03 fd industrial engineering & designing products

7/31/2019 03 FD Industrial Engineering & Designing Products

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Industrial Engineering & Designing Products

e1Procedures Software House

visit to www.e1procedures.com


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What is Industrial Engineering?

Industrial engineers design, install, and improve thecomplex systems which provide both goods andservices vital to our society and economy. Thesesystems integrate people, materials, and equipment,and thereby place unique demands for breadth of preparation upon industrial engineers.

The traditional arenas for the practice of industrialengineering are the manufacturing facilities of

industry. However, today fully one-third of practicingindustrial engineers are employed in non-manufacturing enterprises such as hospitals, banks,and government.


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Industrial Engineering

Industrial engineers perform the following tasks inmanufacturing and service industries. Forecast the demand the product Prepare a plan to produce the product Analyze the cost and benefits of the product Design the layout of the plant to produce the product Select the manufacturing processes to make the product Identify the people and their skills for production and

supervision Integrate people, materials, machines, and processes to work

together

Schedule the machines and processes for production Supervise the day-to-day operation of the facility Design the workplace and procedures for workers to follow Handle occupational and safety concerns Model and analyze the performance of the system and find

ways to improve it


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Industrial Engineering:

the People and Systems Engineers


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Areas of Study Within Industrial Engineering 1. Human Factors (Ergonomics)


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Areas of Study Within Industrial Engineering Human 2. Facilities Design

SLP PATTERN OF PROCEDURES

Input Data: P,Q,R,S,T, & Activities

Flow of Materials

ActivityRelationships

RelationshipDiagram

SpaceRequirements

SpaceAvailable

Space RelationshipDiagram

ModifyingConsiderations

PracticalLimitations

Evaluation

SELECTED LAYOUT PLAN

Muthers Systematic Layout Planning Pattern of Procedures

PLAN X

PLAN Y

PLAN Z


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Work Cell Floor Plan

Office

Tool Room Work Cell

Saws Drills


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Emergency Room Layout

E.R. beds Pharmacy Billing/exit

E.R.Triageroom

Patient B - erratic

pacemaker

Patient A -broken leg

Laboratories


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Store Layout - with Dairy, Bread, HighDrawer Items in Corners


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Areas of Study Within Industrial Engineering Human 3. Simulation


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Factory Lay-out


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Areas of Study Within Industrial Engineering Human 4. The Production Planning and Control

Forecasting

AggregateProduction

Planning

MasterProduction

Planning

MaterialRequirement

Planning

OperationsScheduling

Shop FloorControl Warehousing

Shipping &Receiving

Sales &Marketing

AggregateCapacityPlanning

CapacityRequirement

Planning


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Areas of Study Within Industrial Engineering Human 4. Quality Control

0 10 20 30 40 50

38.0

39.2

40.4

41.6

Xbar and R Chart

Subgr

1

1

1

1 1

1

1

X=40.00

3.0SL=41.29

-3.0SL=38.71

0.0

1.5

3.0

4.5

R=2.232

3.0SL=4.720

-3.0SL=0.000

30 40 50

Last 25 Subgroups

37

39

41

43

Sub rou Num ber

38 42

Ppk: 0.56Pp: 0.56StDev: 1.18146Overall (LT)

Cpk: 0.69Cp: 0.69StDev: 0.959752Potential (ST)

Capability PlotProcess Tolerance

Specifications

I I II I I

I I I

STLT

38.0 40.5 43.0

Normal Prob Plot

36 40 44

Capability Histogram

Process Capability Sixpack for alldata


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Areas of Study Within Industrial Engineering Human 5. Optimization/Operation Research

Factories

Customers

Product FlowInformation Flow

Distributor/RetailerWarehouse


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Sample Industrial Engineering CoursesHuman Factors Engineering Work Measurements andWork DesignFacilities Planning andDesignReliability Engineering Experimental Design ForEngineering Production Planning andControl Engineering ProjectManagement

Integrated ManufacturingSystems Expert Systems inEngineering Industrial Robotics

Quality Control

Automated Inspection Integrated Product andProcess DesignQueuing Methods forServices and Manufacturing Introductory DecisionAnalysis for Engineering Simulation Modeling andAnalysis Engineering InformationSystems Contemporary Topics inIndustrial Engineering


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Career Opportunities for Industrial Engineers

Industrial engineers are the problem solvers in all organizations. Career opportunities for industrial engineeringare limitless.

A sample list of career opportunities for industrial engineers include:Manufacturing: regardless of the product manufactured, every manufacturing company needs IEs to

plan the facility, perform economic analyses, plan and control production, managepeople, handle safety issues, improve quality, evaluate performance, etc.

Health Services: hospitals and clinics need IEs to perform cost/benefit analyses, schedule work load,manage people, evaluate safety concerns, design and maintain facilities, etc.

Transportation: airlines, ground transportation, trucking, and warehousing companies need IEs todesign the best schedules and routes, perform economic analyses, manage crews, etc.

Financial: banks and other savings and lending institutions need IEs to design financial plans,perform economic analyses, etc.

Government: local and federal governments need IEs to design and enforce safety systems,environmental policies, plan for and operate in a number of organizations.

Consulting: IEs may work as consultants to help design and analyze a variety of systems includinginformation systems, manufacturing and service systems.


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What is Engineering Design?

The systematic and creative application of scientific and mathematical principles topractical ends such as the design,manufacture, and operation of efficient andeconomical structures, machines, processes,and systems.


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Thus, the design of theseproducts and services isessential to the livelihoodof a company.

But, what are the

characteristics of anEffective Design?

The basic purpose of any organization is toprovide products or services to their customers.


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Effective Design

Effective designs provide a competitive edge by:

Bringing new ideas to the market quickly Doing a better job of satisfying customer needs Making new products easier to manufacture,use, and repair than existing products


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Types of Design and Redesign

Original Design (or Inventing)Involves elaborating, original solutions for a given task. The

result of original design is an invention.

Adaptive Design (or Synthesis)Involves adapting a known system to a changed task or

evolving a significant subsystem of a current product (suchas antilock brakes).

Variant Design (or Modification)

Involves varying the parameters (size, geometry, materialproperties, control parameters, etc.) of certain aspects of aproduct to develop a new and more robust design.


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Product Design:

Specifies which materials are to be usedDetermines dimensions and tolerances

Defines the appearance of the productSets standards for performance.


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Design has a tremendous impact on the quality of a final product or service.

Quality in the design process involves:Matching product or service characteristics

with customer requirements

Ensuring that customer requirements aremet in the simplest and least costly mannerReducing the time required to design a new

product or service, andMinimizing the revisions necessary to make

a design workable.


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The Design Process1. Idea Generation

(Product Design)

2. Feasibility Study(Performance Specifications)

3. Preliminary Design(Prototype)

4. Final Design(Final Design Specifications)

5. Process Planning(Manufacturing Specifications)


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Sources of idea generation

Surveying suppliers, distributors,and salespersonsMonitoring trade journalsAnalyzing warranty claims, customer complaints, and

other failuresSurveying potential customersBench marking:Comparing a product or process against thebest-in-class product.Reverse engineering:Carefully dismantling a competitors productin order to improve ones own product.


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Involvement of Different Functional Departments inthe Design Process

Marketing Department takes the idea and:Forms a product conceptConducts a study on the feasibility of theproposed product or serviceIf the proposed product meets certainexpectations, performance specifications are

developed.


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Involvement of Different Functional Departments inthe Design Process

Design Engineers take the performancespecifications and:

Develop preliminary technical specifications, and later

Develop detailed design specifications.Manufacturing Engineers take the detailedperformance specifications and:

Develop a process plan that includes specificrequirements for equipment, tooling, and fixtures.

Production Engineers take these manufacturingspecifications and schedule production


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No

Ideageneration

Finaldesign

Preliminarydesign

Feasibilitystudy

Processplanning

Productfeasible? Yes

Prototype

Manufacturing

Design & ManufacturingSpecifications

The Design Process


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Idea generation & pre-designplanning Customer Requirements Functional Specification

Product Specifications Concept Generation Concept Selection Engineering Design Engineering Evaluation Prototype and Testing

Manufacturing Design

A Decision Making Process

Flexibility

Cost


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Breaking Down Barriers


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Final design is concerned with how theproduct will perform.

It consists of three phases:1. Functional design is concerned with

how the product will perform.2. Form design refers to the physical

appearance of a product.3. Production design is concerned with the

ease and cost of manufacturing the product.


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Form Design(How The Product Looks)


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Functional Design(How The Product Performs)

Reliability probability product performs intended function forspecified length of time

A measure for reliability is Mean Time BetweenFailures (MTBF).

Maintainability ease and/or cost or maintaining/repairing product A measure for maintainability is Mean Time To Repair(MTTR).


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DFM Guidelines

1. Minimize the number of parts2. Develop a modular design

3. Design parts for multi-use4. Avoid separate fasteners5. Eliminate adjustments

6. Design for top-down assembly


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7. Design for minimum handling8. Avoid tools9. Minimize subassemblies10. Use standard parts when possible11. Simplify operations12. Design for efficient and adequate testing13. Use repeatable & understood processes

14. Analyze failures15. Rigorously assess value


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Design Simplification

(a) The original design (b) Revised design (c) Final design

Design for push-and-snapassembly

One-piece base &elimination of fasteners

Assembly usingcommon fasteners


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Listening to Customers


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Customers Requirements

Normal Requirements are typically what we get by just asking customers what they want.Expected Requirements are often so basic thecustomer may fail to mention them - until we fail toperform them. For example, if coffee is served hot,customers barely notice it. If it's cold or too hot,dissatisfaction occurs. Expected requirements mustbe fulfilled.Exciting Requirements are difficult to discover.They are beyond the customer's expectations. For example, if full meals were served on a flight fromChicago to Indianapolis, that would be exciting. If not,customers would hardly complain.


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Kano Model

Kano Model [ Noriaki Kano 1984].


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Making Economic Decisions

Engineering economy: the disciplineconcerned with the economic aspects ofengineering. It involves the systematicevaluation of the costs and benefits ofproposed technical projects.


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Rational Decision-Making Process

1. Recognize a decisionproblem

2. Define the goals orobjectives

3. Collect all the relevantinformation

4. Identify a set of feasibledecision alternatives

5. Select the decisioncriterion to use6. Select the best

alternative


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Example: Equipment & ProcessSelection

How do you choose between PlasticComposite and Steel sheet stock for theauto body panel?The choice of material will dictate themanufacturing process for the bodypanel as well as manufacturing costs.


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Which Material to Choose?


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Engineering CostsGeneral Cost Terms

Manufacturing CostsDirect materialsDirect labor

Mfg. OverheadNon-manufacturingCosts

OverheadMarketingAdministrative


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Cost Classification for Predicting Cost Behavior

Cost BehaviorsFixed costsVariable costs

Average unit costs


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Fixed Costs

Total fixed costs (F)

Production volume (Q)

Fixed costsper unit of production(F/Q)



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Variable Costs

Def: Costs that varydepending on the levelof production or salesCost behavior : Increaseor decreaseproportionallyaccording to the level ofvolumeExamples: Costs of rawmaterial, packagingmaterial, direct labor,machine utilities aremain variable costs.


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Variable costsper unit of production (V)


Total variable

costs (TV)


Variable Costs


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Break-Even Analysis (BEA)

The total revenue depends on theproduction level.The higher the production, the higherthe total variable costs.In BEA, it is assumed that price ofproduct is fixed.


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Price per

unit (P)

Production (and sales)

volume (Q)

Total revenue(TR)

Production (and sales )

volume (Q)



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Therefore, the overall break-evenanalysis can be pictorially representedin the following graph

Total revenue (PQ)

BEP: F+VQ=PQ

Total costs(F+VQ)

Profit

Production (and sales) volume(Q)

loss



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Total Cost (TC) = Total Revenue (TR)

TC=F+VQ

TR=PQAt the break-even point: F+VQ=PQ

QBEQ = F/ (P-V)



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Example

500,000$ total yearly fixed costs.150$ / unit variable costs200$ / unit sale priceQ BEQ=500000/(200-150) =10000 unitsIf our market research indicates that thepresent demand is > 10000, then thismanufacturing system is economicallyfeasible.


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Quality Function Deployment

Identify customer wants Identify how the good/service willsatisfy customer wants

Relate customer wants to product hows Identify relationships between thefirms hows

Develop importance ratingsEvaluate competing products

C t


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Customer Requirements

CUSTOMER COMMENTS

Carrots and potatoes are very different. I cut myself with this one.

I just leave the skin on.

Im left -handed. I use a knife.

This one is fast, but it takes a lot off.

How do you peel a squash?

Heres a rusty one.

This looked OK in the store.

Peels a variety of produce Works both right and left handed Creates minimal waste

Saves time Durable Easy to clean Safe to use and store Comfortable to use Stays sharp or is sharpenable


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Go Aheadwith your designs!


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Case Study

Select a household product of your choice, your goal will be to describe howyou think this design evolved. By looking at the product, can you tell:1. How and why the device functions? Can you describe how it works, what

energy sources are used, and what purpose that function serves?

2. How was human engineering involved? How would the human/machine

interface affect this design? What safety issues would have been involved?

3. Why the original designers selected the materials used? What propertiesof the materials were most important in selecting them?

4. What features make this product unique? Compared to similar items, arethere features on your example that would identify this as a betterproduct?

5. How was the production process affected by this design? Are therespecific features that might have been added to make production moreefficient?


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Case Study

As your analysis continues, choose one aspect of the design that intrigues you. Study the designused, and consider how you might improve on it. Develop a list of alternatives, and compare them to the

existing design. Develop some criteria that may help you select one of

your alternatives as most likely to succeed. Finally, select one alternative, and describe how it

improves on the existing design, what its limitationsare, and why you think this is a better alternative thanthe existing design.

1P d S ft H


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THANK YOU

e1Procedures Software House provides a full rangeof consulting, public and in-house training ininternational standards, regulatory requirements,and process improvement techniques whichmaximizes performance and profitability for yourcompany

Contact us and we can help support yourorganizations implementation or transition or otherbusiness process improvement activities

e1Procedures Software House

visit to www.e1procedures.com

03 fd industrial engineering & designing products

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