Saturday, April 19, 2025

Quality and Industrial Engineering

Process Chart Analysis of Industrial Engineering and Quality


Process level quality issues are examined for effectiveness and efficiency in process chart analysis by industrial engineers. Effectiveness issues are referred to quality engineers and quality managers and efficiency improvement is undertaken by industrial engineers. Industrial engineers ensure that there is no negative effect of productivity improvement on quality of output. Quality is a higher level performance measure to productivity and has priority.


2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

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

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Modern Industrial Engineering - Summary Explanation.

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

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Quality and  Industrial Engineering

Industrial Engineering Principle of Quality 


The first move by industrial engineer,  before undertaking productivity improvement through productivity engineering, is to insure against a falling off in quality.  After insuring against deterioration in quality, effective means  are to be developed to increase the output by machine time and operator time reduction, substitution of lower prices materials and parts, and consumable and energy usage reduction.
Quality Principle of Industrial Engineering


Effectiveness First - Efficiency Next Principle of Industrial Engineering.


F.W. Taylor improved inspection activities. 

In process chart method, Gilbreth included analysis of inspection activities.

In the process chart analysis, each activity is examined for its purpose, effectiveness and efficiency. Hence inspection activities were examined whether there is any purpose and whether they are effective. If they are not effective, then quality activities designers were alerted to develop a new method to make them effective. If there is no clear purpose for the activity it is eliminated. Then the efficiency analysis is attempted. So industrial engineers are also concerned with assuring quality output from material transformation or value adding activity.


The main components of ISE knowledge that reflect a categorisation of pertinent industrial and systems engineering theories and models include (1) work design & measurement, (2) operations research & analysis, (3) engineering economic analysis, (4) facilities engineering & energy management, (5) quality & reliability engineering, (6) ergonomics & human factors, (7) operations engineering & management, (8) supply chain management, (9) engineering management, (10) safety, (11) information engineering, (12) design and manufacturing engineering, (13) product design & development, and 14) system design & engineering.

Note number (5) Quality & Reliability Engineering. Industrial engineers learn about quality to maintain quality in IE improvement projects and to improve efficiency of quality activities.


Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc



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Thursday, April 17, 2025

Operations Management and Industrial Engineering

 


2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

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

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Modern Industrial Engineering - Summary Explanation.

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

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Operations Management and  Industrial Engineering



Bulk of industrial engineering activities take place in operations function of organizations.


Operations functions include receiving all customer orders from sales department, planning their production or execution, arranging resources through supply/purchasing functions, production or execution, and despatch or fulfillment and further customer service. Maintenance of equipments and other resources, and monitoring payments to employees and suppliers are also operations functions.


Product Design is generally a separate activity but it is also sometimes included in operations.


Industrial and systems engineering (ISE) is defined as a discipline concerned with the design, improvement and installation of integrated systems of people, materials, information, equipment and energy. It draws upon specialised knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design, to specify, predict, and evaluate the results to be obtained from such systems (IISE 2024). 


The main components of ISE knowledge that reflect a categorisation of pertinent industrial and systems engineering theories and models include (1) work design & measurement, (2) operations research & analysis, (3) engineering economic analysis, (4) facilities engineering & energy management, (5) quality & reliability engineering, (6) ergonomics & human factors, (7) operations engineering & management, (8) supply chain management, (9) engineering management, (10) safety, (11) information engineering, (12) design and manufacturing engineering, (13) product design & development, and 14) system design & engineering.




Operations Management - Industrial Engineering Interface

By Narayana Kvss






Operations Management - People - Job Design - Role of Operations Management 


• Operations Management books do have a chapter on 

managing people. 

• Operations Management books also discuss cost 

management and productivity management. 

• Shop Management by F.W. Taylor - First book on production 

management. 

• Industrial engineering (IE) - A discipline started in 1908 for productivity improvement. 


Inadequate Description of IE in Production/Operations Management Books 


• But most of the operations management - 

production management books deliberately do 

not discuss the role of industrial engineering in 

productivity management, cost management 

and people management. 


Neglect of IE in Management Books 


• Specifically highlighted by Narayana Rao K.V.S.S. in a conference paper. 


• Appreciated by conference attendees 

including international delegates. 

Scientific Management 


• Nigel Slack et al. in their book on Operations 

Management, discuss the role of scientific 

management and the product of it, work study 

in the chapter on people and job design. 

Scientific Management - Science for Work 



• The term ‘scientific management’ became established in 1911 with 

the publication of the book of the same name by Fredrick Taylor. 

• ● All aspects of work should be investigated on a scientific basis to 

establish the laws, rules and formulae governing the best methods of 

working. 

• Workers should be selected, trained and developed methodically to 

perform their tasks. 

• ● Co-operation should be achieved between management and 

workers based on the ‘maximum prosperity’ of both. 

Managers - Workers - Responsibilities 

• Managers have equal responsibility with workers 

for the completion of work. 

• Managers do the work that they can do better. 

• Workers do the work that they can do better. 


Productivity Science 


• Development of science is the responsibility of 

managers. - F.W. Taylor 

• Now development of science is the responsibility 

of Industrial Engineering researchers. 

• Principles of scientific management are in use 

even today even though management textbooks 

are not giving right description of it. 


Systems for Management - Nigel Slack et al. 


• Scientific Management takes an ‘investigative’ approach to 

improving operations. 

• The term ‘systematic management’ was also popular. 

• Taylor’s effort gave birth to Industrial Management and 

Industrial Engineering. 

• Personnel Department is also from Taylor’s effort. 

• Gilbreth’s work gave birth to ergonomics. 



Frameworks for Productivity Science of Machine Effort and Human Effort 


• Science in Scientific Management - Taylor and Gilbreth. 

• Rao, Kambhampati Venkata Satya Surya Narayana. IIE Annual 

Conference. Proceedings; Norcross (2020): 429-434. 

• https://www.proquest.com/openview/5786c4e6edff56abf808b4db26 

f083b3/1.pdf 


Industrial Engineering 


• 1901 & 1908 

• Productivity improvement and productivity management aspects of 

production systems (in general engineering systems). 

• Facilities Industrial Engineering 

• Product Industrial Engineering 

• Process Industrial Engineering 

• Managerial Practices Industrial Engineering 


Industrial Engineering Principles 


• Presentation by Dr. K.V.S.S. Narayana Rao 

• 2017 IISE Annual Conference, Pittsburgh, USA. 

• YouTube Video 

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


https://www.academia.edu/105277135/Operations_Management_Industrial_Engineering_Interface


IISE has to persuade authors of Operations Management Textbooks to discuss role of industrial engineering in operations management adequately. IISE has to publish a paper on it in its publications.



Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc



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Tuesday, April 15, 2025

Management Module for Industrial Engineering Curriculums

  

2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

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

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Modern Industrial Engineering - Summary Explanation.

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

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


Management Module for  Industrial Engineering Curriculums


What should be the focus of management modules for industrial engineering students?

The focus has to be productivity management first.  Second it has to be management of IE studies, projects and IE department. Third, IEs have to improve management systems from productivity improvement perspective. Hence, IE students have to be taught the principles behind design of management systems and components and practices. Improvement issues need to be discussed in the course.

Therefore what subjects are to be there in the management module in the IE curriculum?


1. Principles of Management and Principles of Industrial Engineering.

2. Productivity Management

3. Management of IE Studies, Projects and Department.

4. Engineering Economic Analysis of Resources, IE Recommendations and Projects

5. Organizational Behavior - IE Implications


Electives Offered on Improvement of Various Management Systems

1. Financial Accounting System and Improvement

2. Cost Accounting System and Improvement

3. Management Accounting System and Improvement

4. Financial Management System and Improvement

5. Operations Management System and Improvement

6. Supply Chain Management System and Improvement

7. Marketing Management System and Improvement

8. Human Resource Management System and Improvement

9. Project Management System and Improvement

10. Product and Engineering Design System and Improvement

11. Maintenance System and Improvement

12. Construction Management System and Improvement

13. Transportation System and Improvement

I4. Information Systems and Improvement




Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc



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Job Shop - Industrial Engineering - Productivity Improvement - Cost Reduction


Book Chapters - Shahrukh Irani -  - Industrial Engineering in Job Shops - Job Shop Lean.

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_chapter-1-from-my-book-including-appendices-activity-7316243520120373249-cy55/



 https://books.google.com/books?id=sAarCAAAQBAJ&pg=PA396&lpg=PA396#v=onepage&q&f=false

Case Study of HDS Division, Schlumberger

Summer of 1985


Time to Reform Job Shop Manufacturing

by James E. Ashton and Frank X. Cook, Jr.

From the Magazine (March–April 1989)

https://hbr.org/1989/03/time-to-reform-job-shop-manufacturing


Written instructions.

Schedule adherence


Bibliography


Lekan Olanrewaju

Jan 31, 2023 | 6 minutes read

Overcoming the Challenges of Job Shop Manufacturing

https://www.getmaintainx.com/blog/overcoming-the-challenges-of-job-shop-manufacturing/


Navigating High-Mix, Low-Volume Manufacturing

July 27, 2022

By Kip Hanson, Contributing Editor, SME Media

https://www.sme.org/technologies/articles/2022/july/navigating-high-mix-low-volume-manufacturing/


How to Make a Machine Shop Lean - Dr. Shahrukh Irani - Chapter Summary

https://nraoiekc.blogspot.com/2022/06/how-to-make-machine-shop-lean-dr.html


Home  Concurrent Engineering: Tools and Technologies for Mechanical System Design  Conference paper

Relationship Between Design for Manufacturing, a Responsive Manufacturing Approach, and Continuous Improvement

J. E. Ashton 

Conference paper

Part of the NATO ASI Series book series (NATO ASI F,volume 108)

https://link.springer.com/chapter/10.1007/978-3-642-78119-3_17



Time to Reform Job Shop Manufacturing

by James E. Ashton and Frank X. Cook, Jr.

From the Magazine (March–April 1989)

https://hbr.org/1989/03/time-to-reform-job-shop-manufacturing




Ud. 30.11.2023

Pub. 11.7.2023


Modern Industrial Engineering and Lean in Low Volume - High Mix Production - Job Shop Lean - Shahrukh Irani, Narayana Rao and Others


Popular E-Book on IE

Introduction to Modern Industrial Engineering.  

In 0.5% on Academia.edu. 10,450+ Downloads so far.

FREE Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 


Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems


Shahrukh A. Irani

CRC Press, 04-May-2020 - Business & Economics - 744 pages


In the 1950’s, the design and implementation of the Toyota Production System (TPS) within Toyota had begun. In the 1960’s, Group Technology (GT) and Cellular Manufacturing (CM) were used by Serck Audco Valves, a high-mix low-volume (HMLV) manufacturer in the United Kingdom, to guide enterprise-wide transformation. In 1996, the publication of the book Lean Thinking introduced the entire world to Lean. Job Shop Lean integrates Lean with GT and CM by using the five Principles of Lean to guide its implementation: (1) identify value, (2) map the value stream, (3) create flow, (4) establish pull, and (5) seek perfection. Unfortunately, the tools typically used to implement the Principles of Lean are incapable of solving the three Industrial Engineering problems that HMLV manufacturers face when implementing Lean: (1) finding the product families in a product mix with hundreds of different products, (2) designing a flexible factory layout that "fits" hundreds of different product routings, and (3) scheduling a multi-product multi-machine production system subject to finite capacity constraints.


Based on the Author’s 20+ years of learning, teaching, researching, and implementing Job Shop Lean since 1999, this book


Describes the concepts, tools, software, implementation methodology, and barriers to successful implementation of Lean in HMLV production systems

Utilizes Production Flow Analysis instead of Value Stream Mapping to eliminate waste in different levels of any HMLV manufacturing enterprise

Solves the three Industrial Engineering problems that were mentioned earlier using software like PFAST (Production Flow Analysis and Simplification Toolkit), Sgetti and Schedlyzer

Explains how the one-at-a-time implementation of manufacturing cells constitutes a long-term strategy for Continuous Improvement

Explains how product families and manufacturing cells are the basis for implementing flexible automation, machine monitoring, virtual cells, Manufacturing Execution Systems, and other elements of Industry 4.0

Teaches a new method, Value Network Mapping, to visualize large multi-product multi-machine production systems whose Value Streams share many processes

Includes real success stories of Job Shop Lean implementation in a variety of production systems such as a forge shop, a machine shop, a fabrication facility and a shipping department

Encourages any HMLV manufacturer planning to implement Job Shop Lean to leverage the co-curricular and extracurricular programs of an Industrial Engineering department



Abstracts of chapters



Book Chapters - Shahrukh Irani -  - Industrial Engineering in Job Shops - Job Shop Lean.

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_chapter-1-from-my-book-including-appendices-activity-7316243520120373249-cy55/





Made-to-Order Lean: Excelling in a High-Mix, Low-Volume Environment


Greg Lane

CRC Press, 09-Mar-2020 - Business & Economics - 224 pages


Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs.

About the author:


Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS.


He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales.


Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: glane@lowvolumelean.com

https://books.google.co.in/books?id=mYvVDwAAQBAJ







UNIVERSITÀ DI PISA - Dottorato di Ricerca in Ingegneria Industriale.

Development and implementation of Lean Manufacturing tools and methods for the manufacturing efficiency in Engineer-to-Order production environments

MARRAZZINI, LEONARDO

https://etd.adm.unipi.it/t/etd-08182020-100440/


"Overall Task Effectiveness: a new Lean performance indicator in engineer-to-order environment,"

Marcello Braglia, Roberto Gabbrielli and Leonardo Marrazzini,

Dipartimento di Ingegneria Civile e Industriale,

Università di Pisa, Pisa, Italy.

International Journal of Productivity and Performance Management, Vol. 68 No. 2, 2019, pp. 407-422


The Lean Primer - Solutions for the Job Shop


Roger Kremer, Tom Fabrizio
MCS Media, Inc., 2005 - Costs, Industrial - 96 pages
https://books.google.co.in/books?id=evuK0FpVFPEC



Handbook of Cellular Manufacturing Systems


Shahrukh A. Irani
John Wiley & Sons, 15-Apr-1999 - Technology & Engineering - 762 pages

A hands-on guide to implementing multi-cell manufacturing systems on a large scale.
Cellular manufacturing (CM) is the grouping of similar products for manufacture in discrete multi-machine cells. It has been proven to yield faster production cycles, lower in-process inventory levels, and enhanced product quality.

Pioneered on a large scale by Russian, British, and German manufacturers, interest in CM methods has grown steadily over the past decade. However, there continues to be a dearth of practical guides for industrial engineers and production managers interested in implementing CM techniques in their plants. Bringing together contributions by an international team of CM experts, the Handbook of Cellular Manufacturing Systems bridges this gap in the engineering literature. With the help of numerous in-depth case studies drawn from a wide range of industries, the Handbook covers:

History and basic principles of cellular manufacturing.
Methods for cell formation, layout, and scheduling of large manufacturing systems.
Setup time reduction techniques.
Quality control in CM.
Benchmarking and performance evaluation of cells.
Financial costs and benefits of CM versus traditional approaches.
Human resources and team development issues in CM.
Computer-aided methods and tools for planning, designing, implementing, and managing cells in manufacturing plants.
The Handbook of Cellular Manufacturing Systems is an indispensable resource for industrial engineers and production managers interested in implementing this exciting new alternative to conventional manufacturing system configurations.
https://books.google.co.in/books?id=lmLv68XlCZUC

Ud 12.9.2024, 4.10.2021
Pub 27.0.2021

How to Make a Machine Shop Lean - Dr. Shahrukh Irani - Chapter Summary


According to me lean is initially applied to inventory by MIT team. Then extended to all resources. Then they first extended idea to waste. Basically lean initially is only part of industrial engineering. In a clever way, thelean proponents went extending lean concept to include all the objectives of industrial engineering but they could not accept all the techniques and tools of IE. Hence, the effectiveness of lean is not up to the expectations and sufficient criticism of Lean has surfaced. Now Even Jim Womack accepts that lean is not encountering problems in giving expected results.

But, readers have to learn the recommended lean implementation procedures as lean has value as one of the tasks of industrial engineering. It is certainly an advance in IE based productivity improvement.

Preview the chapter by Dr. Shahrukh Irani

https://books.google.co.in/books?id=binhDwAAQBAJ&pg=330#v=onepage&q&f=false

in the book - Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems  By Shahrukh A. Irani.

Copyright Year 2020

https://www.routledge.com/Job-Shop-Lean-An-Industrial-Engineering-Approach-to-Implementing-Lean-in/Irani/p/book/9781498740692




Lean Tools to Use in Machine Shop


Leanness or "Lean Strategy" Planning

Gemba Walks

Workplace Design with 6S

SMED

TPM

Poka Yoke

Quality at Source - In Process (F.W. Taylor)

Visual Workplace

Right-sized Flexible Machine

Standard Work

Standardized Process

Continuous Problem Solving 


Book Chapters - Shahrukh Irani -  - Industrial Engineering in Job Shops - Job Shop Lean.

https://www.linkedin.com/posts/shahrukh-irani-8b25a55_chapter-1-from-my-book-including-appendices-activity-7316243520120373249-cy55/




Published 8/1/2018 

10 Lean Manufacturing Ideas for Machine Shops

In addition to the right mix of traditional strategies, a new lean manufacturing toolkit can make high-mix, low-volume machining faster, more predictable and less expensive.

DR. SHAHRUKH A. IRANI, LEAN & FLEXIBLE LLC

https://www.mmsonline.com/articles/10-lean-manufacturing-ideas-for-machine-shops


Ud. 15.4.2025

Pub. 30.6.2022