1. MEC057 Attendance CA MTE(T) ETE(T) 5 20 25 50

2.  Concept/Definition of Industrial Engineering  Industrial Engineering Objectives  Industrial Engineering Activities  Role/Functions of Industrial Engineer  Benefits to become Industrial Engineer  Personality Characteristics/Qualities of Industrial Engineer  Place of Industrial Engineering in an Organization  Industrial Engineering Applications/Scope  Production & Productivity  Classification & Type of Production

3.  Concept/Definition of Industrial Engineering  Industrial Engineering Objectives  Industrial Engineering Activities  Role/Functions of Industrial Engineer  Benefit to Become IE

4. Do you like solving problems? Are you interested in how things work? Do you like working with people? Are you an organizer? Do you like working on a team? Does using computers to solve practical problems interest you? Would you like to study a blend of business and technical subjects? Are you interested in the way individual parts of a system work together?

5. Are you looking for a challenge? If you answered yes, then, Industrial Engineering (IE) might be the perfect major for you!

6. Industrial engineering is a branch of engineering dealing with the optimization of complex processes or systems.

7.  Improving operating methods and controlling Costs.

8. As per ASIE the activities are:  Processes Selection  Selection and Design of Tools & Equipment  Facilities Planning, Plant Location & Materials Handling.  System Designing for PPC.  Cost Analysis & Control  Develop Time Standards & Performance Standards.  Development of Wage Incentive Scheme  Development of Job Evaluation System.

9.  Value Engineering & Analysis System Design & Installation.  Operational Research  Performance Evaluation  Project Feasibility Study etc.

10.  Improves work method, establishes standard method.  Establish Performance Standard  Develop Sound Wage Incentive Scheme.  Designs sound Inventory control System.  Prepare and evaluates job description & job specification sheet for each job.

11.  Develops cost reduction and control programme.  Helps in site selection and developing a systematic plant layout.

12. As an Industrial Engineer, you will: Earn an excellent salary Work with people – to make things better, faster, safer, and more rewarding Help a company save money and stay competitive Reap personal and professional satisfaction year after year Work with all levels of a business or organization

13.  Personality Characteristics/Qualities of Industrial Engineer.  Place of Industrial Engineering in an Organization.  Industrial Engineering Applications/Scope  Production & Productivity

14.  Inquisitive mind  Negotiation skills  Listening skills  Creative problem solving  Diplomacy  Patience  Ability to adapt to many environments and interact with a diverse group of individuals  Good common sense  Continuous desire to learn

15. Industrial Engineer Quality Engineer Manufacturing Manager Project Manager Inventory Controller Systems Consultant Process Engineer Manufacturing Engineer Systems Analyst Production Supervisor Consultant Quality Control Supervisor

16.  Leadership skills  Resourcefulness  Desire for organization and efficiency  Good math skills  Strong time management skills  Mechanical aptitude  Excellent communication/salesmanship  Quantitative skills  Technical competency  Continuous drive for improvement  Passion for improvement

17. Industrial Engineering Qualities ExpertAdvisor & Consultant Helps in DMInterpret Data Helps in Designing the SystemReview Data Expert in New TechnologyAdvises for Improvement Analyst of System Trainer Identifies System Faults Helps in WS Analysis Job at Micro Motivates Coordinator Apply New Tech Suggest Productivity Tool

18. Managing Director GM (Manufacturing) Manager PPC GM (Finance) GM (Quality) Manager Materials Manager Industrial Engg Manager Maintenance Supervisor I Supervisor 2 Supervisor 3

20. Industrial Engineers use their problem-solving techniques in almost every organization you can imagine. There are Industrial Engineers working in manufacturing, banks, hospitals, government organizations, transportation, construction, processing, social services, electronics, facility design, safety, and warehousing..

21. Production is defined as the number of units produced per unit time. Production may be defined as a process or procedure to transform a set of inputs into output having the desired quality and quantity.

23. Productivity is nothing but reduction in the wastage of the resources. The recourses may be men, machine, material etc Productivity is the quantitative relation between what we produce and what we use as a resource to produce them. Productivity = Output / Input Increase in production may or may not be an indicator of increase in productivity.

24.  When production is increased without increase in inputs.  The same production with decrease in inputs.  The rate of increase in output is more compared to rate of increase in input.

25.  Labour Productivity = Total Output / Labour Input  Material Productivity = Total Output / Material Input  Capital Productivity = Total Output / Capital Input  Energy Productivity = Total Output / Energy Input  Machine Productivity = Total Output / Actual Machine hours Used

26.  Classification of Production System

27.  Batch Production  Continuous Production (i) Mass production (ii) Flow Production  Job Production

28. A production system in which a process is broken down into distinct operations that are completed on a batch or group of products before moving to the next production stage. or Batch production is the manufacturing technique of creating a component at a workstation before moving to the next step in production.

29.  A Batch produced only once.  A Batch produced repeatedly at regular intervals when need arises.  A Batch produced periodically at known intervals to satisfy continuous demand.

30.  Short Runs  Investment – High  Planning – It changes with fresh Batch  Skill of Labour – High  Quality of Supervisor – Knowledgeable  Plant Layout – Flexible  Material Handling – Less Compared to Job Production

31. It can reduce initial capital outlay because a single production line can be used to produce several products.outlay products Batch production can be useful for small businesses who cannot afford to run continuous production lines

32. There are inefficiencies associated with batch production as equipment must be stopped, re- configured, and its output tested before the next batch can be produced.

33. 1. Batch production is common in bakeries 2. Manufacture of bicycles 3. In the manufacture of sports shoes, 4. Pharmaceutical ingredients (APIs), 5. Inks and paints 6. Adhesives. Batch production is also useful for a factory that makes seasonal items, products for which it is difficult to forecast demand, a trial run for production, or products that have a high profit margin.

34.  It can be used for automobiles industries.  It can be used for shopping malls.  It can be also used for raw material.  It can be also used clothing industries.  It can be also used for wine factory, mostly wines are made of grapes after long process of fermentation.  It can be also used for T- factory. Ex: - Assam tea.  Godrej spare parts are also comes under batch production.

35. Continuous production is a method used to manufacture, produce, or process materials without interruption. Continuous production is used for products that are made in a similar manner. Manufacture of products, such as chemicals or paper, involving a sequence of processes performed by a series of machines receiving the materials through a closed channel of flow.

36.  Mass Production  Flow Production

37.  Mass production is the name given to the method of producing goods in large quantities at low cost per unit. But mass production, although allowing lower prices, does not have to mean low-quality production. Instead, mass- produced goods are standardized by means of precision- manufactured, interchangeable parts.  To make it worthwhile, mass production requires mass consumption.  Mass production also called flow production, repetitive flow production, series production) is the production of large amounts of standardized products, including and especially on assembly lines.

38. 1.The concepts of mass production are applied to various kinds of products, from fluids and particulates handled in bulk (such as food, fuel, chemicals, and mined minerals) 2.To discrete solid parts (such as fasteners)

39. Flow production involves a continuous movement of items through the production process. This means that when one task is finished the next task must start immediately. Therefore, the time taken on each task must be the same. A production process in which a unit undergoes each stage of production sequentially. The unit remains at the first stage until that particular segment is complete; it is then sent to the next stage, where the process is repeated. This method continues until the unit has completed all sequences of the production process.

40. Flow production (often known as mass production) involves the use of production lines such as in a car manufacturer where doors, engines, bonnets and wheels are added to a chassis as it moves along the assembly line. It is appropriate when firms are looking to produce a high volume of similar items. Some of the big brand names that have consistently high demand are most suitable for this type of production. To assemblies of such parts (such as household appliances and automobiles).

41.  Flow of Material – Continuous  Machines - SPM  Investment – High  Flexibility - Less  Skill of Labour – Relatively Low  Quality of Supervisor – Easy  Plant Layout – Product Layout  Material Handling – Less  Manufacturing Cycle Time - Short

42.  Cost production per unit is less.  Material handling is automatic.  Both types of workers skilled unskilled are employed.  Plant layout is as per production requirement.

43. (1) During the period of less demand heavy losses on the invested capital may take place. (2) Because of all the machines used are one purpose machines therefore, this type of production is not changeable to other type production

44. 1.Production of Paper 2.This process is followed in most oil and gas industries 3.Petrochemical plant 4.The float glass industry, where glass of different thickness is processed in a continuous manner. 5.The majority of transducers and controllers employ PID (Proportional, Integral, and Derivative) control which controls the final output element based on the variables response to the control.

45. Job production involves producing a one-off product for a specific customer. Job production is most often associated with small firms (making railings for a specific house, building/repairing a computer for a specific customer, making flower arrangements for a specific wedding etc.) but large firms use job production too.

46.  Job production involves firms producing items that meet the specific requirements of the customer. Often these are one-off, unique items such as those made by an architect or wedding dressmaker. For an architect, each building or structure that he designs will be different and tailored to the needs of each individual client.  With job production, a single worker or group of workers handles the complete task. Jobs can be on a small-scale involving little or no technology. However, jobs can also be complex requiring lots of technology.

47. With low technology jobs, production is simple and it is relatively easy to get hold of the skills and equipment required. Good examples of the job method include:  Hairdressers  Tailoring  Painting and decorating  Plumbing and heating repairs in the home

48. High technology jobs are much more complex and difficult. These jobs need to be very well project-managed and require highly qualified and skilled workers. Examples of high technology / complex jobs include:  Film production  Large construction projects (e.g. the Millennium Dome)  Installing new transport systems (e.g. trams in Sheffield and Manchester)  Designing and implementing an advertising campaign  Auditing the accounts of a large public limited company  Building a new factory  Installing machinery in a factory

49.  Flow of Material – Discontinuous  Production Runs - Small  Flexibility - Less  Skill of Labour – Very High  Quality of Supervisor – High  Plant Layout – Process Layout  Manufacturing Cycle Time - Long

50.  Work is generally of a high quality.  A high level of customization is possible to meet the customer's exact requirements  Significant flexibility is possible, especially when compared to mass production  Workers can be easily motivated due to the skilled nature of the work they are performing

51.  Higher cost of production  Requires the use of specialist labour (compare with the repetitive, low-skilled jobs in mass production)  Slow compared to other methods (batch production and mass production)  Essential features

52. CharacteristicsBatch ProductionContinuous ProductionJob Production Volume of ProductionLimitedLargeOne or Few Jobs Product VarietyMediumOne or Few Std. Products Large Variety LayoutProcess LayoutProduct LayoutProcess Layout Set Up TimeHighLowHigh Manufacturing CTMediumLowLarge Material FlowDiscontinuousUniform & Uninterrupted Flow Discontinuous & Non Uniform Equipment & Machinery General Purpose with High Prod. SPMGeneral Purpose FlexibilityHighVery LowHigh Cost/UnitMediumLowHigh Skill of LabourSkilledSemi-SkilledHighly- Skilled Material HandlingManual or Semi Automatic AutomatedManual

53.  Type of Production System

54.  Make to Stock Production  Make to Order  Assemble to Order

55.  In this system, finished goods are stocked in inventory for immediate shipment.  This system ensures immediate delivery of good quality & reasonably priced standard products.  For example: automobile bearings, ready to wear garments, nuts and bolts, television etc.  Normally, the customer does not accept delay in delivery and management is required to maintain adequate stock of finished products.

56.  MTS implies the manufacturing of products based on well known predictable demand pattern.  The main advantages of this system being the short delivery time.  The limitation being high cost of inventory and inability to express customer for the design of the product.

57.  Fairly constant & Predictable demand  Products are few and they are standardize  Shorter delivery time expected by customer.  Products having higher shelf life.

58.  Some companies manufacture products after the receipt of the firms order from the customer.  Here the production activities will be initiated only after the confirmation of the orders and the products are not supplied from the stock hence lead time is long.  Examples are, custom tailored clothing, SPM etc.

59.  Products are manufactured to customer specifications.  Products are non-standardize.  Longer delivery time.  Products are expensive to store.

60.  When the number of alternative combinations or options are available to the customer as in automobiles, consumer electronics and computers.  In ATO when the customer places the order, the manufacturer does the assembly of parts selected. Since the components are manufactured and stocked, the only time to assembly is needed before delivering product to the customer.

61. CharacteristicsMake to StockMake to OrderAssemble to Order Volume of ProductionHighLowMedium Product RangeLowHighMedium Lead TimeLowHighMedium Customer Producer Interface LimitedHigh at sale and design Level High at sales Level InventoryHighLowMedium

62.  Different type of Layouts  JIT & Cellular Manufacturing System  Principle of Economic Material Handling  Type of Material Handling Equipments  Relationship between Plant Layout & MH

63.  Different type of Layouts

64.  Deals with the physical arrangement of various resources that are available in the system with an objective to improve the performance of the operating system & providing better customer service.  Plant layout refers to the arrangement of physical facilities such as machines, equipment, tools, furniture etc. in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of raw material to the delivery of the final product.

65. Inefficient operations For Example: High Cost Bottlenecks Changes in the design of products or services The introduction of new products or services Accidents Safety hazards

66. Changes in environmental or other legal requirements Changes in volume of output or mix of products Changes in methods and equipment Morale problems

67.  To minimum the Material handling.  To stream line flow of material in plant.  To effective utilisation of the resources.  To effective utilisation of the cubic space.  To flexibility of manufacturing operation and arrangement.

68.  Process or Functional  Product or Line  Fixed Position or Static or Location  Combination or Hybrid Type  Cellular Type or Group Technology

69. 69 Arrangement of resources on the basis of the process characteristics of the resources available. In this type of layout the machines of a similar type are arranged together at one place. This type of layout is used for batch production. It is preferred when the product is not standardized.

70. Process Layout - work travels to dedicated process centers Milling Assembly & Test Grinding Drilling Plating

71. Gear cutting Mill Drill Lathes Grind Heat treat Assembly 111 333 222 444 222 111 444 111333 11112222 222 3333 111 444 111 333333333 44444 333333 22222

72. 72  Car servicing  Hospital-Patient requiring various tests  Volume low & variety is more

73. 73 The resources are placed to follow exactly the visitation sequence dictated by the product. or This type of layout the machines and equipments are arranged in one line depending upon the sequence of operations required for the product. It is also called as line layout. The material moves to another machine sequentially without any backtracking or deviation i.e. the output of one machine becomes input of the next machine. It requires a very little material handling. It is used for mass production of standardized products.

76. 76  The technique employed for product layout is known as line balancing  The resources required to achieve desired /targeted production rate.  Cycle time can be considered as a reciprocal of production rate.  Use of mechanisation and automation can be planned.  Automobile Industry

77. 77 Process  Sharing of specialised and costly equipment  More flexibility  Less vulnerable to breakdowns Product  Standardised product and process routing  Operational control is simpler  High output rate is possible

78. 78 Process  Large inventory build up  Excess material handling Product  Less flexibility due to dedication of resources  Possibility of duplicating equipments leading to higher costs.

79. 79  The material remains in a fixed position, but the machinery, tool workmen etc are brought to the material. or  Fixed position layout involves the movement of manpower and machines to the product which remains stationary. The movement of men and machines is advisable as the cost of moving them would be lesser. This type of layout is preferred where the size of the job is bulky and heavy.

80. AIRCRAFT ASSEMBLY FINISHED PRODUCT (AIRCRAFT) RAW MATERIALS MACHINE & EQUIPMENT LABOUR FIXED POSITION OR STATIC LAYOUT

81. 81  Employed in large project type organisation Example  ISRO  Nuclear Engg. (Division of BHEL)  Locomotives, ships, boilers, generators, wagon building, etc.

82. 82 DimensionFunctionalCellular Number of moves between departments ManyFew Travel distancesLongerShorter Travel pathsVariableFixed Job waiting timesGreaterShorter Throughput timeHigherLower Amount of work in process HigherLower Supervision difficultyHigherLower Scheduling complexityHigherLower Equipment utilizationLowerHigher

83. Many situations call for a mixture of the three main layout types. These mixtures are commonly called combination or hybrid layouts. For example, one firm may utilize a process layout for the majority of its process along with an assembly in one area. Alternatively, a firm may utilize a fixed-position layout for the assembly of its final product, but use assembly lines to produce the components and subassemblies that make up the final product (e.g., aircraft).

84. F.P. G.C. H.T. G.G. RAW MATERIAL PROCESS LAYOUT FINISHED PRODUCTS (GEARS) F.P. = FORGING PRESS G.C. = GEAR CUTTING H.T. = HEAT TREATMENT FURNACE G.G. = GEAR GRINDING MACHINE COMBINATION LAYOUT OR HYBRID LAYOUT FOR GEAR MANUFACTURING PRODUCT LAYOUT

85. 85  This is philosophy that seeks to exploit the commonality in manufacturing and uses this as a basis for grouping components and resources. This is also known as cellular manufacturing.  Pioneered by Russians  Mid volume & mid variety scenario  70% of mfg. industry may fall under this category)

86. 12 3 45 123 12 3 4 21 CELL # 3 CELL # 4 CELL # 1 CELL # 2 PRODUCTION OPERATIONPRODUCT OR MATERIAL FLOW CELLULAR MANUFACTURING LAYOUT PART D PART Y PART X PART A PART B 3

87. Cellular manufacturing is a type of layout where machines are grouped according to the process requirements for a set of similar items (part families) that require similar processing. These groups are called cells. Therefore, a cellular layout is an equipment layout configured to support cellular manufacturing.

88. Processes are grouped into cells using a technique known as group technology (GT). Group technology involves identifying parts with similar design characteristics (size, shape, and function) and similar process characteristics (type of processing required, available machinery that performs this type of process, and processing sequence). An automated version of cellular manufacturing is the flexible manufacturing system (FMS). With an FMS, a computer controls the transfer of parts to the various processes, enabling manufacturers to achieve some of the benefits of product layouts while maintaining the flexibility of small batch production.

89. 89  PPC becomes simpler  Material handling becomes easier  Traceability improves  Employees are able to relate better.  Helps in implementing SGA, Kaizen an JIT

90. 90  Reliance industries- HDPE & LDPE  Titan Industry  ABB( Industrial fans & blowers)

91. -1111 2222 - 2222 Assembly 3333 - 3333 4444 - 4444 Lathe Mill Drill Heat treat Heat treat Heat treat Gear cut Gear cut Grind

92. Just-in-time (JIT) is a philosophy rather than a technique. By eliminating all wastes and seeking continuous improvement, it aims at creating a manufacturing system that is responsible to market needs.

93. The phrase just in time is used because this system operates with very low work with process (WIP) inventory and often with very low finished goods inventory. Product are assembled before they sold, sub assemblies are made just before they are made. This leads to lower WIP and reduce lead times. “Making nothing” if needed and then producing into the highest level of quality. JIT enables one to convince, design, implement and equate a manufacturing and supporting system as an integrated whole based on the principle of continuous improvements and elimination of all kinds of wastes.

94. Shiego Shingo, a Japanese JIT authority and engineer at the Toyota Motor Company find seven wastes as being the targets of continuous improvement in production process. By reducing these wastes improvement was achieved. Seven wastages are as follows: 1. Waste of Over-production 2. Waste of Waiting 3. Waste of Transporting 4. Waste of Inappropriate Processing 5. Waste of Stocks / Unnecessary Inventory 6. Waste of Unnecessary/Excess Motion 7. Waste of Defects

96.  Product cost is greatly reduced due to reduction of manufacturing cycle time.  Quality is much improved because of continuous quality improvement programme.  Employees who possess multiple skills are used more efficiently.  JIT provides better scheduling and work hour consistency. If there is no demand for a product at the time, workers don’t have to work. This saves the company money, either by not having to pay workers or by focusing on other work.  Due to fast response of engineering change, alternative design can be quickly brought on shop floor.  Productivity improvement.  Administrative ease and simplicity.

97.  The JIT system is best suited o a describe parts highly repetitive manufacturing environment such as automobiles. JIT tends to perform less well if:  Set up time and costs are high.  Workers flexibility is low.  The variation in demand throughout the year is high.  The diversity of product line is great.  Quality is poor or scrap rates are high.

98.  Toyota Moto Facility (America)  Harley Davidson Moto Co. U.S.A  Auto Components Co. U.K.  Hewlett Packed Inc. U.S.A.  Toyo Kagyo Automobiles  Cal. Comp. Inc. USA  Sunder stand data control  Avon product  Asian securities printing  Kawasaki electric Japan

99.  Achievement of zero inventory  Minimum WIP  Zero defects, TQC, planned maintenance, preventive maintenance, zero break down, zero scrap.  Zero material handling- group technology  Zero lead time- reduction of queering time, processing and transportation time.