Introduction to Industrial Engineering
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology (RUET)
Email: dibasrmn@gmail.com
LinkedIn: Sharmin Akther Diba
Industrial Engineering(IE)
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
- Always try to lay out workplace within maximum working area.
- Position labels or components so that they only need to be grasped once, and not transferred between hands prior to putting to the machine.
- Make full use of automated devices.
- If possible encourage operators to work with scissors in their hands.
- Machine speed is not always critical if slowing down the machine means that the operator can take fewer bursts.
- Ensure machine is set to correct S.P.C.
- 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.
- Programmable machines with longer cycle times may be able to be used in tandem.
- 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.
•
1) Payment
•
2) Performance
Monitoring
•
3) Planning
•
4) Costing
•
5) Balancing
•
6) Motivation
Two different methods can be used to set piece rates
- Stopwatch
- Predetermined Time motion system
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
- Keep accurate records of all process SMV.
- Keep accurate records of all Style data.
- Report standard minute data and costing information back to costing department to aid accurate future costing.
Roles
of production management
- Output & Workflow
- Performance
- Quality
- Costs
- 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
- 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
- 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
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.
Skills needed to be industrial Engineer
These are common skill of an industrial engineer.
- Critical thinking
- Complex Problem Solving
- Industrial operation management
- Production and planning control
- Data analysis
- Creativity
- Quick decision making
- Cost minimization