1. INTRODUCTION TO
INDUSTRIAL
ENGINEERING

2. WHAT IS INDUSTRIAL ENGINEERING?
Industrial engineering applies methods and principles of SCIENTIFIC MANAGEMENT to business operations:
To make the best use of available RESOURCES
And to LOWER COSTS
While improving QUALITY and increasing SAFETY
Increasing PRODUCTIVITY and EFFICIENCY.

3. DEFINITION OF INDUSTRIAL ENGINEERING
Formal definition from the IIE:
“ 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 results to be obtained from such systems”

4. MAIN DISCIPLINES IN INDUSTRIAL ENGINEERING
There are roughly four main areas of industrial engineering:
Human Factors (ergonomics, human-machine interface, management of human resources)
Operations Research (Quantitative Methods)
Manufacturing
Applied Statistics and Quality
However, Industrial Engineers, such as those in factories, are involved in everything from metal-casting, materials handling and supply chains to technology management and artificial intelligence.

5. TOPICS OF INTEREST
Introduction to Industrial & Systems Engineering
Manufacturing Engineering
Facilities Location and Layout
Material Handling
Work Measurement
Operations Planning and Control
Quality Control
Financial Compensation
CAD/CAM, Robotics, Automation
Human Factors
Resource Management
Engineering Economy
Operations Research
Simulation
Project Management

6. RELATIONSHIP OF IE TO OTHER MAIN ENGINEERING DISCIPLINES

7. WHAT DO INDUSTRIAL ENGINEERS DO?
Industrial Engineers design, plan, coordinate, and control many types of systems in manufacturing and service sectors.
For example, Industrial Engineers;
Design manufacturing processes
Develop automation for high productivity
Develop production schedules and establish inventory levels
Ensure product quality is maintained
Develop software that analyzes data, controls equipment and unites the production system
Design the job itself, so that it conforms to the capabilities and limitations of the human operator.
Analyze and design supply chain

8. WHAT KIND OF PERSON MAY DO WELL AS AN INDUSTRIAL ENGINEER?
First of all, you'll just naturally
like to solve problems,
figure out how things work, or
figure out how to make them work better.
For example, have you ever looked at the dashboard (area where the displays are) of your car and thought that you could come up with a better design? That's ergonomics.
Industrial engineers
Must have both technical and "people" skills,
Will work closely with people from a variety of professions,
Will be expected to perform well as part of a diverse team, and
Will be developing systems that people have to operate.

9. As an industrial engineer, you'll use your extensive background in
math,
science,
engineering science, and
engineering design
to solve the operational problems that face manufacturing and service industries.
You'll combine this technological background with broad training in
economics,
communications, and
business
to help solve the challenging problems facing production and/or service industries.

10. WHERE CAN INDUSTRIAL ENGINEERS WORK?
Just about anywhere a process needs to be designed or improved.
Industrial engineers can work in the obvious places like...
Manufacturing, such as Microelectronics, Aerospace or Automotive
Research and Development
or the not-so-obvious places like...
Service industries, such as banking, health care, insurance, transportation, and even theme parks like Walt Disney world.

11. Therefore, they can find jobs, without any difficulty, in
A distinguishing characteristic of industrial engineering, when compared to other engineering disciplines, is its attention to developing human-centered systems that effectively integrate scientific discovery and societal needs.
Therefore, they can find jobs, without any difficulty, in
Automotive and aerospace industries
Communication services
Customer services
Food industries
Manufacturing industries
Insurance and banking services
Hospitals services
Petroleum industries
Transportation services

12. IN WHAT CAPACITY CAN INDUSTRIAL ENGINEERS WORK?
On the factory floor or in the executive suite: IE's can work as...
Production Engineers
Production Managers
Systems Engineers
Consultants
Project Managers or
Company Presidents.
According to Jobs-Rated Almanac, industrial engineering has the highest level of career satisfaction among traditional engineering disciplines.

13. ORIGIN AND HISTORICAL DEVELOPMENT OF INDUSTRIAL ENGINEERING
Approximately years ago, formal agricultural activities began, with people trying to achieve a higher living standard and increased prosperity.
It can be said that the Industrial Engineering era was introduced at this stage when people started developing and making their own tools.

14. From earliest recorded times, groups of people have been organized to work together towards planned goals.
All required great amount of human effort and thus organization (planning, control, coordination...)
Examples:
Egyptians  Pyramids
Chinese  Great Wall of China

15. Romans  Roads, Aquaducts, Hadrian’s Wall

16. The Industrial Engineering profession, however, evolved only centuries later during the industrial revolution, which was it's real origin.
Technological developments (telegraph, telephone, train, steam ships)
Expanding trade/markets (Markets expanded from local to national and global levels)
Growing populations.
created an opportunity for merchants and entrepreneurs to invest in new factories which brought about the INDUSTRIAL REVOLUTION.
Suddenly, businesses needed to be more efficient to compete. WHY??

17. Outcomes of the Industrial Revolution
Before the industrial revolution people did not explicitly worry about improvement because:
There was less interaction with machines
Engineered systems were not as big and complicated
Competition was strictly local
There was thus a NEED TO:
Improve how to conduct work (work study) to improve the efficiency of doing business
Increase QUALITY of products being produced
Produce products at a ‘lower’ cost
Increase PRODUCTIVITY in factories

18. Inventors of the Industrial Revolution

19. Watt's steam-engine
Bell's "electrical speech machine"

20. Major Inventors Contributing to the Industrial Revolution
~ James Watt (1775) Steam Engine
In 1763 Watt was sent a Newcomen steam engine to repair. While putting it back into working order, Watt discovered how he could make the engine more efficient.
Watt worked on the idea for several months and eventually produced a steam engine that cooled the used steam in a condenser separate from the main cylinder.
Watt's machine was very popular because it was four times more powerful than those that had been based on the Thomas Newcomen design.

21. Watt continued to experiment and in 1781 he produced a rotary-motion steam engine.
Whereas his earlier machine, with its up-and-down pumping action, was ideal for draining mines, this new steam engine could be used to drive many different types of machinery.
In 1783, Richard Arkwright used Watt's steam-engine in his textile factories.

22. Watt's steam-engine

23. ~ Eli WHITNEY (1793) Cotton Gin
Eli Whitney was the inventor of the cotton gin and a pioneer in the mass production of cotton.
By April 1793, Whitney had designed and constructed the cotton gin, a machine that automated the separation of cottonseed from the short-staple cotton fiber.
Eli Whitney's invention of the cotton gin revolutionized the cotton industry in the United States.
Eli Whitney's invention automated the seed separation process. His machine could generate up to fifty pounds of cleaned cotton daily, making cotton production profitable for the southern states.

25. ~ Samuel F. B. Morse (1836) Telegraph
Samuel F. B. Morse was graduated from Yale College in 1810.
He was an American artist, who was struck by a scientific idea and turned into an inventor.
Inspired by the idea that electricity can be sent over any length of wire, he found a way to make an electric current send signals instead of using signals or written messages.
This idea finally led to the invention of the electro-magnetic telegraph and the Morse Code.
Morse devoted his five years in making the telegraph instrument that would work properly.

27. ~ Elias Howe (1844) Sewing Machine
Elias Howe was the inventor of the first American-patented sewing machine.
After loosing his factory job in the Panic of 1837, Howe moved from Spencer to Boston, where he found work in a machinist's shop.
Eight years later, Elias Howe demonstrated his sewing machine to the public.
Elias Howe patented his lockstitch sewing machine on September 10, 1846 in New Hartford, Connecticut.
For the next nine years He struggled, first to enlist interest in his machine, then to protect his patent from imitators.
His lockstitch mechanism was adopted by others who were developing innovations of their own.

28. First patented sewing machine by Elias Howe

29. ~ Isaac Singer (1851) Improves and markets Howe's Sewing Machine
Around 1850, Isaac Merritt Singer began concentrating on improving an existing sewing machine.
The patent claims were for the methods of feeding the cloth, regulating the tension on the needle thread, and lubricating the needle thread so that leather could be sewn.
The development of practical sewing machines contributed to the growth of the ready-made clothing industry in the late 19th and early 20th centuries.

30. Sewing Machine patent model, patented May 30, 1853,
patent number 10975, invented by Isaac M. Singer.

31. ~ Cyrus Field (1866) Transatlantic Cable
Cyrus West Field was an American businessman and financier who led the Atlantic Telegraph Company, the company that successfully laid the first telegraph cable across the Atlantic Ocean in 1858.
The cable broke three weeks afterward.
In 1866, Field laid a new, more durable cable which provided almost instant communication across the Atlantic.
On his return to Newfoundland, he grappled the previously snapped cable, reattached it to new wire, thus allowing for a second, backup wire for communication.

32. ~ Alexander Graham Bell (1876) Telephone
Throughout his life, Bell had been interested in the education of deaf people.
This interest lead him to invent the microphone and, in 1876, his "electrical speech machine," which we now call a telephone.
News of his invention quickly spread throughout the country, even throughout Europe.
By 1878, Bell had set up the first telephone exchange in New Haven, Connecticut.
By 1884, long distance connections were made between Boston, Massachusetts and New York City.
Bell's "electrical speech machine" paved the way for the Information Superhighway.

33. Alexander Graham Bell’s early versions of the Telephone

34. ~ Thomas Edison (1877, 1879) Phonograph, Incandescant Light Bulb
Like Ben Franklin, Thomas Alva Edison was both a scientist and an inventor.
In his lifetime, Edison patented 1,093 inventions, earning him the nickname “The Wizard of Menlo Park."
The most famous of his inventions was an incandescent light bulb.
Besides the light bulb, Edison developed the phonograph and the "kinetoscope," a small box for viewing moving films.
He believed in hard work, sometimes working twenty hours a day.
Edison was quoted as saying, "Genius is one percent inspiration and 99 percent perspiration."

35. Thomas Edison’s Light Bulb

36. ~ Nikola Tesla (1888) Induction Electric Motor
Nikola Tesla was a world-renowned inventor, physicist, mechanical engineer and electrical engineer.
He is best known for his revolutionary work in, and numerous contributions to, the discipline of electricity and magnetism in the late 19th and early 20th century.
Tesla's patents and theoretical work formed the basis of modern alternating current electric power (AC) systems, including the polyphase power distribution systems and the AC motor, with which he helped usher in the Second Industrial Revolution.

37. Aside from his work on electromagnetism and engineering, Tesla is said to have contributed in varying degrees to the establishment of robotics, remote control, radar, and computer science and to the expansion of ballistics, nuclear physics and theoretical physics.
In 1943, the Supreme Court of the United States credited him as being the inventor of the radio.
Later, many of his achievements have been used, with some controversy, to support various pseudoscience's such as UFO theories.

39. ~ Rudolf Diesel (1892) Diesel Engine
Rudolf Diesel designed many heat engines, including a solar-powered air engine.
In 1893, he published a paper describing an engine with combustion within a cylinder, the internal combustion engine.
In 1894, he filed for a patent for his new invention, dubbed the diesel engine.
Rudolf Diesel was almost killed by his engine when it exploded. However, his engine was the first that proved that fuel could be ignited without a spark. He operated his first successful engine in 1897.
In 1898, Rudolf Diesel was granted patent #608,845 for an "internal combustion engine" the Diesel engine.

40. Rudolf Diesel spent years making improvements on hia model engine and in 1896 demonstrated another model with the theoretical efficiency of 75 percent, in contrast to the ten percent efficiency of the steam engine.
By 1898, Rudolf Diesel was a millionaire.
His engines were used to power pipelines, electric and water plants, automobiles and trucks, and marine craft, and soon after were used in mines, oil fields, factories, and transoceanic shipping.

41. ~ Orville and Wilbur Wright (1903) First Engined Airplane
Orville Wright and Wilbur Wright requested a patent application for a "flying machine" nine months before their successful flight in December 1903, which Orville Wright recorded in his diary.
As part of the Wright Brothers' systematic practice of photographing every prototype and test of their various flying machines, they had persuaded an attendant from a nearby lifesaving station to snap Orville Wright in full flight.
The craft soared to an altitude of 10 feet, traveled 120 feet, and landed 12 seconds after takeoff.

42. Prototype of the Wright Brothers' Plane

43. Main Contributers to the Discipline of Industrial Engineering
~ Adam SMITH
Adam Smith is known primarily as the author of two books:
The Theory of Moral Sentiments (1759), and
An Inquiry into the Nature and Causes of the Wealth of Nations (1776).
The latter was one of the earliest attempts to systematically study the historical development of industry and commerce in Europe.
Smith's work helped to create the modern academic discipline of economics and provided one of the best-known intellectual rationales for free trade, capitalism, and libertarianism.

44. Smith believed labour was paramount, and that division of labour would have great effect on the increase in production.
Advantages of division of labour:
Development of skills
Saves Time
Possibility of using specialized tools
Pay workers according to JOB CONTENT
One of the main points of “The Wealth of Nations” is that the free market is, actually, guided to produce the right amount and variety of goods by a so-called "invisible hand".
If a product shortage occurs, for instance, its price rises, creating a profit margin that creates an incentive for others to enter production, eventually curing the shortage.

45. If too many producers enter the market, the increased competition among manufacturers and increased supply would lower the price of the product to its production cost, the "natural price".
Smith vigorously critisized government restrictions which he thought were hindering industrial expansion.
In fact, he attacked most forms of government interference in the economic process. This theory, now referred to as "laissez-faire", which means "let them do", influenced government legislation in later years.

46. ~Charles BABBAGE (1832)
Professor Charles Babbage was a British mathematician, an original and innovative thinker and a pioneer of computing.

47. Critical in setting up the Astronomical Society in 1820.
The 1820s Babbage worked on his 'Difference Engine', a machine which could perform mathematical calculations.
He also worked on another invention, the more complex Analytical Engine, a revolutionary device on which his fame as a computer pioneer now largely rests.
In 1832, Charles Babbage suggested division of labor for improved productivity in his book “On the Economy of Machinary and Manufacturers”.

48. ~ Eli WHITNEY (1798) Standardization or Interchangeable Manufacture
In 1798, Eli Whitney (the inventor of the cotton gin) invented a way to manufacture muskets by machine so that the parts were interchangeable.
Produce parts so accurately that a specific part of a particular unit of a product can be interchanged with the same part from another unit of the product, with no degradation of performance in either unit of the product.
Producing muskets for the American army, brought about the concept of MASS PRODUCTION.

49. ~ Henry Ford (1863-1947) Model T Ford, Assembly Line
Automobile manufacturer Henry Ford constructed his first horseless carriage in 1986.
Ford incorporated the Ford Motor Company in 1903; and in 1908, Henry Ford designed an assembly line to build his Model-T cars.
This led to mass production.
In the Model T's nineteen years of production, nearly 15,500,000 were sold in the United States alone.
The Model-T is atributed to be the beginning of the Motor Age.
Ford revolutionized manufacturing: By 1914, his Highland Park, Michigan plant, using innovative production techniques, could turn out a complete chassis every 93 minutes.
Using a constantly-moving assembly line, subdivision of labor, and careful coordination of operations, Ford realized huge gains in productivity.

50. FORD Assembly Line/Production Line

51. FORD Assembly Line/Production Line

52. Charles Chaplin in "Modern Times" 1939

53. Main contributors in Industrial Engineering : Efficiency Experts
Fredrick Taylor (start 1881)
Frank Gilbreth (early 1900)
Lillian Gilbreth (early 1900)

54. Fredrick Taylor, 1881, Midvale Steel, Philadelphia
Father of INDUSTRIAL ENGINEERING
Founder of modern time study/SCIENTIFIC MANAGEMENT
Came up with system of managing work to make it more efficient:
Managers plan work 1 day in advance
Workers get written instructions on tasks and how to accomplish them
Each job has a “standard time” determined by a time study made by experts
Advocated breaking tasks into “elements”

55. Taylor's Studies
Work Design or Methods Study: Analysis of the work requirements and specifications for a method to perform an operation.
Experiment 1: Pig Iron Study (1898)
At Bethlehem Steel Company
Established methods for carrying 92 lb. “pigs” of iron up ramp to freight car,
Provided financial incentives,
Greatly increased productivity from 12.5 tons/day/worker to 48 tons (4 fold increase)

56. Taylor's Studies (cont.)
Experiment 2:Shoveling Experiment
Redesigned shovels (were same size for all jobs):
Short handle for heavy iron
Long handled scoop for light rice coal
Results:
Productivity increased
Material handling costs decreased
Taylor also worked on WORK MEASUREMENT: Concerned with determining the amount of time an operator should be allowed to perform an operation.

57. Frank and Lillian Gilbreth (early 20th century)
Founders of modern motion study techniques
Study of body motions used in performing tasks
Aimed at:
Simplifying motions
Establishing most favorable motion sequences
As he was in Brick laying trade, Increased performance from 120 bricks/hr to 350

58. Using Strobe Light Technique
Motion Study
Using Strobe Light Technique
Golfer

59. Motion Study
Using Motion Pictures

60. Gilbreths’ Techniques : Therbligs
A therblig is the name for one of a set of fundamental motions required for a worker to perform a manual operation or task. The set consists of 18 elements, each describing a standardized activity. These elements are listed below.
Search
Inspect
Find
Transport loaded
Select
Transport unloaded
Grasp
Pre-position for next operation
Hold
Release load
Position
Unavoidable delay
Assemble
Plan
Use
Rest to overcome fatigue
Disassemble
Avoidable delay

61. An example of therbligs....

62. “Cheaper by the Dozen”
By Gilbreth and Gilbreth, (children of Frank and Lilian)
Lilian and Frank Gilbreth had 12 children
They viewed home as “efficiency lab”
“What will work at home will work in the factory”
Gilbreth shaved with 2 razors (one in each hand)
Filmed all their children getting their tonsils removed.

63. World War II brought other kinds of needs to the fore
World War II brought other kinds of needs to the fore. At this stage analytical applications of modeling were developed.
The development of the personal computer brought the laboratory of the Industrial Engineer to his/her desktop. It contributed tremendously to the growth and success of this engineering discipline.

64. Timeline of IE development

65. The Profession
Today, as in the past, the Industrial Engineer is closely involved in the creation of wealth and prosperity.
This is achieved through designing and implementing better, more productive systems in both a manufacturing and a service environment.
The day to day task of an Industrial Engineer therefore encompasses a wide variety of activities.
(S)he has to ensure that the available resources (labor, machines, material and money) are used as productively as possible.