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INDUSTRIAL ENGINEERING AND MANAGEMENT

DIPLOMA IN MECHANICAL ENGINEERING

6th SEMESTER

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CHANDAN KUMAR SETHI

ASST. PROFESSOR

GANDHI INSTITUTE FOR EDUCATION AND TECHNOLOGY, BANIATANGI, BHUBANESWAR

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What is Industrial Engineering?

  • Electrical Engineering – to engineer an electrical product or system.
  • Computer Engineering – to engineer a computer or a system of networked computers.
  • Industrial Engineering?
    • To engineer an industry?? No.
    • To engineer an industrial product or system (efficiently and effectively): for manufactured goods or services, originally
    • To engineer a product or system for industry, the military, government, education, etc.
    • Efficiency and Quality Engineering!!

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What is Systems Engineering?

  • To engineer a system, with efficiency and quality
  • All Types of Systems:
    • Aviation Systems, including Air Traffic Control Systems
    • Telecommunication and Computer Systems
    • Airline Reservation Systems
    • Software and Database systems
    • Highway Systems
    • Manufacturing Systems, e.g., the Toyota Production System (TPS)
    • …..

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An Early and Modern Example about Manufacturing: �Car Assembly

  • The original “work cell” assembly method
  • Henry Ford’s idea of assembly line, following the efficiency innovations in cattle slaughtering
  • Many innovations for higher efficiency and better quality, including robotics
  • The Toyota Production System (TPS), practiced at The New United Motor Manufacturing Incorporated (NUMMI) in Fremont, California (and elsewhere)

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Early Moving Assembly Line at Ford

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A Glimpse of a Car Assembly Line

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Robots at Work in Car Assembly

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Robots at Work in Car Assembly

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A Modern Car “Assembly Line”�VW Phaeton in Dresden

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A Modern Example about the Service Industry: Disneyland

  • Simple “Take-a-Number” virtual waiting lines at a hospital, to avoid patience discomfort or enable rest
  • The recent implementation of “Take-a-Number” virtual lines at California’s DMVs and recent acceptance of appointments via the Internet
  • Why can’t Disneyland use this simple idea? What may be the unintended consequences?

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A Modern Example about the Service Industry: Disneyland (Cont’d)

  • Disneyland first estimated wait time for the customers and displayed it at each attraction.
  • Disneyland then displayed the estimated wait times at the entrance and other strategic locations, for better planning by the customers.
  • Disneyland recently implemented its version of the “Take-a-Number” system: the “FastPass”.
  • Better customer satisfaction, and higher revenue too, at the restaurants and gift shops, etc.!

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FastPass�Disneyland – Splash Mountain

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FastPass Machine �Disneyland – Splash Mountain

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� FastPass Ticket �Disneyland – Splash Mountain

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A Leading Truck Manufacturing Plant in U.S.

  • Goal: Double the amount of truck they manufactured in a day, by optimizing their resources while maintaining excellence in quality
  • One of the objectives of the study was
    • To know the precise amount of time spent on non value adding tasks at each truck assembly station, in order to optimize their operation
  • Required to evaluate 70 assembly workers

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Beyond the Stopwatch

  • Work measurement studies often use stop watches to collect task times
  • Difficulty
    • Hold the stopwatch and write the information at the same time
    • The results are not accurate
    • Data collection not easy

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State-of-the-Art Software

  • UmtPlusTM: The highest quality work measurement tool that leverages handheld computers
  • This software developed by Laubrass, facilitates and optimizes the data collection process
  • Just need to click on the appropriate icon and your time is logged
  • Easy to use
  • Truck company customized to suit their needs

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Results

  • Two hours of training in using UmtPlus to collect the necessary data
  • Evaluated 70 workers in just three days
  • Once the tasks have been accurately timed on the PDA the results are uploaded to the computer without having to do any data entry
  • Employees prefer to see the PDAs rather than a stop watch

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Industrial & Systems Engineering

  • ISE UG program ranked 3rd in the Nation according to US News
  • Approx 55 Undergraduate students
  • Very active IIE student chapter
  • 165+ Graduate students (MS ISE [110] & MS Human Factors/Ergonomics [55])
  • Current FTES 125, and approximately 60-65% graduate FTES
  • 4 Full time faculty
    • Dr. Dessouky → Undergraduate Advisor
    • Dr. Tsao → Grad Advisor
    • Dr. Freund → HF/E Program Director
    • Dr. Minnie Patel → Assessment
  • ISE Faculty experience in manufacturing, healthcare, civil aviation, transportation, supply chain engineering, biometrics, process control
  • Research funding from NASA, PATH, MTI, NSF, IBM etc.
  • Very good co-op and employment record

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ISE empowers its students to better the world…

  • ISE students learn how to:
    • improve quality of products and services
    • minimize costs
    • improve security
    • reduce risk of injury
    • minimize delays
    • improve accommodation for the disabled
    • improve quality of work life of employees
    • improve service to customers
    • reduce human errors
    • improve on-time performance

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…through innovative applications in many types of organizations:

  • Manufacturing
  • Computers
  • Semiconductors
  • Biomedical Device
  • Consulting
  • Hospitals
  • Restaurant chains
  • Hotel chains
  • Airlines and airports
  • Government agencies
  • Armed forces
  • Worldwide distribution and delivery companies
  • Entertainment companies and retail chains

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ISE Undergraduate Curriculum�Ranked 3rd in the USA* 2009-10

Enterprise Operations

ISE 155 Supply Chain Engineering

ISE 140 Opns Plng & Control

ISE 142 Services Engineering

ISE 115 Computer Integrated Mfg

Quality Control

ISE 131 Quality Control

ISE 135 Design of Expts

ISE 196R Reliability

Math Modeling

ISE 130 Statistics

ISE 167 Simulation

ISE 170 Operations Research

Human Component

ISE 112 Occ Hlth Engrg

ISE 114 Safety Engineering

ISE 120 Work Methods & Measurement

ISE 164 Human Computer Interaction

Eng. Management

ISE 105 Intr Systems Engrg

ISE 102 Engrg Economics

ISE 151 Engrg Mgmt

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Eng. Breadth

Engr 10 Problem Solving

ME 20 Design & Graphics

CmpE 30

MatE 25 Intro to Materials

EE 98 Circuits

Cmp E 131 Software Engrg

Industrial & Systems Engineering

Sr. Design Project

*U.S. NEWS among colleges and Universities without doctoral degrees.

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Multidisciplinary Research: �Efficient and Safer Large-truck Operations

  • Proven US oil reserve: 22 billion barrels
  • Daily US consumption: 21 million barrels
  • “Desperate” need for fuel efficiency
  • Public transportation for passengers, but how about freight transportation?
  • Longer Combination Vehicles (LCVs) for higher fuel efficiency: 5.4 MPG for a 40,000-lb “straight truck” and 4.6 MPG for a 140,000-lb “turnpike double”

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Efficient and Safer Large-truck Operations

  • LCV for higher productivity: tractor utilization, driver utilization and speed of freight movement
  • But, only 20 states allow such operations.
  • California does not allow them. Why?
  • Safety hazard and damage to roadway
  • A major source: “off-tracking”
  • Innovative concept: Automated Trailer Steering, for virtual elimination of off-tracking [Rangavajhula & Tsao]
  • Multidisciplinary research: mechanical engineering, electrical engineering, electrical engineering, industrial engineering, economics, public policy, etc.

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Industrial & Systems Engineering

  • Questions?
  • Comments? You are the customer, and the product too.