ISE 195 Introduction to Industrial Engineering

1. ISE 195Introduction to Industrial Engineering

2. Lecture 1: Introduction to Industrial Engineering

3. History • Early history really did not distinguish between science and engineering. Advancements involved application of knowledge • Early advancements largely result of physical phenomena and from these advancements emerged various disciplines

4. Modern Disciplines • Civil engineering emerging from military engineering • Mechanical engineering emerging from growth of mechanical devices after steam engine • Electrical engineering after the telegraph (and other products) appeared • Chemical engineering (lubricants, etc)

5. Post WWII Disciplines • Nuclear engineering • Electronic engineering • Aeronautical engineering • Astronautical engineering • Computer engineering • Environmental engineering • Bioengineering

6. Mass Production • Mass production has had an enormous impact on civilization • Interchangeable parts • Labor specialization • Reduced the cost of products while drastically changing society • Older practices soon became outdated requiring the development of better, more efficient processes and systems

7. Chronology of IE • The industrial revolution in large part led to the emergence of industrial engineering as a profession • Babbage thought to specialize labor by skill required • Taylor really started IE • Analyze and improve the work method • Reduce the times required for the work • Set standards for the times required

8. Chronology of IE (cont.) • Gilbreth extended work of Taylor to consider the human aspects of work to include motion involved in work • Henry Gantt developed his chart to preplan, schedule, and monitor work activity • Shewhart developed the fundamental principles of statistical process control • Disciples became big names in quality

9. Definition Industrial Engineering is concerned with the design, improvement, and installation of integrated systems of people, materials, information, equipment, and energy. It draws upon specialized 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.

10. Design Impacts • Industrial and systems engineers design systems at two levels • The first level is called the human activity level and is concerned with how work gets accomplished • The second level is called the management control system level and addresses the planning, measurement, and control of organizational activities

11. Level One Elements • Processes within the organization • Layout of facilities and machines • Design of the workplace • Storage space and location • Work methods

12. Level Two Elements • Planning systems • Forecasting systems • Material and inventory planning and control • Scheduling activities • Cost control and analysis • Quality control system

13. IS&E Activities • The actual activities performed by IS&E personnel will vary by firm • Traditionally, activities were focused on the operational level of the organization • Recent trends involve the IE getting involved in the design of the management systems as well as getting more involved in systems design

14. Production Operations • Analysis of proposed product or service • Analysis of manufacturing process • Facilities issues • Work methods and standards • Production planning and control

15. Product/Service Analysis • Will it be profitable? • Is product compatible with line? • Can it be manufactured? • Where are there opportunities for improvement? • Analyze distribution of product or delivery of service to customers

16. Manufacturing Process • What is the best process by which to manufacture and assemble the product • What is the mix of equipment, robots, or personnel • How can the assembly lines best be balanced • What is the best material flow and material handling procedures

17. Facilities Concerns • What is the best facility layout? • How should material and goods be stored? • What maintenance processes should be adopted to include preventative maintenance, test, and inspection • Utilities required • Security and emergency planning

18. Work Methods and Standards • Perform work measurement studies and establish time standards • Perform work improvement studies • Value engineering studies to determine and eliminate sources of waste and excess cost

19. Prod. Planning & Control • Forecast potential sales • Is capacity and resources being taxed to their limit • Establish inventory procedures • Plan for any materials requirement planning • Scheduling

20. Prod. Planning & Control • Design quality control system and inspection processes • Shop floor control procedures • Reports • Cost • Quality • Labor • Productivity

21. Management Systems • Information Systems • Financial and cost systems • Personnel systems

22. Information Systems • Help decision makers make decisions • Determine data requirements and maintain lineage of data • Design and maintain database to support the information system • Analyze data communications requirements

23. Financial and Cost Systems • Budgeting • Engineering economy studies • Cost tracking and cost reduction systems • Cost estimation systems

24. Personnel Systems • Employee testing, selection and placement • Training and education programs • Job evaluation and incentive programs • Ergonomics and human engineering applied to jobs, workplaces and workplace in general • Quality improvement activities

25. Corporate Services • Planning • Policies and procedures • Performance measurement • Analysis

26. Planning • Support corporate strategic planning to include national and international planning • Perform enterprise modeling • Support and perform system integration activities • Provide support to major decisions and participate in major decisions • Total quality management activities

27. Policies and Procedures • Study organizational analysis and design • Perform analyses of functional groupings • Policy manuals • Procedures

28. Performance Measurement • Identify meaningful performance measures for those areas of interest key to the firm success • Identify critical success factors • Specify and design corrective action procedures • Design reports for all levels of management

29. Analysis • Analyze systems and construct models • Apply appropriate solution methodologies • Perform simulation studies • Perform operations research studies • Perform statistical analysis • Conduct designed experiments • And more…

30. IE and Systems • Industrial engineering really takes a system-level perspective • The tools and techniques of the IE allow the IE to examine the system, the interactions among the components of the system, all while keeping in mind the objective or purpose of the system • An IE seeks to optimize systems

31. IE Coverage • Simulation • Optimization • Human Factors • Ergonomics • Production Systems • Statistical and stochastic modeling • Design of experiments • Modeling of human decision makers

32. This Week’s Readings

33. From “IE Lifestyle” in IE Magazine “My wife and I are both IEs. We use a two-bin inventory system for many commonly used cooking and baking items. When the main bin is out, we put the item on our shopping list and use the safety stock from the second bin (which, in the case of baking supplies, we keep in our refrigerator). A while ago we reduced the number of items we carried safety stock for and put a note on our refrigerator to remind us (‘No safety stock in fridge for wheat flour’). A friend (also an IE) saw the note on our refrigerator and said, ‘You sure know you are in the home of two IEs when you see a sign like that.’” Russell D. Meller, Associate Professor, Department of Industrial and Systems Engineering Virginia Tech, Blacksburg, Va.

34. From “What is an IE”, IE Magazine “An industrial engineer maximizes the utilization of scarce resources — namely, time and money.” - Bill Tolo, Minneapolis

35. From “Report for Duty’, IE Magazine Roger Goodwin helps improve the quality of life for people needing tissue transplants.

36. Readings for April 8th • Quiz for April 8th class session • Read the Chapter “History of Manufacturing in America”, from Hopp and Spearman, Factory Physics, Third Edition, McGraw-Hill, 2008 • You can bring a hardcopy, or use the online link during your quiz on April 8th.

37. Questions?