Introduction to Industrial Ensures the Workers' Health

and Safety
Engineering 7. Analyze and Design Supply
Chain
What is Industrial Engineering?
To design systems or make What are some of the topics the
systems more productive and Industrial engineer studies?
efficient, Industrial Engineers
develop ways of integrating... o People
o People The IE undergoes several
o Machines courses in psychology and social
o Materials science to help them understand
o Energy some of the workplace dynamics
o Information involved in managing people.
Other areas of concern for the
There are roughly four main
IE are how many people are
areas of industrial engineering:
required, is the job designed
o Human Factors (ergonomics,
correctly for a human operator
human-machine interface) (Ergonomics), is the operation safe,
o Operations Research what level of pay should be offered
o Manufacturing for the work, does the job require
o Statistics and Quality the employee to get more training,
and is there good communication
What do Industrial Engineers do? between management and their
Industrial Engineers design, employers.
plan and control many types of
systems in manufacturing and o Manpower Requirements
service sectors. To understand the manpower
requirement a great deal of time
Industrial Engineers... study and motion study activity will
1. Design Manufacturing need to occur.
Processes
2. Develop Automation for High o Performing a motion study.
Productivity The process is a continuous
3. Develop Production process. To stay competitive
Schedules and Establish companies must continue to
Inventory Levels increase the production capacity of
4. Ensure Product Quality is their facilities while reducing their
Maintained cost. The IE will be expected to
5. Develop Software that come up with additional
Analyzes Data, Controls improvements each year.
Equipment and Unites the
Production System o Performing a time study.
6. Design the Job Itself, so that A good time study will take into
it Conforms to the account the unavoidable delays,
Capabilities and Limitations fatigue, and to an extent, outside
of the Human Operator and interferences. Time for wasteful
steps, such as searching for tools,
will not be included in the final o Machines
standard. The expectation is that
the workplace will be designed to o Capacity
accommodate the work and will be The IE will be looking at the
free from this type of waste. amount of time it will take to set-up
the machine, the cycle time of the
o Ergonomics machine, the number of operators
The idea of mass production is required, the power requirements,
to take a complex job and break it as well as the ergonomic design.
down into simple and repeatable
task that can be performed with a o Set-Up Times
high level of precision by the same Set up time is the amount of
set of operators. If the workstation, time it takes to begin producing
task, and environment are not different parts on a machine.
designed properly the worker will be
subjected to safety and health risk. o Cost
o Compensation o Lifetime
From the company's point of The IE will also take into
view, they want to minimize the account how long the machine is
amount of money they have to pay expected to last when developing
to the employees. This goal often the cost analysis. A straight-line
goes against the other goal of depreciation may be decided upon
management and that is over the machine’s life. The salvage
productivity. The productivity of the value, or the value of the machine
employee is directly linked to the at the end of its’ useful life, is also
monetary rewards for the employee. taken into account.
There are several plans that have
been developed over time with the o Efficiency
intent of balancing the cost with
The traditional way of looking at
productivity.
efficiency was to keep the machine
An IE will help the company
running at a 100% whether the
analyze their current situation and
products can be used or not. The
will often be responsible for
idea was that the cost of the
suggesting an appropriate plan
machine could be spread out over
the amount of time it was kept
o Training
running. Therefore, the higher the
The operators must be machines efficiency, time running /
appropriately trained. Standards are time available, the better the
set using people that are familiar accounting numbers looked in
with the job and people who have regard to machine cost. This
mastered the skills required to tended to increase the work in
perform the job. If other individuals progress as well as build finished
are going to be expected to goods inventories, which is
perform at this level, then they will undesirable.
need to be trained.
 excessive amounts of rework into
o Maintenance each of the processes. If the
The amount of maintenance that company accepts poor material,
the machine is going to require is a then their product will possibly end
variable that must be considered by up shoddy and may or may not
the IE before the machine is put cause the company to lose
into the system. All machines are business. A typical job for an IE
going to require some amount of would be to work with the quality
maintenance, but care should be department to set up a Total Quality
taken when selecting machines so Management system TQM.
maintenance time is minimized.

o Material
The IE is concerned with the
delivery and flow of material Introduction to Motion and
throughout the plant. Time Study
o Facilities Layout Industrial engineering is the
IE will be responsible of laying engineering discipline that concerns
out the equipment and material the design, development,
storage locations for the plant. The improvement, implementation and
key part of this analysis is how evaluation of integrated systems of
things will flow through the plant. people, knowledge, equipment,
You don’t want the parts to travel energy, material and process.
any further than they must. Industrial engineering draws upon
Traveling is a form of waste that the principles and methods of
needs to be minimized. engineering analysis and synthesis,
as well as mathematical, physical
o Lot size and social sciences together with
An IE can look at the lot size of the principles and methods of
a company as an indicator of engineering analysis and design to
flexibility of a company. specify, predict and evaluate the
results to be obtained from such
o Economic Order Quantity systems. Industrial engineers work
This is one of the calculations to eliminate wastes of time, money,
that can be used to determine the materials, energy and other
quantity of material that should be resources.
ordered to minimalist the shipping
and additional cost of raw material. There are a number of things
industrial engineers do in their work
o Inventory Levels to make processes more efficient,
to make products more
manufacturable and consistent in
o Quality
their quality, and to increase
The quality of the material can productivity.
affect all parts of the system. Poor
quality material often introduces Role of IE in Motion and Time Study
 management theory from early
Industrial engineers study how time-and-motion studies to the
workers perform their jobs, the goal latest total quality control ideas.
is to reduce the time it takes to o Taylor's ideas, clearly
perform a certain job and enunciated in his writings, were
redistribute work so as to require widely misinterpreted. Employers
fewer workers for a given task. used time and motion studies
History of Motion and Time Study simply to extract more work from
Overview employees at less pay. Unions
condemned speedups and the lack
o Techniques that led to of voice in their work that
methods-time analysis spring from "Taylorism" gave them. Quality and
an era of belief in progress, growth, productivity declined when his
the rationality of the capitalist principles were simplistically
system, and material prosperity as a instituted.
very high societal good.   o Frederick Taylor developed
o Perceived need for such Scientific Management which was a
techniques arose from development time-based approach to efficiency.
of batch production in great (Taylor also emphasized method,
quantity, intense competition but his followers tended to
between manufacturers to reduce emphasize it less and focus on the
cost per unit, and a heavy reliance time it took to complete tasks rather
on manual labor alone or in than the methods used.)
combination with basic supporting o The fundamental assumption
electromechanical devices. behind Scientific Management was:
o An early distinction existed "The greatest production results
between time studies and methods when a worker is given a definite
studies, which later coalesced into task to be performed at a definite
methods-time analysis, or time- time and in a definite manner. “
motion studies. o Taylor's work is responsible
for workplace phenomena such as
1. Frederick Winslow Taylor reengineering and total quality
(1856-1915) management.
o Frederick Winslow Taylor, o He developed the basic
“the father of scientific elements of what later came to be
management.” known as "scientific management".
o Frederick Winslow Taylor o He developed the basic
devised a system he called elements of what later came to be
scientific management, a form of known as "scientific management"
industrial engineering that -- the breakdown of work tasks
established the organization of work into constituent elements, the
as in Ford's assembly line. This timing of each element based on
discipline, along with the industrial repeated stopwatch studies, the
psychology established by others at fixing of piece rate compensation
the Hawthorne Works of Western based on those studies, the
Electric in the 1920s, moved standardization of work tasks on
detailed instruction cards, and Objectives of Scientific
generally, the systematic Management
consolidation of the shop floor's The four objectives of management
brain work in a "planning under scientific management:
department." 1. The development of a
o Taylor's initial experiments science for each element of a
were aimed at determining man's work to replace the old rule-
(scientifically, of course), how of-thumb methods.
much work a “first-class man” 2. The scientific selection,
could perform. It was Taylor's goal training and development of
to collect raw data about the jobs in workers instead of allowing them to
the workplace, and then to choose their own tasks and train
systematize that knowledge; to themselves as best they could.
replace old habits and rules of 3. The development of a spirit
thumb with precise and usually of hearty cooperation between
quantitative analysis. He was workers and management to ensure
convinced that scientific study that work would be carried out in
would reveal a better way -- the accordance with scientifically
one best way -- of doing things. devised procedures.
No task was too mundane for 4. The division of work between
scrutiny. workers and the management in
o Taylor recognized that almost equal shares, each group
knowledge is power. Management taking over the work for which it is
had to understand what was best fitted instead of the former
happening on the factory floor. condition in which responsibility
o Taylor conducted extensive largely rested with the workers.
experiments to determine the
optimal size of a shovelful of dirt to Self-evident in this philosophy
maximize the total amount shoveled are organizations arranged in a
in a day. hierarchy, systems of abstract rules
o And the one best way is to and impersonal relationships
between staff.
conduct:
 time and motion study
2. Henry Gantt
 standardized tools and o Henry Gantt (of Gantt chart
materials,
fame) provides an early contrast
o Simplification of methods,
with the approach of Taylor. Gantt
 careful selection and felt that Taylor paid insufficient
training of workers, attention to the motivation of
 rigorous measurement people, treating them instead as
of work output, and stages in a process. Instead, Gantt
 Benchmarking... focused on motivational schemes,
 Collaboration between emphasizing the greater
management and effectiveness of rewards for good
workers in building a work rather than penalties for poor
larger surplus. work (he initiated bonus schemes).
 o Henry Gantt developed the
Gantt chart, which is used for o Frank and Lillian Gilbreth
scheduling multiple overlapping emphasized method by focusing on
tasks over a time period. identifying the elemental motions in
o He focused on motivational work, the way these motions were
schemes, emphasizing the greater combined to form methods of
effectiveness of rewards for good operation, and the basic time each
work (rather than penalties for poor motion took.
work). o They believed it was possible
o He developed a pay incentive to design work methods whose
system with a guaranteed minimum times could be estimated in
wage and bonus systems for advance, rather than relying upon
people on fixed wages. observation-based time studies.
o Gantt focused on the o Frank Gilbreth, known as the
importance of the qualities of Father of Time and Motion Studies,
leadership and management skills filmed individual physical labor
in building effective industrial movements.  This enabled the
organizations manager to break down a job into
its component parts and streamline
3. Frank and Lilian Gilbreth the process.
o The Gilbreths (Lillian and o His wife, Lillian Gilbreth, was
Frank) emphasized method, rather a psychologist and author of The
than time. Psychology of Work. In 1911 Frank
o Frank and Lillian Gilbreth Gilbreth wrote Motion Study and in
were active in the years around 1919 the couple wrote Applied
WWI (1910s and 1920s). Motion Study
o Frank Gilbreth had been o One of Frank Gilbreth's first
impressed, when on an early job, at studies concerned bricklaying. (He
the number and variety of had worked as an apprentice
*methods* bricklayers would use bricklayer.) He designed and
when laying a brick. This led him to patented special scaffolding to
a lifetime's work on methods reduce the bending and reaching
analysis. which increased output over 100
per cent. However, unions resisted
Much of the Gilbreth's work was his improvements, and most
laboratory based, focusing on workers persisted in using the old,
identifying the elemental motions in fatiguing methods.
work, the way these motions were
combined to form methods of
operation, and the basic time each
motion took. In principle, it was
then possible to "design" work
methods whose times could be
estimated in advance, rather than
relying upon observation-based
Time studies.