An Introduction

from Prof. Goldsman’s lecture notes

How would you define How would you define

““Industrial EngineeringIndustrial Engineering”?”?

What is IE?Frederic W. Taylor Frederic W. Taylor Father of Industrial Engineering Father of Industrial Engineering

““Industrial Engineering is concerned with the Industrial Engineering is concerned with the design, design, improvement, and installation of integrated systemsimprovement, and installation of integrated systems of of people, materials, information, equipment, and energy. people, materials, information, equipment, and energy. It draws upon specialized knowledge and skill in the It draws upon specialized knowledge and skill in the mathematical, physical, and social sciencesmathematical, physical, and social sciences together together with the principles and methods of engineering analysis with the principles and methods of engineering analysis and design to specify predict, and evaluate the result to and design to specify predict, and evaluate the result to be obtained from such systems”be obtained from such systems”

– Industrial versus ManufacturingIndustrial versus Manufacturing– A big-picture thinking disciplineA big-picture thinking discipline

PROBLEM SOLVER!!PROBLEM SOLVER!!

What is IE? (Cont’d)““A branch of engineering that engages in the A branch of engineering that engages in the study of how to describe, evaluate, design, study of how to describe, evaluate, design, modify, control and improve the performance modify, control and improve the performance of complex systems, viewed over time and of complex systems, viewed over time and within their relevant context.”within their relevant context.”

• Logistics/Supply Chain SystemsLogistics/Supply Chain Systems• Financial/Economic SystemsFinancial/Economic Systems• Health SystemsHealth Systems• Manufacturing SystemsManufacturing Systems• Etc.Etc.

IE Core CoursesBased on Tech’s Curriculum:Based on Tech’s Curriculum:

1.1. Probability TheoryProbability Theory2.2. Statistics and Its ApplicationStatistics and Its Application3.3. ModelingModeling4.4. Engineering EconomyEngineering Economy5.5. Stochastic Processes Stochastic Processes 6.6. Quality ControlQuality Control

7.7. SimulationSimulation8.8. LogisticsLogistics9.9. ManufacturingManufacturing10.10.Human Machine InterfaceHuman Machine Interface11.11.OptimizationOptimization12.12.Senior DesignSenior Design

Fundamental Issues

Flow (accumulation and conversion): 3, 5, 7, 8, 9 Flow (accumulation and conversion): 3, 5, 7, 8, 9

Randomness: 1, 2, 3, 5, 6, 7Randomness: 1, 2, 3, 5, 6, 7

Complex decision making (preferences): 5, 7, 8, 9, Complex decision making (preferences): 5, 7, 8, 9, 1111

Optimization: 3, 11Optimization: 3, 11

People (learning): 10People (learning): 10

Economics: 3, 4Economics: 3, 4

Diner Dash Game

Diner Dash Game

Learn how to think like an IELearn how to think like an IE

What can you observe in the game? What can you observe in the game?

KISS Rule!KISS Rule!

Remember, Remember, IE is not equal to IE is not equal to manufacturing jobmanufacturing job!!

More on … What is IE?Improve system performance by:Improve system performance by:

Analyzing: Complex and uncertain interactionsAnalyzing: Complex and uncertain interactionsFormulating: Formulating: Fundamental topics Fundamental topics specialized studies specialized studiesSolving:Solving:““Management Control Systems” (finance)Management Control Systems” (finance)““Production Planning and Control Systems” Production Planning and Control Systems” ““Human Activity System” (synchronize for Human Activity System” (synchronize for quality)quality)

MCS and PPCSManagement Control System:Management Control System:

ForecastingForecastingEngineering EconomyEngineering EconomyRecruiting, training, and placement of employeesRecruiting, training, and placement of employeesMRP, QC, Inventory Control, etcMRP, QC, Inventory Control, etc

Production Planning and Control System:Production Planning and Control System:Manufacturing ProcessManufacturing ProcessMaterials, machines, and equipmentsMaterials, machines, and equipmentsFacility Layout and flow of materialFacility Layout and flow of materialWarehousingWarehousingDatabaseDatabaseSafety procedures, etcSafety procedures, etc

System ClassificationNaturalNatural versus versus Man-made Man-made SystemsSystems

Natural: nature activityNatural: nature activityMan-made: human activityMan-made: human activity

StaticStatic versus versus DynamicDynamic Systems SystemsStatic: no associated activityStatic: no associated activityDynamic: time-varying behaviorDynamic: time-varying behavior

PhysicalPhysical versus versus AbstractAbstract Systems SystemsPhysical: physically existing componentsPhysical: physically existing componentsAbstract: symbol representationAbstract: symbol representation

OpenOpen versus versus ClosedClosed Systems SystemsOpen: Interacts with its environmentOpen: Interacts with its environmentClosed: little interchange with its environmentClosed: little interchange with its environment

What is Manufacturing Engineering?

Designing the production process of a Designing the production process of a productproduct

Compared to IE? Compared to IE?

QAQA

EvaluateEvaluateSelect& Set

Select& Set

DesignDesign

Cost Estimation

Cost Estimation

Product Structure and Specifications

Hierarchical chart:Hierarchical chart:

ProductProduct

Sub-assemblySub-assembly

ComponentsComponents

RMRM

…

Bill Of Materials (Taken From Heizer and Render)

Assembly Drawing & Charts(Taken From Heizer and Render)

Operation Process Chart(Taken from Francis et. al.)

Cost Calculation

Two Types:Two Types:Fixed CostFixed Cost: constant regardless of the number of : constant regardless of the number of parts are madeparts are made

e.g. Setup Cost, Design Cost, Location Coste.g. Setup Cost, Design Cost, Location Cost

Variable CostVariable Cost: cost varies directly with the number : cost varies directly with the number of parts producedof parts produced

e.g. Operator Cost, RM Cost, Utility Coste.g. Operator Cost, RM Cost, Utility Cost

Total Cost = Fixed Cost + Variable Cost * Number of Units

TC = FC + VC * (#units)

Total Cost = Fixed Cost + Variable Cost * Number of Units

TC = FC + VC * (#units)

Industrial Processes

Refining and alloyingRefining and alloyingAlloy: combining >= 2 metals to get better Alloy: combining >= 2 metals to get better propertiesproperties

Metal properties (important):Metal properties (important):Tensile Strength (withstand elongation forces)Tensile Strength (withstand elongation forces)

Hardness (withstand penetration forces)Hardness (withstand penetration forces)

Impact Resistance (absorb energy)Impact Resistance (absorb energy)

Malleability (to be shaped or extended)Malleability (to be shaped or extended)

Fatigue Resistance (withstand repeated application of a Fatigue Resistance (withstand repeated application of a force)force)

Corrosion Resistance (withstand corrosive forces)Corrosion Resistance (withstand corrosive forces)

Industrial Processes (Cont’d)

CastingCastingForming objects by pouring liquid material into a mold Forming objects by pouring liquid material into a mold and allowing the material to solidify and allowing the material to solidify i.e. making puddingi.e. making puddingOld process but economical and effectiveOld process but economical and effective

Metal FormingMetal FormingHot: temperature above its re-crystallization Hot: temperature above its re-crystallization temperaturetemperatureCold: temperature below its re-crystallization Cold: temperature below its re-crystallization temperaturetemperatureProcesses: Roller, wire drawing, forging, extrusion, Processes: Roller, wire drawing, forging, extrusion, bending, and drawing and stretchingbending, and drawing and stretching

Metal Cutting Metal Cutting e.g. Shearing, Turning, Drilling, Shaping, Milling, e.g. Shearing, Turning, Drilling, Shaping, Milling, Broaching, Sawing-Filling, Grinding, etc. Broaching, Sawing-Filling, Grinding, etc.

Industrial Processes (Cont’d)

WeldingWeldinge.g. Electric Arc, Resistance Welding, Beam Welding, e.g. Electric Arc, Resistance Welding, Beam Welding, Thermit Welding, Pressure Welding, Gas Welding, Thermit Welding, Pressure Welding, Gas Welding, Brazing and Soldering, etcBrazing and Soldering, etc

AssemblingAssemblingVarious parts and sub-assemblies are put together to Various parts and sub-assemblies are put together to form a complete productform a complete productBatch process versus continuous processBatch process versus continuous process

FinishingFinishingProduct is made to be more presentable or effectiveProduct is made to be more presentable or effectivee.g. honing, lapping, polishing, buffing, brushing, e.g. honing, lapping, polishing, buffing, brushing, tumbling, surface cleaning, coating, etctumbling, surface cleaning, coating, etc

Cost EstimationTotal manufacturing cost, consists of:Total manufacturing cost, consists of:

MaterialMaterial DirectDirect: any material cost chargeable to a product directly: any material cost chargeable to a product directly

e.g. paper cost for printing a booke.g. paper cost for printing a bookIndirectIndirect: all other material costs: all other material costs

e.g. cleaning compound and brushese.g. cleaning compound and brushes– LaborLabor

• DirectDirect: any labor cost chargeable to a product directly: any labor cost chargeable to a product directlye.g. operatore.g. operator

• IndirectIndirect: all other labor costs: all other labor costse.g. marketing salarye.g. marketing salary

OverheadOverheadCosts other than direct labor or direct material costsCosts other than direct labor or direct material costse.g. indirect material and labor costse.g. indirect material and labor costs

Supply Chain

DREAM Cycle

What are the main things What are the main things customers care about? customers care about?

Customer Value Drivers

Cost Cost

QualityQuality

Speed Speed

InnovationInnovation

So… what is IE?

““Man, if you have to ask what it is, you’ll Man, if you have to ask what it is, you’ll never know.”-Louis Armstrong’s definition never know.”-Louis Armstrong’s definition of jazzof jazz