12T052 INDUSTRIAL ENGINEERING

CONCEPT OF INDUSTRIAL ENGINEERING:

• Definition

• History & development

• Various techniques of Industrial Engineering

• Scope in Textiles

SYLLABUS - 12T052 INDUSTRIAL ENGINEERING CONCEPT OF INDUSTRIAL ENGINEERING: Definition, history & development, various techniques of Industrial Engineering,

scope in Textiles.

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PRODUCTION PLANNING & CONTROL: Definition, Difference between production & productivity. Productivity analysis inspinning and weaving. Causes for low productivity in textile and apparel industries. Suggestions for productivityimprovement. LINE BALANCING: Objectives. Procedure. Techniques and applications in Textile and Apparel industries.

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WORK STUDY: Definition, purpose, techniques of work study. Procedure of work study. Method study-steps in conductingmethod study, principles of motion economy. Motion study Therbling, SIMO chart, Left hand & right hand chart, flowdiagram, flow chart, string diagram, process flow, multiple activity chart. Work Measurement-Techniques of workmeasurement, Time study-time study equipments, steps in conducting time study, scale of rating, basic time,allowances and standard time. PTMS, MTM .Case studies in textile and apparel industries.

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LAYOUT: Layout planning and development. Types of layout – process, product, combination and fixed. Layout for Textile and Apparel industries.

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WORK ENVIRONMENT AND SERVICES: Lighting. Ventilation. Climatic Condition – Temperature Control and Humidity Control. Noise Control, Safety, Ergonomics. Services- Stores, Health, Feeding and Convenience related services).

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MATERIAL HANDLING: Objectives, Classifications of material handling equipments. Descriptions and characteristics of material handling equipments. Specialized material handling equipments related to Textile and Apparel industries.

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Total L : 45

Reference – Unit 1

• Kiell B.Zandin, “Maynard’s “Industrial Engineering Hand Book”, Mc Graw Hill, Inc., New York, 2001. – CHAPTER 1.1 - THE PURPOSE AND EVOLUTION OF INDUSTRIAL

ENGINEERING, By Louis A. Martin-Vega, National Science Foundation Arlington,Virginia

History

• Provides insights into many principles that dominated its practice

History

Pyramids

History and Development

• 18th century – first engineering school• IE born in 19th century• Dominated – practice and development -20th

century• Early engineering

– Military– Civil– Mechanical– Electrical– Chemical

Textile

• Technological innovations -mechanize - many manual operations in the textile industry.

– Flying Shuttle

– Spinning jenny

– Water frame

The flying shuttle was patented by John Kay (1704–c. 1779) in 1733.

The spinning jenny is a multi-spindle spinning frame, andwas one of the key developments in the industrialization ofweaving during the early Industrial Revolution. Itwas invented in 1764 by James Hargreaves in Stanhill,Oswaldtwistle, Lancashire in England.

The water frame is the name given to a spinning frame, when water power is used to drive it. Both are credited to Richard Arkwright who patented the technology in 1768.

History and Development

• Industrial Revolution, which began in England duringthe mid eighteenth century

• As industrial organizations profit from technologicaldevelopments, the size and the complexity ofmanufacturing units increased dramatically.

• Interchangibility of parts

• Specialization of labor

Mass production

• The Industrial Revolution

• Specialization of Labor

– Charles Babbage

• Interchangeability of Parts

– Eli Whitney

PIONEERS OF INDUSTRIAL ENGINEERING

• Taylor and Scientific Management - Frederick W.Taylor– Taylor’s system consisted of breaking down the production process into

its component parts and improving the efficiency of each. – Development of “time study”

• Frank and Lillian Gilbreth– motion-picture camera to the task of analyzing motions and categorize

the elements of human motions into 18 basic elements or therbligs– Motion study– human factors or ergonomics– 1912

• 1912 –Henry Towne and Henry Gantt, Frederick Halsey,• Gantt chart: a systematic graphical procedure for planning and

scheduling activities that is still widely used in project management.

Milestones1. The idea that engineers have to design and fabricate products at costs, large number of

consumers can afford to pay was advocated. This idea gave birth to the subject of Engineering Economics subsequently. H.R. Towne’s address in 1886 to American Society of Mechanical Engineers (ASME) “The Engineer as an Economist” was a classic paper in this area. The papers of Oberlin Smith also fall in this group.

2. Engineers got interested in wage incentive methods. Papers by Towne, F.R. Halsey and H.L.Ganttbetween 1880 ad 1895 addressed this issue.

3. Engineers got involved in factory accounting issues. An English engineer and accountant, Emile Garcke and J.M. Fells published a book on factory accounts in 1889.

4. Engineers recognized the importance of production control and paid attention to improve the procedures of production control. H.C. Metcalfe’s “ A Shop Order System of Accounts” was an early paper in this regard.

5. F.W. Taylor addressed issues related to shop management in a more comprehensive manner in his paper “Shop Management” (1903).

6. Frank Gilbreth developed the motion study technique.

7. H.L. Gantt advocated training of operators.

8. Harrington Emerson came out with a book that emphasized efficiency of business organizations and systems.

9. Lillian Moller Gilbreth work along with Frank Gilbreth on applied psychology to industrial work.

10. Hugo Diemer authored book on Factory Management emphasizing industrial engineering (1910).

11. Charles Going authored the book, Principles of Industrial Engineering (1911).

Match the following

PIONEERS OF INDUSTRIAL ENGINEERING

1. H.R. Towne’s

2. Gilbreth

3. F.W. Taylor

4. Hugo Diemer

5. H.L.Gantt

CONTRIBUTION

a. motion study

b. Engineering Economics

c. Incentive

d. Factory Management

e. Time study

Match the following

Pioneers of Industrial Engineering

1. 1890s

2. 1930s

3. 1960s

4. 1990s

Significant events

a. Operations Research

b. Mass Production

c. Systems Engineering

d. Industrial Engineering

Definition -IISE official definition

• Industrial and systems engineering isconcerned with the design, improvement andinstallation of integrated systems of people,materials, information, equipment and energy.It draws upon specialized knowledge and skillin the mathematical, physical, and socialsciences together with the principles andmethods of engineering analysis and design,to specify, predict, and evaluate the results tobe obtained from such systems.

• Design - Some industrial engineering tasks involve the creation of a new facility, process, orsystem.

• Improvement - Most industrial engineering tasks involve the improvement of an existingfacility, process, or system.

• System - Most engineers design physical objects, but most IEs design systems. Systemsinclude physical components, but also include processes, rules, and people. Components ofa system have to work together. Material and information flow between the components ofa system. A change to one part of system may affect other parts of the system.

• People - Among all types of engineers, IEs think the most about people.

• Machines - An IE must select the appropriate machines - including computers.

• Information - Data can be used for immediate decision making and can be analyzed to makeimprovements to the system.

• Money - An IE must weigh costs and savings now against costs and savings in the future.

• Goal - Every designed system exists for some purpose. The IE must think about differentways to accomplish that goal and select the best way.

• Efficiency - Whatever the goal of the system, the IE usually seeks to have the system achievethat goal quickly and with the least use of resources.

• Quality - The IE’s organization always has a customer and the organization must delivergoods and services to the customer with the quality that the customer wants.

• Safety - IEs have to make sure that the system is designed so that people can and will worksafely.

Role of Industrial Engineer

Techniques of Industrial Engineering

Following tools and techniques are used to improve productivity of the organization by optimum utilization of resources.

1- Method Study2- Time Study (Work Measurement).3- Motion Economy.4- Financial and Non Financial Incentives.5- Value Analysis.6- Production, Planning and Control.7- Inventory Control.8- Job Evaluation.9- Material Handling Analysis.10-Ergonomics (Human Engineering).11- System Analysis.12- Operations Research Techniques.

Work Study

• Work Study -( Method and Time Study)

Definition: Work study may be defined as the analysis of a job for the purpose of finding the preferred method of doing it and also determining the standard time to perform it by the preferred (or given) method. Work study, therefore, comprises of two areas of study: method study (motion study) and time study (work measurement).

Method study

• Method study (also sometimes called Work MethodDesign) is mostly used to improve the method of doingwork. It is equally applicable to new jobs. Whenapplied to existing jobs and existing jobs, method studyaims to find better methods of doing the jobs that areeconomical and safe, require less human effort, andneed shorter make-ready / put-away time. The bettermethod involves the optimum use of best materialsand appropriate manpower so that work is performedin well organized manner leading to increased resourceutilization, better quality and lower costs.

Time study-Work Measurement

• Time study, on the other hand, provides the standard time, that is the time needed by worker to complete a job by the standard method. Standard times for different jobs are necessary for proper estimation of

• manpower, machinery and equipment requirements

• daily, weekly or monthly requirement of materials

• production cost per unit as an input to better make or buy decision

• labor budgets

• worker's efficiency and make incentive wage payments.

Work Study and Ergonomics

• The work study and the ergonomics are the two areas of study having the same objective: design the work system so that for the operator it is safe, and the work is less fatiguing and less time taking.

LAYOUT PLANNING

• OBJECTIVES IN PLANT LAYOUT

1. Minimize investment in equipment.2. Minimize overall production time.3. Utilize existing space most effectively.4. Provide for employee convenience, safety and comfort. 5. Maintain flexibility of arrangement 6. Minimize Material handling cost. 7. Minimize variation in types of material handling equipment.8. Facilitate the manufacturing process. 9. Facilitate the organizational structure

Material handling

• Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.

PRODUCTION PLANNING & CONTROL

What is Productivity?

• Productivity, in simple words, is the relation ship between output and input.

•

OutputProductivity = ————

Input