🇺🇦🇬🇧


Executive Coach | Board Advisor | Interim Executive | Co-Creator of The Flow System | Creator of Scrum The Toyota Way | Forbes Noted Author | Toyota Alumni | Renowned Speaker


❗️Kanban vs The Theory of Constraints❗️ Which is better? Kanban or The Theory of Constraints? Read on and decide for yourself.

I was prompted to create this post by a question sent to me to ask my opinion on this topic as a lecturer had claimed ToC was superior to Toyota's Kanban System.

Now, I will say from the get go, this post will be hugely controversial, so I will immediately highlight that my reference material is Don Reinertsen’s highly regarded work “Product Development Flow” published in 2009. I also took training from Don. He is in my view a true master of Flow mathematics, and probably the best there is.

I also added my Flow buddy Steve Tendon as it’ll just speed up response times 🤭 He's also the main ToC guy on here and will probably vehemently disagree. 😉

Quoting variously, paraphrasing where it makes sense for brevity, from pages 147-150 I'll write how Don explains ToC, and in his opinion the better system of Kanban, citing Toyota’s usage of Kanban specifically.

1️⃣ The Theory of Constraints

Page 147 - ToC acts to constrain the total pool of work in progress (WIP) that is upstream of the bottleneck. Goldratt suggests the size of the global pool should only be large enough to ensure that the bottleneck is not starved for inventory. This approach is simple and appealing but is not useful for unpredictable, moving, and limited time duration bottlenecks of product development. Read that carefully Agile folks❗️

Page 148 - Don states two issues with this ToC approach.

1. Only the primary bottleneck is acting as a control so a temporary bottleneck at another process will not generate any control signal until it causes WIP starvation at the primary bottleneck.

2. When the primary bottleneck capacity drops, WIP will tend to concentrate in front of this bottleneck.

2️⃣ The Kanban System of Toyota - Page 148

Kanban has none of these issues. Any emergent bottleneck will begin to send a control signal that throttles its upstream process. This propagates upstream, station by station, rapidly stabilizing the system, with each upstream process holding its maximum WIP. When capacity is regained, there are no WIP starved processes and smooth flow begins immediately.

The key principle in Don's book is W4: If possible, constrain local WIP pools. ToC does not do this as it is not designed to do so. However, Kanban does.

Page 150 - W5 describes how Kanban decouples batch sizes to account for difference economic batch sizes. This is buffer in the system between an upper constraint and zero. ToC does not do this.

Toyota further enhances this effectiveness by cross training workers at adjacent work stations so that when the WIP constraint throttles the upstream process, this frees up capacity that can easily assist the downstream process.

https://www.linkedin.com/posts/nigelthurlow_lean-leansixsigma-agile-activity-6944251115769126912-sFPJ


Narayana Rao KVSS
Interesting discussion topic and references. "❗️Kanban vs The Theory of Constraints❗️ Which is better?" What is the purpose or context? Facilities improvement (Facilities IE)? Process improvement? or Production planning and control improvement?

Narayana Rao KVSS

Nigel Thurlow 🇺🇸🇺🇦🇬🇧,    " I teach both" So should you compare and contrast and when both are simultaneously required? Certain teachers are unnecessarily comparing two simultaneously required activities and are trying to vilify one of them. For instance, effectiveness and efficiency. Both are required simultaneously for revenue and profit.

Nigel Thurlow 🇺🇸🇺🇦🇬🇧
Narayana Rao KVSS it’s simply a way to stimulate interest and inquiry. This is social media, not a classroom.

Narayana Rao KVSS
Nigel Thurlow 🇺🇸🇺🇦🇬🇧 Thank you. It stimulated interest and inquiry. I shall inquire further on my own.



Monday, July 13, 2009
On The Principles of Product Development Flow by Don Reinertsen



Six Myths of Product Development
by Stefan Thomke and Donald Reinertsen
From the HBR Magazine (May 2012)
https://hbr.org/2012/05/six-myths-of-product-development

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



14.6.2022 - Shahrukh Irani


I help any high-mix low-volume (HMLV) manufacturer customize their impleme

Fellow IEs, how can we rejuvenate our profession? There is a lot of IE that is missing in the Toyota Production System. It just takes for each of use to take an IE textbook, each to identify a chapter whose content matches a lot of what we know about the Toyota Production System, and put those chapters through the "Leanification grinder". Infusing "Lean IE" into the IE we know is going to produce an IE BoK that is much-needed, both by educators (and students) as well as all of us practitioners.

If nothing else, is Lean going to wipe out Industrial Engineering? If yes, then when somebody asks an IE, "Quo Vadis", will their reply be, "My professional grave?".

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_introduction-to-work-study-activity-6942196518644850690-gmv0

Narayana Rao KVSS

" It just takes for each of use to take an IE textbook, each to identify a chapter whose content matches a lot of what we know about the Toyota Production System, and put those chapters through the "Leanification grinder"."

We just have to take temporary delays and storage time of process chart and examine ways to minimize them. Cycle time can reduce to processing time + inspection time + transport time. All TPS innovations will enter IE BOK.

News - Information for Industrial Engineering Analysis of Delays in Processes - Lean Inventory Design in Processes

Davie Thomson
Problem Solver | Kaizen Pioneer | Speaker | Facilitator | Polymath

Before 5S or the ensuing wave of Bullshido arrived, with 6S, 7S, 10S or whatever, let’s not forget that Henry Ford, love him or hate him, gave us CANDO.

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

14.6.2022 - Osamu Higo

Change Management Professional (Results-driven)

A Toyota one manager once said that TPS (Toyota Production System) is a mass of IE (Industrial Engineering), and if "Lean" comes from TPS, "Lean" is also a mass of IE, I think.
And if so, "Lean" is not only "people" (man/woman), but machine, material, method (so-called 4M of IE).

https://www.linkedin.com/feed/update/urn:li:activity:6940202854745837568



Osamu Higo
 ðŸ”˜ Hein Winkelaar , TPS is IE + Gemba people's ideas.

Narayana Rao KVSS
Professor (Retired), NITIE, Mumbai - Offering FREE IE ONLINE Course Notes

Osamu Higo,  TPS is IE plus rational inventory reduction. Then the best practices for people involvement came into being. Gemba people's idea is not of TPS origin. It is the idea of Taylor and more specifically that of Gilbreth. More systematization was done by Alan Mogensen. Then only TPS practices come and of course, the results were extraordinary.

Osamu Higo
Narayana Rao KVSS , "inventory reduction"? I do not think so. TPS is a mass of IEs, as I explained.

Narayana Rao KVSS

Osamu Higo,  "Mass of IE" IE is basically reduction of resources in say in production. The popular focus is reduction of machine time and man time to produce a unit. Inventory is also a resource which was planned using EOQ model and safety stock formula. Ohno concentrated on Inventory as waste which can be reduced by reducing setup cost that is setup time. Inventory reduction is a major theme of TPS and then many other traditional activities and even new activities. Lot of machine time reductions and man time reductions happened in TPS. Employee involvement increased in TPS. Inventory reduction can be related to "mass of IE", but it is a very special and unique focus of TPS that also became popular as JIT, no inventory production, just in time for delivery to the customer for use.


Osamu Higo
 
Narayana Rao KVSS , "inventory reduction is a major theme of TPS"? I do not think so. There is a misunderstanding about TPS when people say or seek "No stock".
The point is "Flow", and If the stocks (volume) contribute to keep the "Flow", that's o.k. After then, the people need to reduce the level of the stocks, while keeping the "Flow".

Sticking to Ohno' words often does not make sense, why? After the big efforts by the Kaizen men with long journey, they realized the excellent system, and if the people only focus on Ohno (words), they may miss something (Why long journey? What system behind TPS? How about the relationship with the supplier? etc.).


Narayana Rao KVSS

  "Sticking to Ohno' words often does not make sense, why? After the big efforts by the Kaizen men with long journey, they realized the excellent system, and if the people only focus on Ohno (words), they may miss something (Why long journey? What system behind TPS? How about the relationship with the supplier? etc.)."

Yes. I agree with you regarding what is to be done today. What is to be done today is the understanding of today's consultants regarding current TPS or any other system and the client company's situation.

According to my reading of Shingo's books, Ohno's books and the early books on TPS, the focus is on cost reduction. And the special unique focus is on inventory. Inventory was not attacked and reduced to that extent till that time by other companies. TPS reduced machine hours and man hours in the traditional IE way modified by the focus on machine work and engineering improvement. TPS focused on quality to reduce safety stocks and developed Poka-yoke.

Osamu Higo But the improvements are in multiple dimensions and multiple ways in TPS. Today, if some consultants say it is development of people. Some others say it is respect for people. Some say it is Kaizen orientation. They may be correct. For me process improvement and production quantity planning (that is batch size reduction) seem to be the fundamental pillars. Jidoka is process improvement and JIT is production batch quantity reduction to even single piece giving flow production and minimum cycle time. Producing to takt is reduction in inventories.

I interpret that new development in TPS in IE is the unique attack on inventory. In engineering area, they followed original Taylor's focus on machine work and improvement of all engineering elements.

But the improvements are in multiple dimensions and multiple ways in TPS. Today, if some consultants say it is development of people. Some others say it is respect for people. Some say it is Kaizen orientation. They may be correct. For me process improvement and production quantity planning (that is batch size reduction) seem to be the fundamental pillars. Jidoka is process improvement and JIT is production batch quantity reduction to even single piece giving flow production and minimum cycle time. Producing to takt is reduction in inventories.

I interpret that new development in TPS in IE is the unique attack on inventory. In engineering area, they followed original Taylor's focus on machine work and improvement of all engineering elements.


Osamu Higo

Narayana Rao KVSS , basically I agree with your comment.
Based on your opinion, it seems that the people do not need to stick to Ohno (words). Am I wrong?




13 June 2022
Yes. 5s seeks to ensure that workplaces in production plants are #safe, #clean and well #organized.

https://www.linkedin.com/posts/florian-palatini_5s-ergonomics-safe-ugcPost-6942045699635068928-sD4Y


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?

https://www.linkedin.com/posts/narayana-rao-kvss-b608007_industrialengineering-activity-7139107873980141568-huXX 



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

Product Redesign to Reduce Cost - Product Industrial Engineering - Are You Doing It?
PRODUCT INDUSTRIAL ENGINEERING. MODERN INDUSTRIAL ENGINEERING.


The major techniques that constitute  Product Industrial Engineering. 

1. Value Analysis and Engineering
2. Design for Manufacturing
3. Design for Assembly
4. Design for Additive Manufacturing
5. Design to Cost
6. Design to Value
7. Design to Target Cost
8. Engineering Product Design Optimization
9. Six Sigma for Design Improvement - Robust Design (Video)
10. Life Cycle Cost Analysis based redesign
11. Design analysis done during Process Industrial Engineering
12. Lean Product Design Concept



Economically Efficient Design of Products and Production Processes 

Economic Decision Making and Design and Process Changes by Engineers


Dr. K.V.S.S. Narayana Rao

Professor, NITE, Mumbai
Industrial 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 1

Design 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

Synthesis
Analysis
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,  1923
The 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 collection
Support to accounting function
Cost estimating
Economic analysis

Economic Analysis Concepts

Time value of money
Compound 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 Selection
Economic 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. Miles
http://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 Analysis
Operation Analysis
Motion Analysis

Process Analysis for Process Economic Efficiency

After Process Synthesis do Process Analysis
Rationalize 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 Synthesis
Subject 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 ergonomics

Thank You

Thank You
Ready 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


Ud. 25.11.2023
Pub. 10.9.2013


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

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


METHOD STUDY.
The principles of Methods Efficiency Engineering are fundamental, and they can be applied to any class of work. It makes no difference if a plant is manufacturing toys, tools, trains, or tractors ; the principles apply equally to all. - H.B. Maynard.
They are applicable to job shops as well as mass production shops. There are also applicable to all engineering branches.
Scope and Limitations of Process Industrial Engineering - Methods Efficiency Engineering.

Basic Production Processes and Technologies and Industrial Engineering


Developing basic production processes and technologies in the direction of increasing productivity is the responsibility of industrial engineering discipline.


Production/Manufacturing Processes


1. Casting
2. Rolling
3. Forging
4. Sheet Metal Work
5. Machining
6. Welding
7. Assembling
8. Wood Working
9. Additive Manufacturing

New Non-traditional Machining Processes

Electrochemical Machining


Industrial Engineering Focus Areas



1. Productivity Science
2. Production Process Industrial Engineering
3. Product  Industrial Engineering
4.  Industrial Engineering Economics
5.  Industrial Engineering  Optimization
6.  Industrial Engineering Statistics
7. Human Effort  Industrial Engineering
8.  Industrial Engineering Measurement
9. Productivity Management
10. Applied Industrial Engineering
     IE/Productivity Improvement in 3D Printing





Concepts, Research Papers and Case Studies in Production Industrial Engineering 





1. Productivity Science


Machining

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

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 steels
1993
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

Production Industrial Engineering - Six Sigma Case Studies in Machining Processes.


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



3D Printing - Additive Manufacturing Industrial Engineering - Productivity Science and Engineering
#IndustrialEngineering #Productivity #CostReduction
https://nraoiekc.blogspot.com/2017/08/3d-printing-additive-manufacturing.html


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

Engineering in Industrial Engineering - Machine Effort Productivity Engineering, Product Value Engineering, Design for Manufacturing and Assembly.
Lesson 246 of Industrial Engineering ONLINE Course Notes. 




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

Design for 3D Printing - Additive Manufacturing - Product Industrial Engineering
https://nraoiekc.blogspot.com/2019/01/design-for-3d-printing-additive.html


Assembly

Introduction to Design for (Cost Effective) Assembly and Manufacturing
http://me.gatech.edu/files/capstone/L071ME4182DFA

4.  Industrial Engineering Economics

5.  Industrial Engineering  Optimization

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



6.  Industrial Engineering Statistics


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


Additive Manufacturing - 3D Printing - Human Effort Industrial Engineering




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


9. Productivity Management

10. Applied Industrial Engineering

IE/Productivity Improvement in 3D Printing

  



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