EduNotes

  1. Process Design and Optimization   It is the systematic effort to analyze existing workflows and design new, highly efficient systems to maximize output while minimizing inputs and waste. 2. The Goal The primary aim is continuous improvement in three main areas: Reduce Waste (Muda): Eliminating non-value-added activities (e.g., waiting, excessive motion, defects, unnecessary inventory). Increase Productivity: Maximizing the ratio of Output / Input (e.g., more units produced with the same or fewer hours of labor and materials). Enhance Quality: Building quality into the process so that products/services are right the first time. 3. DMAIC Cycle (Six Sigma Methodology) The DMAIC cycle is a structured, data-driven approach used in process improvement and optimization to reduce defects and improve quality. D – Define Clearly define the problem , project goals, and customer requirements. Identify process boundaries , stakeholders, and critical-to-quality (CTQ) factors. ...

  1. The major roles of an industrial engineer include: Roles of an Industrial Engineer Productivity Improvement: Enhances efficiency by reducing waste, idle time, and unnecessary motions. Process Optimization: Designs and improves production and service processes for smoother workflow. Work Study & Method Study: Analyzes jobs to develop the best methods and set standard times. Layout and Facility Planning: Plans plant layout, material handling systems, and workspace design. Quality Management: Implements quality control, Six Sigma, and continuous improvement practices. Cost Reduction: Identifies cost-saving opportunities without compromising quality. Supply Chain & Logistics Management: Optimizes inventory, transportation, and distribution systems. Human Factors & Ergonomics: Improves worker safety, comfort, and job satisfaction. Data Analysis & Decision Support: Uses data, simulation, and analytics to support managerial decision...

 “Modern Industrial Engineering (IE)” is an evolution of traditional industrial engineering that integrates advanced technologies, data analytics, and optimization techniques into managing and improving complex industrial systems. It goes beyond classic time-motion studies and focuses on efficiency, productivity, sustainability, and flexibility in modern industries. Here's a structured explanation: 1. Definition Modern Industrial Engineering is the application of engineering principles, advanced analytics, and management techniques to design, improve, and optimize integrated systems involving people, materials, information, equipment, and energy 2. Key Focus Areas Process Optimization : Using data-driven methods to improve efficiency and reduce waste. A utomation & Robotics : Integrating automated machines and robotic systems in manufacturing and logistics. Lean & Six Sigma : Modern lean methods combined with quality improvement techniques for zero-defect production. Supply...

  Definition Operations Research (OR) is a scientific and quantitative approach to decision-making that uses mathematical models, statistics, and optimization techniques to find the best possible solution to complex industrial and managerial problems. Objectives of Operations Research To achieve optimal utilization of resources To minimize cost or maximize profit/output To improve decision-making To handle complex problems involving uncertainty and constraints Features of Operations Research Uses mathematical and analytical models System-oriented approach Interdisciplinary in nature Focuses on optimization Data-based and scientific Basic Steps in OR Problem formulation Construction of a mathematical model Collection of relevant data Solution of the model Testing and validation Implementation of results Common OR Techniques Linear Programming (LP) Transportation and Assignment Models Inventory Models Queuin...

  Harrington Emerson – The “High Priest of Efficiency” Harrington Emerson was a pioneer in efficiency engineering and management. He is called the “High Priest of Efficiency” because he emphasized improving overall organizational efficiency , unlike F. W. Taylor who mainly focused on individual tasks. Focus and Philosophy Emerson focused on the entire organization , not just shop-floor operations. He believed efficiency is achieved by eliminating waste in systems , not merely by making workers work harder. Emphasized planning, coordination, and control at all levels of management. Key Contributions Standard Costs Introduced the concept of standard costing . Actual costs are compared with standard costs. Variations are analyzed to improve efficiency and control costs. 12 Principles of Efficiency (1912) Emerson proposed twelve universal principles applicable to any organization:           The principles move from high-level stra...

 Developed by Henry L. Gantt •A bar chart used for planning and scheduling. •Each activity is shown by a horizontal bar indicating its start and completion time. •R evolutionary Concept : Before Gantt, managers looked at quantities (e.g., "We need 500 engines"). Gantt visualized Time as a resource. • Purpose : To show the dependency between tasks—what must be finished before something else can start. •Shows activities vs time •Displays start and finish dates of tasks •Helps in monitoring progress •Widely used in production and project management IMPORTANCE OF GANTT CHART Visibility: It makes the invisible (time) visible. Control: It allows managers to see if they are "ahead" or "behind" schedule instantly. Legacy: It is the foundation of modern Project Management software (like Microsoft Project, Jira, Asan Features of a Gantt Chart Horizontal bars represent activities Length of the bar indicates duration Time scale shown at the top Actual prog...

  Frank & Lillian Gilbreth – Motion Study Frank and Lillian Gilbreth were pioneers in motion study , a technique used to improve work efficiency by analyzing and eliminating unnecessary motions involved in performing a task. Focus on eliminating unnecessary motions Improves work methods and efficiency Introduced Therbligs (17 basic hand motions) Reduces worker fatigue Increases productivity and safety Foundation for ergonomics and method study Concept of Motion Study Motion study is the systematic study of movements of workers while performing a job to: Eliminate wasteful motions Simplify work Reduce fatigue Improve productivity Objectives of Motion Study Find the best method of performing a job Reduce unnecessary motions Improve worker efficiency Minimize fatigue Increase output and quality Therbligs (Basic Motions) The Gilbreths identified 18 basic motions , called Therbligs (Gilbreth spelled backward). Effective motions (value-add...

 Industrial Engineering – Definition •Application of engineering principles to design, improve, and install integrated systems •Concerned with people, materials, machines, information, and energy •Aims at efficient and effective system performance • It applies engineering analysis and principles to optimize productivity, quality, cost, and safety in organizations. Focus of Industrial Engineering •Emphasis on systems and processes, not individual operations •Analysis of entire workflow from input to output •Identification and elimination of waste and inefficiencies 1.2.1 Adam Smith (1776): Division of labour Definition of Division of Labour Division of labour is the practice of breaking down a job into smaller, specialized tasks, where each worker performs a specific operation to increase efficiency and productivity. Example: Automobile Assembly Line •One worker fits the engine •Another worker installs the gearbox •Another worker fixes the wheels •Another worker does electrical wiri...

UNIT I – INTRODUCTION Concepts of Industrial Engineering – History and Development of Industrial Engineering – Roles of Industrial Engineer – Applications of Industrial Engineering – Production Management vs. Industrial Engineering – Production System – Input–Output Model – Productivity – Factors Affecting Productivity – Increasing Productivity of Resources – Kinds of Productivity Measures. UNIT II – PLANT LOCATION AND LAYOUT Factors Affecting Plant Location – Course Objectives of Plant Layout – Principles of Plant Layout – Types of Plant Layout – Methods of Plant and Facility Layout – Storage Space Requirements – Plant Layout Procedure – Line Balancing Methods. UNIT III – WORK SYSTEM DESIGN AND ERGONOMICS Need – Course Objectives – Method Study Procedure – Principles of Motion Economy – Work Measurement Procedures – Time Study – Work Sampling – Ergonomics and Its Areas of Application in the Work System – Physical Workload and Energy Expenditure – Anthropometry: Measures and Design Pro...