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Introduction to Industrial Engineering

Introduction to Industrial Engineering
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology (RUET)
Email: dibasrmn@gmail.com

Industrial Engineering(IE)
Industrial  Engineering is an engineering which deal with optimization of all resources to make complex process better and efficient. Industrial engineering works to improve process process flow, development, quality, efficiency increasing; an engineer who can plan, design, control and develop a system for manufacturing excellence.

Role of an Industrial Engineer
To aid the management team within all factory departments to achieve the most cost effective methods and thereby make a valuable contribution towards overall company profitability.

Industrial Engineering functions are to implement and maintain the following within the factory
1. Determine best methods, and set SAM/standard minute rates accordingly.
2. Aid the management to improve efficiency/utilization and reduce excess cost.
3. Work with the management team on performance boosting and line balancing.
4. Review workplace/factory layouts and workflow methods.
5. Build database of historical information and keep accurate records of all rates and style detail.
6. Evaluate potential machinery investments and payback periods.

Determine the Best Method
Investigating and determining the quickest method with the equipment available and considering all quality requirements.

Tips for effective production methods
  1. Always try to lay out workplace within maximum working area.
  2. Position labels or components so that they only need to be grasped once, and not transferred between hands prior to putting to the machine.
  3. Make full use of automated devices.
  4. If possible encourage operators to work with scissors in their hands.
  5. Machine speed is not always critical if slowing down the machine means that the operator can take fewer bursts.
  6. Ensure machine is set to correct S.P.C.
  7. De-chain panels onto lap if possible. Check that panels need to be separated; they could be left in a chain for the next operator.
  8. Programmable machines with longer cycle times may be able to be used in tandem.
  9. Ensure that the method of folding and aiding is best for the next operator.

Setting Piece Rate Values (SMV)
      SMV – stands for Standard Minute Value
      A Standard Minute is one minutes worth of work at a 100 (standard) performance including contingency and relaxation allowances.

      And is used for:
      1) Payment
      2) Performance Monitoring
      3) Planning
      4) Costing
      5) Balancing
      6) Motivation

Two different methods can be used to set piece rates
  1. Stopwatch
  2. Predetermined Time motion system
Sequence of events

1) Break job down into elements (Both sewing and handling)
2) Time each element with a stopwatch.
3) Apply ratings (performance level) to each element, by trained work study personnel.
4) Work this through to an average Basic minute
5) Add any allowances required, (personal, fatigue, machine delays and bundling)
6) This will then be in Standard minutes

Applying a Rating
A rating is a value for the speed and efficiency of a movement.
The guidelines:
0     -  No Activity
50   -  Very slow and clumsy
75   -  Steady, deliberate and unhurried
100 -  Brisk, business like, achieving the correct quality and accuracy with confidence.
125 -  Very fast, well above average, with high dexterity and co-ordination.
150 -  Exceptionally fast, requires intense concentration and is unlikely to be kept up for long periods.

Addition of allowance
2 categories:
Contingency Allowances:
Covering minor delays which occur frequently. This includes thread breaks, cone changes, unpicking and re-sewing.
Typical allowances:
Lockstitch  7%
Overlock   4%
Ancillary  2%

Relaxation Allowances:
To allow the workers to recover from the effects of doing their job.
A typical machining operation would be allowed 11% which consists of :-
7% Personal Needs – Using the toilet, morning break etc.
4% Basic Fatigue – For energy used and to relieve the monotony of doing the job.

2. How a Standard Minute Value is calculated by using a Predetermined Time Motion System?

Sequence of events
1) Set best method(simplify and develop most economical method)
2) Video operation
3) Break method down to standard motions ie, gets & puts
4) Apply proven time values to each motion sequence (TMU’s)
5) Add times values together
6) Divide answer by 2000 for Basic minute conversion
7) Add allowances as previous
8) This will then be in Standard minute

Build a database of historical information and liaise with Costing department
  1. Keep accurate records of all process SMV.
  2. Keep accurate records of all Style data.
  3. Report standard minute data and costing information back to costing department to aid accurate future costing.
Production management
Roles of production management
  1. Output & Workflow
  2. Performance
  3. Quality
  4. Costs
  5. Training
    a)  How to calculate Efficiency?
  • Standard minutes earned = 320
  • Time clocked = 600 minutes
  • Efficiency = sms / clocked minutes
  • Therefore:   320 / 600 x 100
  • = 53.3% efficiency
b) How to calculate Performance?
  • Standard minutes earned = 320
  • Time clocked = 600 minutes
  • Time on standard 400 minutes
  • Time off standard 200 minutes
  • Performance = sms / time on standard
  • Therefore:  320 / 400 x 100
  • = 80% performance
c) How to calculate utilization?
  • Standard minutes earned = 320
  • Time clocked = 600 minutes
  • Time on standard 400 minutes
  • Time off standard 200 minutes
  • Utilization = time on standard / time clocked
  • Therefore:  400 / 600 x 100
  • = 66.7% utilization
The Managements objectives for the Business
a) To Increase Efficiency
b) To Raise Team/Operators Performance
c) To Control Utilization
d) To Minimize Excess Costs
e) Maintain Quality Standards
f) To ensure operators are fully trained

Skills needed to be industrial Engineer
These are common skill of an industrial engineer.

  1. Critical thinking
  2. Complex Problem Solving
  3. Industrial operation management
  4. Production and planning control
  5. Data analysis
  6. Creativity
  7. Quick decision making
  8. Cost minimization