Introduction to module and IE.ppt

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Industrial Engineering and Management
For MSc Course @ Gloucestershire U
Session 1
6:43 AM,
Thursday, 12 October
2023
Module Introduction and Industrial Engineering
Welcome to
By
Shujun Zhang

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Module Introduction

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Module Description - 1
This module equip the students with the professional
knowledge of design, improvement, and installation of
integrated systems by optimising the utilisation of human
resources, facilities, equipment, tools, technologies,
information, energy and handling of materials to produce
quality products and services safely and cost-effectively
considering the needs of customers and employees. It
draws upon specialised knowledge and skills in the
mathematical, physical, and social sciences together with
principles and methods of engineering analysis and
design to specify, predict and evaluate the results to be
obtained from such systems.

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Module Description - 2
The module will prepare students for an exciting and
rigorous system engineering education that will allow
them to serve an increasingly complex society with
focuses on the methods and approaches to problem
solving and the knowledge for solving more complex
system design challenges.

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Learning outcomes
1) Fully understand how Industrial Engineering can support the
Company Strategy and evaluate and appreciate the full
contributions which Industrial Engineering can make to a modern
business
2) Apply a range of Industrial Engineering tools, techniques and
systematic approach for practical engineering system problems.
3) Use the both theoretical knowledge and practical experience
gained on the module to enable participants to apply the learning
beneficially to other situations
4) Develop own program of learning as required for successful
completion of the assigned project.
5) Solve the issues associated with ergonomics and safety,
compensation management and labour relations.
6) Apply statistics, operations research and optimisation methods
for industrial engineering.

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Learning and Teaching
Scheduled learning and teaching activities: 36 hours
Guided independent study: 114 hours
Assessment
Assessment Criteria
MSc Engineering Assessment Guide encompassing knowledge
and understanding, comprehension (effectiveness of
communication and presentation), application (planning and
management of the material), analysis, synthesis (creativity) and
evaluation. You need to achieve at least 40% to pass this
assessment.
Individual Report: Course work (4000 ±10%words equivalent) – 100%

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Indicative Reading
Core Text Book
V. Ravi, (2015) Industrial Engineering and Management. PHI Learning
Badiru, A.B. (2013) Handbook of Industrial and Systems Engineering.
2nd Edition. CRC Press
Others:
Elsevier Science (Firm) (1976) “Computers & Industrial Engineering.”
Available at: https://glos-on-worldcat-
org.glos.idm.oclc.org/oclc/222755706
Institution of Production Engineers (Great Britain), Institution of Electrical
Engineers and Institution of Engineering and Technology (1989)
“Manufacturing Engineer : Me.”

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Badiru, A.B. (2013) Handbook of Industrial and
Systems Engineering. 2nd Edition. CRC Press
For e-book, Please to go
https://glos.on.worldcat.org/search?databaseList=1080%2C2375%2C33
84%2C2272%2C251%2C197%2C1855%2C199%2C1996%2C1875%2
C2007%2C233%2C950%2C3313%2C2585%2C217%2C239%2C638%
2C2507%2C1715%2C2462%2C2262%2C1271%2C283%2C285%2C14
3%2C1842%2C2897%2C1621%2C245%2C203%2C3909&queryString=
handbook+of+industrial+engineering+and+system
Core Text Book – On-line resources

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Schedule

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Introduction to
Industrial Engineering

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Please give your definition of IE
Why do we need IE
Is IE related to technologies or
to management?
Any experiences?
Classroom activities

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Video clips (Introduction to IE)
https://www.youtube.com/watch?v=Ww9hDlwjeF4
This is a video clips about 9 minutes. It is suggested view the whole
video post session.
You can search more video clips on this topic
Useful webpage for definition of IE
http://nraoiekc.blogspot.com/2012/02/industrial-engineering-definitions-1911.html
Supporting materials

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Definition
There are many definitions, different at different stages and availability
of the technology, experiences, skills.
Industrial engineering directs the efficient conduct of
manufacturing, construction, transportation, or even
commercial enterprises of any undertaking, indeed in which
human labour is directed to accomplishing any kind of work .
Industrial engineering has drawn upon mechanical
engineering, upon economics, sociology, psychology,
philosophy, accountancy, to fuse from these older sciences a
distinct body of science of its own . It is the inclusion of the
economic and the human elements especially that
differentiates industrial engineering from the older established
branches of the profession (Going, 1911) [1].

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Definition
“Industrial engineering is the engineering approach applied
to all factors, including the human factor, involved in the
production and distribution of products or services.”
(Maynard, 1953)
"Industrial engineering is an art for creating the most
efficient system composed of people, matters, energy, and
information, by which a specific goal in industrial,
economic, or social activities will be achieved within
predetermined probabilities and accuracy. The system may
be for a small single work station, a group, a section, a
department, an institution or for a whole business
enterprise. It may be also be of a regional, national,
international, or inter-planetary scope."(Sawada, 1977)

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Definition
Industrial engineering defined as system efficiency engineering has
application in all branches of engineering. Productivity improvement is
needed in engineering systems of all branches and therefore industrial
engineering needs to be used in all branches of engineering. It needs to
be taught in all engineering branches. (Principles of Industrial
Engineering, Narayana Rao, K.V.S.S., 2017).
"Industrial Engineering is Human Effort Engineering and System
Efficiency Engineering. It is an engineering-based management staff-
service 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."(Narayana Rao, 2011)

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Definition
IE is the engineering that deals with the design,
improvement, and installation of integrated systems
(as of people, materials, and energy) in industry
https://www.merriam-
webster.com/dictionary/industrial%20engineering
the branch of engineering that is concerned with
designing and managing systems to make the best use
of industrial resources such as workers,
materials, equipment, and information
Collins English Dictionary.
https://www.collinsdictionary.com/dictionary/english/indu
strial-engineering

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Definition
Salvendy, Gabriel. Handbook of Industrial Engineering. John Wiley & Sons,
Inc; 3rd edition
Industrial engineering is an engineering
profession that is concerned with the optimization
of complex processes, systems,
or organizations by developing, improving and
implementing integrated systems of people,
money, knowledge, information, equipment,
energy and materials.

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Industrial Engineering & Management Program
• As engineers design and build more complex systems, the
need to oversee and ensure adequate performance of the
system becomes more pronounced. IE’s as managers and
engineers will have a significant role in understanding
performance requirements and improving efficiency of these
systems.
• Industrial engineers work in every type of enterprise –
manufacturers of every sort of industrial and consumer product;
healthcare, financial, transportation, distribution and other
types of service industries; government units and agencies.
• Industrial engineers concentrate on designing, installing, and
improving procedures, systems, and processes for effective
and efficient operation of any enterprise.

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Common Denominator:
• People
• Facility
• Processes
All of the above are needed to produce products and
services
In all businesses there is always a need to improve the
processes and the facilities so the employees (people)
can better perform their job producing goods and
services

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Are the professionals trained as productivity and quality
improvement specialists.
Work to eliminate waste of time, money, materials,
energy, and other commodities.
Figure out how to do things better.
Engineer processes and systems that improve quality
and productivity.
Manage Projects by engaging early in the process.
Industrial Engineers

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Production and Process Engineering
Quality and Reliability
Management of People and Processes
Workplace Design and Improvement
Computer Aided Manufacturing
Systems Engineering
Simulation Modeling and Analysis
Operations Research
Production and Inventory Management
Logistics and Supply Chain Management
Project Management
Study Areas

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Industrial Engineer
Logistics Engineer
Management Engineer
Process Engineer
Plant Engineer
Improvement Advisor
Manufacturing Engineer
Production Engineer
Project Manager
Facility Safety Engineer
Quality Engineer
Supplier Development
Engineer
Job Opportunities
Industries: health care, manufacturing, consulting,
transportation and distribution, food, and information system.

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Top Reasons to Become an Industrial Engineer
1. Work is exciting and challenging. The job is never boring.
Projects typically change frequently.
2. You can work in several types of organizations; e.g.,
manufacturing, transportation, financial, healthcare,
consulting. Organizations need an IEs
3. IEs usually have a broader view of the organization. For
example, while MEs or EEs might design a product, the
IEs would use their creativity to design a production
system to manufacture the product.
4. IE is more management-oriented than other engineering
disciplines. Consequently, IEs are more people-oriented.

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Top Reasons to Become an Industrial Engineer
5. Good job opportunities for IEs in the region and
across the nation.
6. Big £
7. IE is a gateway to entrepreneurship and provides
more upward mobility in an organization.
8. IE provides a good background for other fields; e.g.,
law.
9. IEs have a strong economic and business sense in
addition to their strong engineering background-
excellent combination!

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An Early and Modern Example about Manufacturing: Car Assembly
• The original “work cell” assembly method
• Henry Ford’s idea of assembly line,
following the efficiency innovations in cattle
slaughtering
• Many innovations for higher efficiency and
better quality, including robotics
• The Toyota Production System (TPS)

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Early Moving Assembly Line at Ford

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Robots at Work in Car Assembly

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Robots at Work in Car Assembly

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A Modern Car “Assembly Line” - VW Phaeton in Dresden

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History of IE
1. Phase I – Pre-industrial revolution – upto early
1800s
2. Phase II – Industrial revolution- early 1800s to late
1800s
3. Phase III – Scientific management phase – late
1800s to 1940 – Frederick Winslow Taylor – Father
of scientific management
4. Phase IV – Operations Research and quantitative
techniques – Late 1940s to early 1980s
5. Phase V – Automation and Computer Integrated
Manufacturing – since early 1980s
6. Phase VI – E-business – since 2000
7. Phase VII – IoTs or Industry 4.0 ot 5.0 – from 2025

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• Industrial Engineers work to make things better, be they
processes, products or systems
• Typical focus areas include:
– Project Management
– Manufacturing, Production and Distribution
– Supply Chain Management
– Productivity, Methods and Process Engineering
– Quality Measurement and Improvement
– Program Management
– Ergonomics/Human Factors
– Technology Development and Transfer
– Strategic Planning
– Management of Change
– Financial Engineering
What Do IEs Do?

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• Develop the detailed work breakdown structure of
complex activities and form them into an integrated plan
• Provide time based schedules and resource allocations
for complex plans or implementations
• Use project management techniques to perform
Industrial Engineering analyses and investigations
• Conduct facility planning and facility layout development
of new and revised production plants and office
buildings
• Form and direct both small and large teams that work
towards a defined objective, scope & deliverables
• Perform risk analysis of various project options and
outcomes
Project Management

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Manufacturing, Production and Distribution
• Participate in design reviews to ensure
manufacturability of the product
• Determine methods and procedures for production
distribution activity
• Create documentation and work instructions for
production and distribution
• Manage resources and maintain schedule
requirements to meet required production and
distribution schedules
• Process Optimization utilizing Simulation tools
(Arena, etc)
• Facilitate and Lead process improvement teams

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• Manage Supplier relationships
• Managing and report on company Supplier Cost/
Performance Indices to management
• Audit Suppliers and ensure supplier processes and
procedures are being followed
• Travel to suppliers to resolve issue
• Coordinate first article Inspections
• Work with Outsource Manufacturers to ensure
product quality, delivery and cost, is maintained
Supply Chain Management

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• Define proper work methods for tasks
• Define appropriate processes for work flow activities
• Define key production measures
• Define goals and data capture/analysis for key
measures
• Perform root cause analysis to improve poor
performing processes
• Develop appropriate incentive plans for work task
• Determine capacity requirements and subsequent
investment options
Productivity, Methods and Process Engineering

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• Resolve quality-related issues in all aspects of the
business
• Work with design and production teams and
outsource manufacturers to ensure product quality is
maintained during the design and production phases
• Audit defined processes and procedures to ensure
that they are being followed
• Coordinate and Facilitate 3rd Party Quality Audits
• Provide refresher training on procedures for
company personnel on Quality and process-related
issues, including the use of analytical tools and
techniques such as SPC (Statistical process control),
Six Sigma, etc.
Quality Measurement and Improvement

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• Develop proposals for new programs
• Manage program/project teams to ensure program
stays on schedule, on budget, and meets
performance expectations
• Coordinate a matrix of team member across
departments within an organization to ensure
completion of project tasks
Program Management

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• Ensure Human Factors Engineering is utilized in New
Product Design
• Ensure Human Factors Engineering disciplines are
utilized in production setup and configuration
• Ensure company Ergonomics policies are defined to
minimize causes of employee injury and discomfort
Ergonomics/Human Factors

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• Identify basic business problems requiring analysis
• Determine if technology or process based solution
best
• Characterize problem, identify prospective
providers/bidders and submit requests for proposals
• Evaluate bid responses, select successful bidder(s)
and establish technical feasibility
• Conduct small scale/medium scale tests to determine
operational feasibility, implementation methods and
training requirements
• Conduct enterprise wide implementation
• Transition support activities/responsibilities to long
term business and technology owners
Technology Development and Transfer

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• Develop long range planning models, typically 5-10
years in scope
• Model all areas affected by operation
• Identify anticipated investment in plant, capacity,
network, etc
• Tie to preliminary production cost, operational cost,
sales forecasts
• Develop preliminary financial impacts, including
profitability and ROI
Strategic Planning

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• Ensure that change programs are coordinated,
support one another and move along the critical path
• Create and maintain the imperative for the change,
establish priorities and provide visible sponsorship
for the change
• Provide the skills, knowledge, processes,
organization structure and tools required to deliver
the change
• Ensure that the individuals involved buy into the
change, actively support it and adopt their behaviour
accordingly
Management of Change

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• Determine production costs using specific cost
based methodology
• Develop budgets, forecasts for operating cost
centres
• Measure actual performance vs budget goals
and investigate variance
• Develop capital and expense budgets for capacity
expansion
• Perform cost analysis/justification for capital and
expense expenditures
• Perform make vs buy vs lease analyses
Financial Engineering

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Techniques Utilized by IEs
• Benchmarking
• Design of Experiments
• Employee Involvement
• Equipment Utilization
• Flow Diagramming
• Information & Data
Flow Diagramming
• Interviewing for
Information
• Lean Manufacturing
• Modelling & Testing
• Operations Auditing
• Organizational Analysis
• Pilot Programs
• Plant & Equipment
Layout
• Project Management
• Simulation
• Six Sigma projects
• Statistical Analysis
• Strategic Planning
• Theory of Constraints
• Time Studies
• Work Sampling

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IEs Work in Many Types of Industries

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