Total Industrial Engineering

H. Yamashina of Japan developed World Class Manufacturing approach and he included Total Industrial Engineering along with Total Quality Management, Total productive Maintenance and Cost Deployment.

According to him TQM is the brain, TPM is the muscle and TIE is the humanware.

I am trying to find out the details of the concept. So far I could only access three or four slides on the concept. Covered in a post on Knol.

Total Industrial Engineering - H. Yamashina

Strategic Facilities Planning - Terminology

Facilities experts William Wrennall and Quartermann Lee have identified four basic elements and four derived elements for every layout. The basic elements are space planning identifiers, affinities, spaces, and constraints. The derived elements are the configuration diagram, the layout primitive, macro layout options, and the populated layout.

William Wrennall wrote chapter 8.2 Facilities Layout and Design in Maynard's IE Handbook, 5th Edition.

Space planning identifiers (SPIs). An SPI represents a function, department, or feature that requires space, impacts placement, or has flow or non-flow relationships with other SPIs.

SPIs may be:

• product-focused (e.g., a lamp assembly cell);

• functional departments (e.g., a powder paint unit);

• storage areas (e.g., tool crib); or

• building features (e.g., loading dock).

Within the SPI definitions, the items, areas, and functions that are included and excluded should be noted. This is done to ensure that the fundamental elements are communicated.

Affinities and relationships. An affinity is the degree of closeness between two SPIs. The affinity is based on material flow and non-flow considerations or a combination of the two. Affinity values and their generally accepted definitions include:

• A is absolute/adjoining

• E is "especial"/close (touching, if possible)

• I is important/nearby

• O is ordinary/conveniently near

• U is unimportant

• X indicates that proximity is not desirable

• XX indicates that separation is important

These are demonstrated best on an affinity chart (which is similar to a mileage chart), with the SPIs listed along the side and the affinities posted in the look-up intersections.

This is a good time to develop and agree on tiebreakers, which are rules to apply when procedures do not provide a definite design choice. In many cases, the tiebreakers may create a placement protocol that incorporates elements from operations and manufacturing strategy.

The affinity chart is converted into a graphical form called a configuration diagram that organizes the SPIs into an arrangement based on affinities . The arrangement is accomplished by using several SPI placement iterations. The A and E affinities are placed first, with subsequent iterations adding the I, O, X, and XX affinities.

Lines indicate the affinity between SPI pairs. Line designations include:

• A = 4 red lines

• E = 3 orange lines

• I = 2 green lines

• O = 1 blue line

• X and XX = black, spring-like lines

The configuration diagram can be used as a diagnostic tool.

Space requirements for each SPI. The space required for an SPI should reflect growth, either positive or negative, for each SPI over the planning horizon. The planning horizon should be between five and 10 years. This interval is best because any less may not allow for necessary growth and any more is probably a guess.

The SPI with the incorporation of space is the space-planning unit (SPU).

Layout primitive. Space-planning units are substituted for their corresponding SPIs in the configuration diagram. The result of the substitution is a layout primitive . The layout primitive is important because it is an unconstrained macro (block) layout. The next step will implement any constraints, including the building or its footprint.

Macro layouts. Apply constraints to the layout primitive. The layout primitive is constrained into a footprint, which sometimes causes several solutions to present themselves. These multiple solutions are the primary macro layout options.

A number of considerations have to be taken into account during this step, including the SPI space and shape. The variability of changes to the shape or geometry of space indicates the dynamic nature of usable blocks of space and should be considered block dynamics. Block dynamics describe how the block assumes a characteristic geometry based on the population and orientation of the population. In addition, columns and column spacing have an impact on block dynamics.

Populating the layout. Populate the selected layout option is placement of individual facilities or equipment in the block of space specified for a space planning identifier. The term "populate" is more appropriate than "detail." Although detail is being incorporated, the population of the block validates the space planning unit with its associated block space and geometry.

Source: http://www.iienet.org/uploadedFiles/IIE/Technical_Resources/Archives/IEMagazine/june_kerns.htm

Knol Day of Industrial Engineering

Birth Day of Frank Gilbreth 7th July is celebrated as the Knol Day of Industrial Engineering for the year 2010. Many articles on Industrial Engineering are being written for the occasion.

Students of NITIE are posting number of articles which are summaries of various articles published in Industrial Engineer magazine

Index of articles written by IE students of NITIE, Mumbai, India on the occasion of Knol Day of Industrial Engineering

Industrial Engineer Magazine Article Summaries by 2010 IE Students NITIE, Mumbai, India

All visitors are requested to write comments on various issues related to industrial engineering in comments blocks.

Knol Day of Industrial Engineering

By Narayana Rao K.V.S.S.

Industrial Engineering Concepts Course - Class 1 at NITIE

In the first class the definition of industrial engineering will be explained.
It will be emphasized that engineering knowledge gained during undergraduate course is to be retained, refreshed and developed further for successful IE career.

The assignments will be announced.

The course page will be informed.

IE is Management Service

Management of an organization is the process of establishing objectives and goals of the organization periodically, designing the work system and the organization structure, and maintaining an environment in which individuals, working together in groups, accomplish their aims and objectives and goals of the organization effectively and efficiently.

Industrial engineering is a discipline that evolved out the involvement of engineers in managing engineering departments of enterprises. Frederick Taylor and Frank Gilbreth are pioneers of this branch of engineering which is a service to management.

Narayana Rao defined industrial engineering as: "Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved." ( Industrial Engineering )

The statement "Industrial Engineering is Human Effort Engineering and System Efficiency Engineeering" appeared in the Industrial Engineer (March 2010 issue), magazine of Institute of Industrial Engineers (IIE), which is the global association of Productivity and Efficiency professionals.

IE is management service.

http://knol.google.com/k/narayana-rao-k-v-s-s/management-and-industrial-engineering/2utb2lsm2k7a/2380#

Crankshaft Manufacturing - Machining Organizations - India

1. Alloy Steel Company
Plot No.-92, Pocket-M, Sec.-2, Bawana DSIDC Indl. Area, Delhi - 110039, IndiaPhone:91-11-27552620

An ISO 9001 : 2008 certified company manufacturing crank shaft under the brand name NEELKANTH GI3(regd.) since 1972

Manufacturing Facilities:


CNC Horizontal Turning Center – 3 Nos.
CNC Key Way Milling – 1 No.
Delapena Horizontal Honing Machine- 3 Nos.
WMW Surface Grinder – 2 Nos.
WMW Internal Grinder – 2 Nos. (Fully Hydraulic )
WMW Cylindrical Grinder – 2 Nos. (Fully Hydraulic )
MSO Cylindrical Grinder – 1 Nos. (Fully Hydraulic )
WMW Double drilling machine – 2 Nos. (Fully Hydraulic )
Drilling SPM – 3 Nos.
BEMCO Hydraulic Press -1 No.
Hydraulic Press SPM – 1 No.
Auto Copying Lathe – 2 Nos.
Lathe Machine – Colchester Make – 5 Nos.
Lathe Machine – Amar Make – 8 Nos.
Drilling Machine HERBERT – 3 nos.
Drilling Machine FOBCO – 1 no.
Drilling & Taping Machine – 1 no.
Horizontal milling Machine ADCOCK SHIPLY – 2 Nos.
Centering & Facing machine – 2 Nos.
Blue Star Hardness Tester – 1 No.
Milling SPM – 2 nos.

More detals
http://alloysteel.tradeindia.com/

Manufacturing Process Improvements - Ignored by Industrial Engineers?

Industrial engineering focused on manufacturing processes as well as planning and control systems right from the Taylor's days.

But in the recent days, manufacturing processes were ignored and more attention was given to postions and profiles in direct management jobs in IE programs.

There is a need to refocus on application of IE techniques in manufacturing processes and also on improving planning and control processes in the area of efficiency. The emphasis by IE has to be on improving the processes rather than on managing the planning and control processes.

It is a fact that Industrial engineering emerged out of managerial activities of engineers but as it has evolved it became a staff service that focuses on efficiency improvement of systems with the involvement of operating managers, supervisors and operators.

I am collecting information related to design and production of crankshafts to develop the topic as a basis for introducing various industrial engineering techniques in the subject Introduction to Industrial Engineering.

http://knol.google.com/k/narayana-rao-k-v-s-s/crank-shaft-machining-for-reference-in/2utb2lsm2k7a/2319#

Any suggestions for further references are welcome