INDUSTRIAL ENGINEERING

INDUSTRIAL ENGINEERING
Section A
Definition of Industrial Engineering Productivity & Workforce Management

Section B
Manufacturing Cost Analysis Materials Management

Section C
Quality Management Production Planning & Control (PPC) :

Section D
Management Information Systems (MIS) : Product Design and Development:

SECTION-A(I) TOPICS
Definition of Industrial Engineering: Objectives. Method study, Principle of motion economy. Techniques of Method study - Various charts, THERBLIGS. Work measurement - various methods, time study PMTS, Determining time, Work sampling, Numericals.

INDUSTRIAL ENGINEERING
THE AMERICAN INSTITUTE OF INDUSTRAIL ENGINEERS(AIE) HAS DEFINED INDUSTRAIL ENGINEERING AS A BRANCH WHICH IS CONCERNED WITH THE DESIGN,IMPROVEMENT & INSTALLATION OF INTEGRATED SYSTEM OF MEN,MACHINE ,EQUIPMENTS & ENERGY It draws upon specialized knowledge & skill in mathematical, physical & social sciences together with the principles & methods of engineering analysis to specify, predict & evaluate the results from such systems. IE is engineering approach to detailed analysis of the use & cost of resources of organization. The main resources are men, machine, money,& equipments. Industrial Engineer carries out such analysis in order to achieve objectives. If an Industrial engineer has to focus on only one concept to describe his field of interest & objective, it would be productivity improvement. [Productivity improvement implies:-(i)A more efficient use of resources(ii)less wastage per unit of inputs supplied(iii)higher levels of outputs for fixed levels of inputs supplied.]

ROLE OF AN INDUSTRIAL ENGINEER

Advisor-Available to others for interpretation of data,review. Activist-promotes actively a process/approach. Analyst-Separate a whole into parts & examine them to explore for characteristics. Descision maker-Select the preference from among many alternatives for a topic of concern. Designer/planner-Produce the solution specifically. Expert-Provides high level of knowledge,Skill & Experience on specific topic. Measure-Obtains data & facts about the existing conditions. Project manager-Operate,Supervise & Evaluate Projects. Trainer/Educator-In the skills & Knowledge of Industrial engineering.

APPLICATION OF INDUSTRIAL ENGINEERING

Before 1940s,Industrial Engineering was mainly applied to manufacturing industries for improving the methods of production,to develop work standards. Later on, the use of Industrial Engineering also spreaded to non-manufacturing activities such as construction & transportation, airline operations & maintenance. In industries beside the production, other departments utilizing Industrial Engineering concept are Marketing,Finance,Purchasing etc.

WORK STUDY
Work study, as defined by British Standard Institution, is a term for those techniques particularly method study & Work measurement, which are used in the examination of human work in all its contexts & which leads to investigation of all factors ,which effects the efficiency of the system. Work Study Investigates the work done in an organization & it aims at finding the best & the most efficient way of using the available resources,i.e. Men,Machine,Money & Materials.

METHOD STUDY
It may be defined as the systematic investigation of existing method of doing a job in order to develop & install an easy ,rapid, efficient & less fatiguing way for doing the same job at lower costs. This is generally achieved by eliminating the unnecessary motions involved in a certain procedure or by changing the sequence of operation.

Work Measurement
It may be defined as the application of different techniques to measure & establish the time required to complete the job by qualified worker at a definate level of performance.

Advantages of Work Study

Uniform & Improved Production Flows. Reduced Manufacturing Cost. Fast & Accurate delivery dates. Better Employee-Employer Relationships. Better services to the customers. Job Satisfaction to the workers. Better working conditions.

Application to work study

Manufacturing Industries Marketing, Sales Offices, Stores & Warehouses. Design Building & other Constructions. Transport Hospital Agriculture,etc.

Method Study Procedure

Select Record Examine Develop Install Maintain

Method Study Procedure(Contd.)

Select, the work worth studying and define the
objectives to be achieved. An objective may be to reduce the manufacturing cost or to reduce the fatigue incurred by the workers inorder to increase their efficiency.

Record, all

the relevant informations pertaining to the existing methods in details & in the form of a chart to obtain a more clear picture about the same.Recording is done with the help of charts or diagrams.

Method Study Procedure(Contd.) Examine,the recorded events critically & in

the sequence.Critical Examination involves answers to the number of questions.An activity can be eliminated,Simplified or combined with another.

Develop,the best method as resulted from

critical examination & record it.The developed method should be practical,Feasible,Safe & Effective.

Method Study Procedure(Contd.) Install,the best method.Installation improves 3

phases-Planning, arranging & Implementing.

Maintain,the new method i.e.ensure the

proper functioning of installed method by periodic checks & verifications.

Process charts symbols

EVENT 1)Operation SYMBOL DESCRIPTION Operation represent action. It is a step in procedure. An operation involves change in location or condition of product. It represents a stage, when a finished good or raw material awaits an action Delay occurs when something stops the process It indicates the movement of an item from one location to another.

2.)Storage

3.)Delay

4.)Transport

5.)Inspection

Act of checking the correctness of quantity or quality.

Process charts symbols(Contd)

EVENT 6)Operation cum-Transport SYMBOL DESCRIPTION If the work is done on the material & simultaneously it moves to the next station.Ex:-Articles are being painted as they are transported by chain conveyor Ex:-A powder milk tin is being weighed as it is filled. Both the events occurs simultaneously & are controlled automatically.

7.)Inspection cum operation

PROCESS CHART
A chart may be a diagram, a picture or graph which gives an overall view of the process. It helps in visualizing the possibilities of alteration or improvement. A chart representing a process is called process chart. A process chart records graphically in sequence, the operation connected with the process. A chart portrays the process with the help of symbols & aids in better understanding & examining the process with the purpose of improving the same.

Types of process charts

Process chart
Outline Process chart Flow Process chart Two handed Process chart

Flow Process chart(Men)

Flow Process chart(materials)

Flow Process chart(Equipments)

Outline process chart

It surveys & records an overall picture of the process & states only the main events sequence wise. It considers only main operations & Inspection.

Two Handed Process Chart

It records the activities of left & right hand as related to each other. The activities of the two hands can be synchronized by providing a time scale on the chart. Such a chart is generally used for repetitive works of short duration.

Two handed process chart

SYMBOLS
Left hand Left Hand Pick up the bolt Pick up the nut Hold Right Hand Idle Right hand

To left hand Hold Assemble (Screw up)

Hold

Flow process chart

It is a detailed version of outline process charts & it records all the events. It
Sets out sequence of flow. Records all events in sequence using process chart symbols. Marks distances travelled & time taken for completing an activity. Mentions other important points,if any.

Flow process chart (contd.)

Flow process chart (men),records the activities of an operator. Flow process chart (Equipment)-records the manner in which the equipments are used. Flow process chart (materials),records what happens to the material ,i.e. changes the material undergoes in location or condition.

Flow Diagram
A flow diagram is a drawing or a diagram, which is drawn to the scale. It shows the relative position of production machinery, Jigs, Fixtures etc. & marks the path followed by men & materials. Steps in drawing flow diagram
Draw to scale the plan of work area. Mark the position of machine tools,benches ,stores,racks etc. From different observations,draw actual movement of materials or worker on diagram & indicate the direction of movements.

FLOW DIAGRAM

1 store 1

String Diagram
When the paths are many & repetitive, a flow diagram becomes congested & it is neither easy to trace nor to understand. Under such conditions, a string diagram is preferred. A string diagram is a model or scale plan of the shop ,in which every machine or equipment is marked with a peg is struck in the area representing a facility. A continuous coloured thread traces the path taken up by the materials or workers, While performing a particular operation.

String Diagram(Contd.)

Multiple Activity Chart

Where a number of workers, work in a group or an individual operator handles two or more machines ,then the activities have to be coordinated for achieving proper results. A multiple activity chart records simultaneously the activities of all the workers & machines on the common time scale & thus shows the interrelationships between them.

Purpose of Multiple Activity Chart

To detect the idle times being enforced on machines & workers. To optimize work distributions between the worker & the machines. To decide the number of workers in a group. To balance the work teams. To develop an improved method of accomplishing a task & have an efficient labor control.

Applications of Multiple activity chart

Plant repair & maintenance. Construction jobs. Planning team work.

THERBLIGS
THERBLIGS are used to describe the basic elements of movement or fundamental hand motions of the work cycle. Every THERBLIG is represented by a symbol, a definite color & with a word or two to record the same. A S.I.M.O. Chart employs THERBLIGS which are of microscopic nature, whereas a process chart uses symbols like operation, Inspection, Transport which are macroscopic.

THERBLIGS(Contd)
Advantages:
One macroscopic motion may contain a number of microscopic motions. At times, it may not be possible to eliminate a macro motion ,but an unnecessary micro motion can definitely be avoided. It is simpler to understand what precisely a worker is doing. THERBLIGS colors make charts more meaningful.

THERBLIGS

S.I.M.O. (Simultaneous-Motion-Cycle) CHART It is extremely detailed left & right hand operation chart. It shows on a common time scale the simultaneous minute movements (THERBLIGS) performed by the two hands of an operator. Beside hand, the movements of other limbs of an operator may also be recorded. The time scale is represented by winks(1/2000 minutes)

S.I.M.O. CHART(Contd.)
S.I.M.O. Chart is generally used for micro motion analysis of :
Short cycle repetitive jobs. High Order skill jobs,& finds applications in the jobs like component assembly, packaging, inspections etc.

ADANTAGES & DISADVANTAGES OF S.I.M.O. CHART

ADVANTAGES DISADVANTAGES

It is advantageous ,because it permits very accurate & detailed analysis. The work cycle can be studied at ease, peacefully & away from the disturbing surroundings of the actual work place

This technique is limited because of high cost of filming & analysis.

Analysis of motion
Motions or movements of limbs of a worker plays an important role in fabrication or manufacturing a product. By carefully observing a worker while he is doing an operation ,a number of movements made by him which appears to be unnecessary & unproductive can be identified & eliminated. Analysis of an operation, when carried out in terms of individual motion of workers is known as motion analysis. The purpose of motion analysis is to design an improved method, which eliminates unnecessary motions & employs human efforts more productively.

Principles of Motion Economy

A set were designed by Gilbreth in order to develop better methods. A better method of doing a job is one which consumes minimum time & energy in performing limb motion, in order to complete the task & this is possible only, by economizing the use of motion. Rules Concerning Human Body Rules Concerning Workplace Layout & Material handling. Rules Concerning Tools & Equipment Design. Rules Concerning Time Conservation

1. Rules Concerning Human Body

Both hands should be used for productive works. Both the hands should start & finish their motion at the same time. Except for the rest period, the two hands should not be idle at one time. Motion should be simple & involve minimum number of limbs. The purpose is to perform work in shortest duration of time & with the minimum fatigue. Motion should be smooth & continous.

2.Rules Concerning Work place Layout & Material Handling There should be definite, fixed & easily accessible location for materials & tools. As far as possible, materials, tools & other mechanical devices should be kept close to workplace. Gravity should be preferred for delivering materials at the workplace. An assembled or final product should be dropped on a conveyor near workplace, so that gravity delivers the job at the required place. Good Illumination is necessary for proper seeing,fast operating & reducing accidents.

3.Rules Concerning Tools & Equipment design

Whenever possible those tools should be used, which can perform more than one operations. This saves a lot of time, otherwise wasted in searching & picking a number of tools. Preferably, tools & materials should be preplaced & located near the workplace. It saves time otherwise wasted in searching & bringing the tools for doing job. Where the work is carried out by fingers, the load distribution on to each fingers should be as per the normal capacity of the finger.

4. Rules concerning Time conservation

Even temporary ceasing of work, by a man or machine not to be encouraged. Number of motions involved in completing a job should be minimized. Two or more jobs should be worked at the same time or two or more operations should be carried out on a job simultaneously.

Work Measurement
Work measurement may be defined as the application of different techniques to measure & establish the time required to complete the job by a qualified worker at a definate level of performance. The time required to complete the jib is determined from the number of observations.

Purpose of work measurement

To evaluate the workers performance. To determine the labor's input to the required to perform the task. Determine available capacity. Compare work methods. Establish wage incentives scheme.

Methods of work measurement

Work Sampling or Acceptance Sampling Stop Watch Time Study. Predetermined Motion Time standard(PMTs) Standard Data.

Work Sampling
It may be defined as a technique in which large number of observations are made over a period of time of one or group of machines, Processes or workers. Each observation records what is happening at that instant & fraction occurrence is recorded for a particular activity. It can tell what percentage of working day, a person spends how.

Principle of work sampling

It relies on the principle of statical theory of sampling . Normal frequency distribution & confidence level are associated with work sampling. Statical theory of sampling explains the adequate random samples of observations spread over a sufficient period of time can construct an accurate picture of actual situation in the system.

Work Sampling Procedure

Define the problem Make sure that all persons connected with work study understands its objective. State the desired accuracy limits for ultimate results. Conduct the pilot experiments. Design the actual study Using value of fractional occurrence (p),calculate the number of observations to be made.

Mathematics involved in acceptance sampling

Formula: P.S=Kp P.S=K

Where, P is the fractional occurrence S is the accuracy. n is no. of observations K is confidence level

(K=1,for 68 % confidence interval)

(K=2,for 95 % confidence interval) (K=3,for 99.73% confidence interval)

Stop Watch Time Study.

Stop Watch Procedure for collecting Time Study Data

Define the objective of study. Verify the standard method & conditions existing for the operation & Operator is trained. Select the operator to be studied. Record the information on time study observation sheet. Divide the operations into reasonably small elements, & Record them.

Stop Watch Procedure for collecting Time Study Data(Contd)

Time the operator for each of the elements ,Record the data for a few number of cycles on Time study observation sheet. Collect & record the data of required number of cycles by timing & rating the operator. Calculate the representative watch time for each element of operation. Calculate Normal time by formula Normal Time=Observed Time x Rating

Stop Watch Procedure for collecting Time Study Data(Contd)

Determine the allowances for fatigue & Various other delays. Determine the standard time by using formula Standard time=Normal Time + Allowances.

Predetermined Motion Time study (PMTs)

PMTs can be defined as work measurement technique, whereby times established for basic human motions are used to build up the time for a job at a defined level of performance.

Predetermined Motion Time study (PMTs)

Steps involved in Predetermined Motion Time study (PMTs)

Select the large number of workers doing variety of job under normal working conditions in an industry. Record the Job Operations on a movie film Analyze the film, note down the time taken to complete each elements & compile the data in a form of table or chart. Once the table for basic movements is ready, normal time for the new job can be calculated.

USES OF PMTs
It helps in modifying the work methods. It sets the time standards for various jobs. It facilitates the training of workers & supervisors.

Types of PMTs
Method time measurement(M-T-M) Work Factor system

Method Time Measurement(M-T-M)

This system was developed by time measurement association . M-T-M does not require any modifications of basic time values.Moreover the basic human movements in this system are analyzed in more details. M-T-M measures time in TMUs(Time measurement units) & 1 TMU=0.0006 minutes.

Method Time Measurement(M-T-M)

It analyses the industrial job into basic human movements required. From the tables of basic motions,depending upon the kind of motion ,and conditions under which it is made,predetermined time values are given to each motion. When all such times are added up,it provides the normal time to the job. Standard time can be found by adding suitable allowances.

Work Factor System

It also relies on manuals containing time values of different elements, Predetermined from high speed films of large number of Industrial operations. It has simple & accurate procedures. It considers the non productive items also. It has standard for an experienced skilled worker, whearas M-T-M standards are based upon the performance of an average operator. In this,1 TMU=0.0001 minutes.

Standard data
Standard data is a catalogue of normal time values for different elements of jobs or for minute movements involved in different jobs. This catalogue is prepared by compiling the timings of number of standard elements. Once the standard data is ready one requires to list the job elements or minute hand movements of an operation,read their times from standard data catalogue & then add up. Standard time can be found by adding normal time to the allowances.

Types of standard Data

Standard Data(Macromotion) Standard Data(Micromotion)

Standard Data (Macromotion)

It is based upon the elements of Job,is known as element standard data & is compiled for representative group of elements by macroscopic method. It is for the families of Jobs & gives the normal time for various elements of jobs. This shortens considerably the amount of time & labour needed to find the standard data for the new job.

Standard Data (Microdata)

It is based on minute movements involved in an opeartion & is compiled by microscopic method. The method lies on the principle that all jobs consist of very little hand movements called THERBLIGS. Microdata compiles normal time for a work cycle ,or a task by analsing the fundamental types of motions(Therbligs)