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Industrial Engineering
Industrial engineers perform the following tasks in manufacturing and service industries. Forecast the demand the product Prepare a plan to produce the product Analyze the cost and benefits of the product Design the layout of the plant to produce the product Select the manufacturing processes to make the product Identify the people and their skills for production and supervision Integrate people, materials, machines, and processes to work together Schedule the machines and processes for production Supervise the day-to-day operation of the facility Design the workplace and procedures for workers to follow Handle occupational and safety concerns Model and analyze the performance of the system and find ways to improve it
Relationship Diagram Space Requirements Space Relationship Diagram Modifying Considerations Practical Limitations Space Available
PLAN X PLAN Y
PLAN Z
Evaluation SELECTED LAYOUT PLAN Muthers Systematic Layout Planning Pattern of Procedures
Tool Room
Work Cell
Laboratories
E.R. beds
Pharmacy
Billing/exit
Factory Lay-out
Areas of Study Within Industrial Engineering Human 4. The Production Planning and Control
Forecasting Aggregate Capacity Planning Aggregate Production Planning Master Production Planning Material Requirement Planning Capacity Requirement Planning Sales & Marketing
Operations Scheduling
Warehousing
Capability Histogram
Means
40.4
Ranges
Last 25 Subgroups
43
Capability Plot
Potential (ST) StDev: 0.959752 Cp: 0.69 Cpk: 0.69 Overall (LT) StDev: 1.18146 Pp: 0.56 Ppk: 0.56 Process Tolerance
I I I I I I I I I ST LT
Values
41 39 37 30 40 50
38
42
Specifications
Subgroup Number
Factories
Distributor/Retailer Warehouse
Customers
Product Flow Information Flow
Human Factors Engineering Work Measurements and Work Design Facilities Planning and Design Reliability Engineering Experimental Design For Engineering Production Planning and Control Engineering Project Management Integrated Manufacturing Systems Expert Systems in Engineering Industrial Robotics
Quality Control Automated Inspection Integrated Product and Process Design Queuing Methods for Services and Manufacturing Introductory Decision Analysis for Engineering Simulation Modeling and Analysis Engineering Information Systems Contemporary Topics in Industrial Engineering
Industrial engineers are the problem solvers in all organizations. Career opportunities for industrial engineering are limitless.
A sample list of career opportunities for industrial engineers include: Manufacturing: regardless of the product manufactured, every manufacturing company needs IEs to plan the facility, perform economic analyses, plan and control production, manage people, handle safety issues, improve quality, evaluate performance, etc. Health Services: hospitals and clinics need IEs to perform cost/benefit analyses, schedule work load, manage people, evaluate safety concerns, design and maintain facilities, etc. airlines, ground transportation, trucking, and warehousing companies need IEs to design the best schedules and routes, perform economic analyses, manage crews, etc. banks and other savings and lending institutions need IEs to design financial plans, perform economic analyses, etc. local and federal governments need IEs to design and enforce safety systems, environmental policies, plan for and operate in a number of organizations.
Transportation:
Financial:
Government:
Consulting:
IEs may work as consultants to help design and analyze a variety of systems including information systems, manufacturing and service systems.
The systematic and creative application of scientific and mathematical principles to practical ends such as the design, manufacture, and operation of efficient and economical structures, machines, processes, and systems.
The basic purpose of any organization is to provide products or services to their customers.
Thus, the design of these products and services is essential to the livelihood of a company.
Effective Design
Effective designs provide a competitive edge by: Bringing new ideas to the market quickly Doing a better job of satisfying customer needs Making new products easier to manufacture, use, and repair than existing products
Product Design:
Specifies which materials are to be used Determines dimensions and tolerances Defines the appearance of the product Sets standards for performance.
Design has a tremendous impact on the quality of a final product or service. Quality in the design process involves: Matching product or service characteristics with customer requirements Ensuring that customer requirements are met in the simplest and least costly manner Reducing the time required to design a new product or service, and Minimizing the revisions necessary to make a design workable.
2. Feasibility Study
(Performance Specifications)
3. Preliminary Design
(Prototype)
4. Final Design
(Final Design Specifications)
5. Process Planning
(Manufacturing Specifications)
Involvement of Different Functional Departments in the Design Process Marketing Department takes the idea and: Forms a product concept Conducts a study on the feasibility of the proposed product or service If the proposed product meets certain expectations, performance specifications are developed.
Final design
Prototype
Process planning
Design
Cost
Final design is concerned with how the product will perform. It consists of three phases: 1. Functional design is concerned with how the product will perform. 2. Form design refers to the physical appearance of a product. 3. Production design is concerned with the ease and cost of manufacturing the product.
Form Design
Functional Design
Reliability
probability product performs intended function for specified length of time A measure for reliability is Mean Time Between Failures (MTBF).
Maintainability
ease and/or cost or maintaining/repairing product A measure for maintainability is Mean Time To Repair (MTTR).
DFM Guidelines
1. Minimize the number of parts 2. Develop a modular design 3. Design parts for multi-use 4. Avoid separate fasteners 5. Eliminate adjustments 6. Design for top-down assembly
7. Design for minimum handling 8. Avoid tools 9. Minimize subassemblies 10. Use standard parts when possible 11. Simplify operations 12. Design for efficient and adequate testing 13. Use repeatable & understood processes 14. Analyze failures 15. Rigorously assess value
Design Simplification
(a) The original design (b) Revised design (c) Final design
Listening to Customers
Customers Requirements
Normal Requirements are typically what we get by just asking customers what they want. Expected Requirements are often so basic the customer may fail to mention them - until we fail to perform them. For example, if coffee is served hot, customers barely notice it. If it's cold or too hot, dissatisfaction occurs. Expected requirements must be fulfilled. Exciting Requirements are difficult to discover. They are beyond the customer's expectations. For example, if full meals were served on a flight from Chicago to Indianapolis, that would be exciting. If not, customers would hardly complain.
Kano Model
Engineering economy: the discipline concerned with the economic aspects of engineering. It involves the systematic evaluation of the costs and benefits of proposed technical projects.
Recognize a decision problem Define the goals or objectives Collect all the relevant information Identify a set of feasible decision alternatives Select the decision criterion to use Select the best alternative
Engineering Costs
General Cost Terms
Manufacturing Costs Direct materials Direct labor Mfg. Overhead Non-manufacturing Costs Overhead Marketing Administrative
Fixed Costs
Variable Costs
Def: Costs that vary depending on the level of production or sales Cost behavior: Increase or decrease proportionally according to the level of volume Examples: Costs of raw material, packaging material, direct labor, machine utilities are main variable costs.
Variable Costs
Therefore, the overall break-even analysis can be pictorially represented in the following graph
Profit Total costs (F+VQ) BEP: F+VQ=PQ loss
TC=F+VQ TR=PQ
At the break-even point: F+VQ=PQ
QBEQ = F/ (P-V)
Example
500,000$ total yearly fixed costs. 150$ / unit variable costs 200$ / unit sale price QBEQ=500000/(200-150) =10000 units If our market research indicates that the present demand is > 10000, then this manufacturing system is economically feasible.
customer wants Identify how the good/service will satisfy customer wants Relate customer wants to product hows Identify relationships between the firms hows Develop importance ratings Evaluate competing products
Customer Requirements
CUSTOMER COMMENTS
Case Study
Select a household product of your choice, your goal will be to describe how you think this design evolved. By looking at the product, can you tell: 1. How and why the device functions? Can you describe how it works, what energy sources are used, and what purpose that function serves? 2. How was human engineering involved? How would the human/machine interface affect this design? What safety issues would have been involved? 3. Why the original designers selected the materials used? What properties of the materials were most important in selecting them? 4. What features make this product unique? Compared to similar items, are there features on your example that would identify this as a better product? 5. How was the production process affected by this design? Are there specific features that might have been added to make production more efficient?
Case Study
As your analysis continues, choose one aspect of the design that intrigues you. Study the design used, and consider how you might improve on it.
Develop a list of alternatives, and compare them to the existing design. Develop some criteria that may help you select one of your alternatives as most likely to succeed. Finally, select one alternative, and describe how it improves on the existing design, what its limitations are, and why you think this is a better alternative than the existing design.
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