1. An Introduction from Prof. Goldsman ’ s lecture notes

2. How would you define “ Industrial Engineering ” ?

3. What is IE? Frederic W. Taylor  Father of Industrial Engineering “ Industrial Engineering is concerned with the design, improvement, and installation of integrated systems of people, materials, information, equipment, and energy. It draws upon specialized knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design to specify predict, and evaluate the result to be obtained from such systems ” –Industrial versus Manufacturing –A big-picture thinking discipline PROBLEM SOLVER!!

4. What is IE? (Cont ’ d) “ A branch of engineering that engages in the study of how to describe, evaluate, design, modify, control and improve the performance of complex systems, viewed over time and within their relevant context. ” Logistics/Supply Chain SystemsLogistics/Supply Chain Systems Financial/Economic SystemsFinancial/Economic Systems Health SystemsHealth Systems Manufacturing SystemsManufacturing Systems Etc.Etc.

9. IE Core Courses Based on Tech ’ s Curriculum: 1.Probability Theory 2.Statistics and Its Application 3.Modeling 4.Engineering Economy 5.Stochastic Processes 6.Quality Control 7.Simulation 8.Logistics 9.Manufacturing 10.Human Machine Interface 11.Optimization 12.Senior Design

10. Fundamental Issues Flow (accumulation and conversion): 3, 5, 7, 8, 9 Randomness: 1, 2, 3, 5, 6, 7 Complex decision making (preferences): 5, 7, 8, 9, 11 Optimization: 3, 11 People (learning): 10 Economics: 3, 4

11. Diner Dash Game

12. Learn how to think like an IE What can you observe in the game? KISS Rule! Remember, IE is not equal to manufacturing job!

13. More on … What is IE? Improve system performance by: Analyzing: Complex and uncertain interactions Formulating: Fundamental topics  specialized studies Solving: “ Management Control Systems ” (finance) “ Production Planning and Control Systems ” “ Human Activity System ” (synchronize for quality)

14. MCS and PPCS Management Control System: Forecasting Engineering Economy Recruiting, training, and placement of employees MRP, QC, Inventory Control, etc Production Planning and Control System: Manufacturing Process Materials, machines, and equipments Facility Layout and flow of material WarehousingDatabase Safety procedures, etc

15. System Classification Natural versus Man-made Systems Natural: nature activity Man-made: human activity Static versus Dynamic Systems Static: no associated activity Dynamic: time-varying behavior Physical versus Abstract Systems Physical: physically existing components Abstract: symbol representation Open versus Closed Systems Open: Interacts with its environment Closed: little interchange with its environment

16. What is Manufacturing Engineering? Designing the production process of a product Compared to IE? QA Evaluate Select & Set Select & Set Design Cost Estimation Cost Estimation

17. Product Structure and Specifications Hierarchical chart: Product Sub-assembly Components RM …

18. Bill Of Materials (Taken From Heizer and Render)

19. Assembly Drawing & Charts (Taken From Heizer and Render)

20. Operation Process Chart (Taken from Francis et. al.)

21. Cost Calculation Two Types: Fixed Cost: constant regardless of the number of parts are made e.g. Setup Cost, Design Cost, Location Cost Variable Cost: cost varies directly with the number of parts produced e.g. Operator Cost, RM Cost, Utility Cost Total Cost = Fixed Cost + Variable Cost * Number of Units TC = FC + VC * (#units) Total Cost = Fixed Cost + Variable Cost * Number of Units TC = FC + VC * (#units)

22. Industrial Processes Refining and alloying Alloy: combining >= 2 metals to get better properties Metal properties (important): Tensile Strength (withstand elongation forces) Hardness (withstand penetration forces) Impact Resistance (absorb energy) Malleability (to be shaped or extended) Fatigue Resistance (withstand repeated application of a force) Corrosion Resistance (withstand corrosive forces)

23. Industrial Processes (Cont ’ d) Casting Forming objects by pouring liquid material into a mold and allowing the material to solidify i.e. making pudding Old process but economical and effective Metal Forming Hot: temperature above its re-crystallization temperature Cold: temperature below its re-crystallization temperature Processes: Roller, wire drawing, forging, extrusion, bending, and drawing and stretching Metal Cutting e.g. Shearing, Turning, Drilling, Shaping, Milling, Broaching, Sawing-Filling, Grinding, etc.

24. Industrial Processes (Cont ’ d) Welding e.g. Electric Arc, Resistance Welding, Beam Welding, Thermit Welding, Pressure Welding, Gas Welding, Brazing and Soldering, etc Assembling Various parts and sub-assemblies are put together to form a complete product Batch process versus continuous process Finishing Product is made to be more presentable or effective e.g. honing, lapping, polishing, buffing, brushing, tumbling, surface cleaning, coating, etc

25. Cost Estimation Total manufacturing cost, consists of: Material Direct: any material cost chargeable to a product directly e.g. paper cost for printing a book Indirect: all other material costs e.g. cleaning compound and brushes –Labor Direct: any labor cost chargeable to a product directlyDirect: any labor cost chargeable to a product directly e.g. operator Indirect: all other labor costsIndirect: all other labor costs e.g. marketing salary Overhead Costs other than direct labor or direct material costs e.g. indirect material and labor costs

26. Supply Chain

27. DREAM Cycle

28. What are the main things customers care about?

29. Customer Value Drivers CostQualitySpeedInnovation

30. So … what is IE? “ Man, if you have to ask what it is, you ’ ll never know. ” -Louis Armstrong ’ s definition of jazz