EPRescober - IEM 635 - SPECIAL TOPICS IN INDUSTRIAL ENGG. AND MGT

Republic of the Philippines
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

Graduate School
Master of Science in Industrial Engineering and Management Society
IEM 635- SPECIAL TOPICS IN INDUSTRIAL ENGG. AND MGT.
FINAL REQUIREMENTS
Prepared by:
Engr. Elbenson P. Rescober
Submitted to:
Dr. Ben B. Andres
First Semester, S.Y. 2019-2020

Graduate School
PART 1
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1. The following are functions and/or competencies expected from industrial engineering
and management graduates:
1.1 Perform production planning, scheduling, and control functions;

1.2 Design and implement quality assurance systems;
1.3 Prepare logistics plan;
1.4 Draw up facilities design and layout;
1.5 Develop efficient information systems; and
1.6 Conduct research and development.
Considering your professional experience coupled with supervisory/management immersion,

what additional functions and/or competencies will you recommend for advanced Industrial
Engineering and Management graduates? Give at least three (3) with justification.
IEM Functions/Competencies Justification

1. RISK MANAGEMENT SYSTEM –  Risk management strengthens Industrial
Able to develop and implement Engineers professional profile and proves that
business risk management system we have the know-how to create value for our
organization by successfully managing risk.
 With this new focus and competency, IE

professionals would be able to strengthen
 identifying, analyzing, assessing, controlling,
avoiding, minimizing, or eliminating
unacceptable hazards.
 Risk management is a subject of great depth and

breadth.
2. BUSINESS INTELLIGENCE  This programme is designed for managers across
ANALYTICS – perform data different functions who are interested in
collection, analytics and implementing analytics projects at their
recommend change to the organisation.
business  It provides business managers with the
techniques needed to transform their organisation
into a data-driven organisation. The assignments
and cases in the programme focus on interpreting
the results of analysis and taking decisions based
on those analysis.
 The programme will also include demonstration of
some advanced analytics tools and softwares.
3. EMERGENCY & DISASTER  Create response plans for multiple types of
MANAGEMENT – Provide scientific emergencies and disasters (including natural
solutions in managing emergency disasters, terrorist attacks, public health
and vulnerable disasters. emergencies, and technological disasters) and
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demonstrate agile problem-solving skills and the

ability to adapt to changing situations.
 Apply a strong ethical framework to evaluate crisis
situations and exercise critical decision-making
skills during times of extreme pressure and rapidly
changing variables.
 Understand social and cultural aspects of disaster
preparedness and response in order to best serve
diverse and/or vulnerable populations.
 Devise targeted communications plans for
stakeholders (e.g., the public, supervisors,
colleagues, private sector, military, and other
officials).
 Understand how to coordinate and manage
different organizations, agencies, and levels of
government before, during, and after a disaster.
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2. Based from your gained technical know how from this course/subject and industry
experience, give three (3) special topics in IEM which you strongly believe are very important
for an IEM practitioners. Highlight the applications and benefits that could be derived from
these.
Special Topics Industry Applications Organizational Benefits

1. Maintenance Maintaining the production capability of an  The goal of maintenance is to
Management organization is an important function in any keep the production system in
production system. Maintenance good working order at minimal
encompasses all those activities that relate to cost
keeping facilities and equipment in good  Reasons for wanting to keep
working order and making necessary repairs equipment and machines in
when breakdowns occur, so that the system good operating condition:
can perform as intended.  Avoid production or service
disruptions
Maintenance activities are often organized into  Not add to production or
two categories: (1) buildings and grounds and service costs
(2) equipment maintenance. Buildings and  Maintain high quality
grounds is responsible for the appearance and  Avoid missed delivery dates
functioning of buildings, parking lots, lawns,
fences, and the like. Equipment maintenance is
responsible for maintaining machinery and
equipment in good working condition and
making all necessary repairs.
2. Forecasting Businesses make plans for future operations Forecasts are a basic input in the
based on anticipated future demand. decision processes of operations
Anticipated demand i derived from two possible management because they
sources, actual customer orders and forecasts. provide information on future
demand.
For businesses where customer orders make
up most or all of anticipated demand, planning The importance of forecasting to
is straightforward, and little or no forecasting is operations management cannot
needed. be overstated. The primary goal of
operations management cannot
Forecasts are the basis for budgeting planning be overstated.
capacity, sales, production and inventory,
personnel, puchasing and more. Forecasts The primary goal of operations
play an important role in th eplanning process management its to match supply
because they enable managers to anticipate to demand.
the future so they can plan accordingly.
Having a forecast of demand is
essential for determining how
much capacity or supply will be
needed to meet demand.
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3.Management of The importance of quality cannot be 1. Create constancy of purpose

Quality overstated; two key elements of every toward improvement of product
puchasing decision are price and quality. and service.
Consequently, having a focus on quality and 2. Reduce levels of delays,
quality improvement should be a part of every mistakes, defective materials, and
business organization, whether the defective workmanship.
organization’s business is making cars, selling 3. Cease dependence on mass
electronic goods, providing financial services, inspection. (Prevent defects
providing medical services or baking cookies. rather than detect defects.)
4. Eliminate suppliers that cannot
Quality is more than just a statistical analysis qualify with statistical evidence of
tool for manufacturing lines. When done right, quality.
quality should encompass the entire enterprise. 5. Find problems. It is
management’s job to work
Successful management of quality requires continually on system
that managers have insights on various improvement.
aspects of quality. These include defining 6. Institute modern methods of
quality in operational terms, understanding the training on the job.
costs and 7. Emphasize quality instead of
benefits of quality, recognizing the volume alone. Management must
consequences of poor quality, and recognizing prepare to take immediate action
the need for ethical behavior. We begin with on reports from foremen
defining quality. concerning barriers such as
inherent defects, machines not
Business leaders are increasingly recognizing maintained,
the importance of their supply chains in poor tools, and fuzzy operational
achieving their quality goals. Achievement definitions.
requires measuring customer perceptions of 8. Drive out fear, so that everyone
quality, identifying problem areas, and may work effectively for the
correcting those problems. company.
9. Break down barriers between
When dealing with supplier quality in global departments. People in research,
supply chains, companies are finding a wide design, sales, and production
range in the degree of sophistication must
concerning quality assurance. Although work as a team.
developed countries often have a fair level of 10. Eliminate goals and slogans
sophistication, little or no awareness of modern asking for new levels of
quality practices may be found in some less- productivity without providing
developed countries. This poses important methods.
liability issues for companies that outsource to
those areas
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3. Scan at least three (3) real life IEM issues, challenges and/or problems from the
contemporary industrial set-up and give your recommendations by using
principles, tools, techniques, solution using mathematical model, etc. based from
the discussed special topics in IEM.
Issues/Challenges/Problems Recommendations
1. Company without We have identified 3 different ways of measuring work and
Productivity Measures productivity:
a. 360-degree feedback method uses the feedback
and comments of co-workers to measure productivity.
This method can only be used if the employees in your
organization interact with one another a great deal
b. Production Efficiency – measuring of the total
output generated over the total input. It can be in
terms of manhour inputted and volume generated. For
example, the total input can be represented by the
total working hours devoted multiplied by the number
of manpower who worked. While for the input, it is
represented by the cycle time or standard time allotted
to produce one unit multiplied by the total good
quantity produced.
c. Defect per Unit measurement – measuring the
quality of the output generated is one way to measure
the productivity. It is done by computing how many
defects encountered per parts.
These three measures of productivity is actually being applied to
the company that I am engaged with, today.
2. Low Operation Operation Research tools that can be applied are the following:
Optimizationa
a. Linear Programming (LP) is an optimization method
used to achieve the best outcome (such as
maximum profit/revenue or lowest cost) in a
mathematical model whose requirements are
represented by linear relationships
b. Weighted Moving Average Forecasting - Used when
some trend might be present, Weights based on
experience and intuition
Operation Research is of great help to attain the optimization of

each process if we only study each model and search for its
applicability in our own company. It can help us reduce cost and
at the same time maximize our company’s profit.
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3. Poor product quality As an IE there are many avaialble Quality Tools that will help the
organization manage poor product quality.
The following most common quality tools are:
Cause-and-effect diagram (also called Ishikawa or fishbone

diagrams): Identifies many possible causes for an effect or
problem and sorts ideas into useful categories.
Check sheet: A structured, prepared form for collecting and

analyzing data; a generic tool that can be adapted for a wide
variety of purposes.
Control chart: Graph used to study how a process changes over

time. Comparing current data to historical control limits leads to
conclusions about whether the process variation is consistent (in
control) or is unpredictable (out of control, affected by special
causes of variation).
Histogram: The most commonly used graph for showing

frequency distributions, or how often each different value in a set
of data occurs.
Pareto chart: A bar graph that shows which factors are more
significant.
Scatter diagram: Graphs pairs of numerical data, one variable on

each axis, to look for a relationship.
Stratification: A technique that separates data gathered from a

variety of sources so that patterns can be seen (some lists
replace "stratification" with "flowchart" or "run chart").
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PART 2
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IEM 635- SPECIAL TOPICS IN INDUSTRIAL ENGG. AND MGT.
MAINTENANCE MANAGEMENT
Prepared by:
Engr. Elbenson P. Rescober
Submitted to:
Dr. Ben B. Andres
First Semester, S.Y. 2019-2020

Graduate School
Maintaining the production capability of an organization is an important function in

any production system. Maintenance encompasses all those activities that relate
to keeping facilities and equipment in good working order and making necessary
repairs when breakdowns occur, so that the system can perform as intended.
Maintenance activities are often organized into two categories: (1) buildings and
grounds and (2) equipment maintenance. Buildings and grounds is responsible for
the appearance and functioning of buildings, parking lots, lawns, fences, and the
like. Equipment maintenance is responsible for maintaining machinery and
equipment in good working condition and making all necessary repairs.
Maintenance
All activities that maintain facilities and equipment in good working order so that
a system can perform as intended
Maintenance Goals
The goal of maintenance is to keep the production system in good working order
at minimal cost
Reasons for wanting to keep equipment and machines in good operating condition:
 Avoid production or service disruptions

 Not add to production or service costs
 Maintain high quality
 Avoid missed delivery dates
Maintaining the production capability of an organization is an important function in

any production system. Maintenance encompasses all those activities that relate
to keeping facilities and equipment in good working order and making necessary
repairs when breakdowns occur, so that the system can perform as intended.
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Maintenance activities are often organized into two categories: (1) buildings and
grounds and (2) equipment maintenance. Buildings and grounds is responsible for
the appearance and functioning of buildings, parking lots, lawns, fences, and the
like. Equipment maintenance is responsible for maintaining machinery an
equipment in good working condition and making all necessary repairs.
Breakdown Consequences
1 Operations capacity is reduced, and orders are delayed
2 There is no output, but overhead continues, increasing the cost per unit
3 There are quality issues
a. Output may be damaged
4 There are safety issues
a. Employees or customers may be injured
Maintenance Management Theoretical Flow – Good Maintenance and

Reliability Management requires employee involvement and good procedure
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Maintenance Options
• Reactive:
 Breakdown maintenance
• Dealing with breakdowns or problems when they occur
• Proactive:
 Preventive maintenance
• Reducing breakdowns through a program of lubrication, adjustment,
cleaning, inspection, and replacement of worn parts
PREVENTIVE MAINTENANCE
 The goal of preventive maintenance is to reduce the incidence of breakdown or failures

in the plant or equipment to avoid the associated costs
 Loss of output
 Idle workers
 Schedule disruption
 Injuries
 Damage to other equipment, products, or facilities
 Repairs
 Inventories of spare parts
 Repair tools and equipment
 Repair specialists
Preventive Maintenance Schedule
 It is periodic
 It can be scheduled according to the availability of maintenance personnel and to avoid
interference with operating schedules
 Maintenance is scheduled using some combination of
1. The result of planned inspections that reveal a need for maintenance
2. According to the calendar (passage of time)
3. After a predetermined number of operating hours
Preventive Maintenance: Frequency

 The goal is to strike a balance between the cost of preventive maintenance and the
cost of breakdown
 The amount of preventive maintenance, therefore, is a function of the expected
frequency of breakdown, the cost of breakdown, and the cost of preventive
maintenance
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Computerized Maintenance System
Reliability and maintenance are of such importance that most systems are now computerized.
The figure shows the major components of such a system with files to be maintained on the
left and reports generated on the right.
Maintenance Approaches
 Predictive maintenance
 An attempt to determine when best to perform preventive maintenance
activities
 It is based on historical records and analysis of technical data to predict
when a piece of equipment or part is about to fail.
 Total productive maintenance (TPM)
 JIT approach where workers perform preventive maintenance on the machines
they operate
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Breakdown Programs
 Approaches to dealing with breakdowns:

 Use of standby or backup equipment
 Inventories of spare parts are maintained
 Use operators who are able to perform at least minor repairs on the equipment
they operate
 Have repair people who are well trained and readily available to diagnose and
correct problems
Replacement
 When breakdowns become frequent and/or costly:

 What is the cost of replacement compared to continued maintenance?
 Issues:
 Predicting breakdowns
 Technological change
 System disruptions
 Training employees on the use of new equipment
 Forecast of future demand
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References:
Montgomery, D. C. (2009). Introduction to Statistical Quality Control. USA: John Wiley &
Sons.
Slack, N., Chambers, S., & Johnston, R. (2010). Operations Management 6th Ed. . England:
Pearson Education.
Stevenson, W. J. (2015). Operations Management 12th Ed. . New York: McGraw-Hill

Education.
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IEM 635: Special Topics in Industrial Engineering and

Management
A Case Study of Maintenance Management Systems in

Complex and High-rise Industrialized Building System
Buildings
Prepared by:
Elbenson P. Rescober
Submitted to:
Dr. Ben B. Andres
First Semester, A.Y. 2019-2020
Graduate School
INTRODUCTION
The selected of assessment or diagnosis tools on industrialized building system

(IBS) building maintenance has the significant to affect the lifetime performance of
building structures owing to the knowledge level of designer or contractor to determine
the appropriate concepts and technologies in IBS building maintenance. In this
situation, the absence of available defect diagnosis techniques and integration
approaches on design and construction aspects of cooperation among particular
parties create an additional cost to redesign the project when measuring the
maintenance delivery in IBS building (Chen et al., 2010).
The repairing method in maintenance through conventional method (paper-

based reports/unsystematic database) restrict contractors and manufacturers from
being involved in the knowledge sharing in improving project performance level, which
often results in design changes and a corresponding maintenance and operation cost
increase including materials cost, labor cost and maintenance duration (Yunus and
Yang, 2012; Chang and Tsai, 2013).
According to Kamaruddin et al. (2013) and Rahman and Omar (2006), the
management level in Malaysia, defect identification (DI) process, repairing method
and use of technology in building defect diagnosis of IBS buildings is far behind some
developed countries. Compared with the relatively high level of IBS construction in the
USA and Japan, the supporting technologies and large-scale production systems
(such as supervision systems and matching construction technologies) are used to
improve the maintainability of components and could diagnose the maintenance
problems with safety monitoring process including the avoidance of conflicts involving
the parties in the construction (e.g., the designer and contractor) undesirable from
happening (Zhang et al., 2014).
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Less understanding of building defect level and limited technology supports

such as technology in building defect diagnosis to help identify the defect problems of
IBS components during building maintenance management process may cause great
economic losses and personal casualty incidents due to the disaster building defect.
For example, concrete roof of the Gong Badak stadium collapsed in Kuala
Terengganu on June 2, 2009 (Kaos, 2013). The roof structure crash occurred under
construction for SMK Taman Connaught in Kuala Lumpur and three labours were
injured on Jan 15, 2010 (Isa, 2010). In addition, a few of ceilings at a Hospital Serdang
in Selangor collapsed for a third time as a result of its structural failure (steel corrosion)
on November 14, 2013 (Ramli, 2013). Based on the studies about inappropriate
maintenance assessment through building collapse cases, there is a need for efficient
maintenance management in IBS building construction projects by integration among
relevant players. Inappropriate building defect level assessment method will affect the
overall quality or productivity, budget and concept of the IBS building maintainability
(defect repetition and delay). The effective maintenance management is also required
to avoid related problem, such as process quality in making strategic decision for IBS
building projects There are still cases where complex and high-rise building projects
constructed using IBS contributes to poor productivity and maintenance quality due to
defects problem and building deteriorates (Ahzahar et al., 2011; Qureshi et al., 2015).
The inefficiency in decision making process has been found to be a major cause of
aesthetic and functional faults (Chiu and Lin, 2014). The defects include cracks,
blemishes, moisture penetration, water leakage due to improper jointing and poor
thermal insulation (Onyeizu et al., 2011). Many factors stimulate ineffective decision
support to provide the sufficient information of maintenance strategy with the
extensive coordination on technical knowledge requirements and schedules prior to
maintenance operations of project implementation, however poor maintenance
management or inappropriate method in assessment and defect diagnosis can give a
major impact to the IBS building maintenance decisions (Chiu and Lin, 2014; Qureshi
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et al., 2016). According to Chen et al. (2010), the main reasons for not optimum
decision making on IBS building construction projects were lack of knowledge and
exposure to IBS technology, since the resolution implementation were based on
familiarity and personal preferences (e.g., experience of the design team) rather than
rigorous data between team members through regular meetings. This is also
supported by Bari et al. (2012), who agree with that the incorrect strategic decision at
the initial project phase was a major cause of cost overrun and supply chain integration
problem due to lack of comprehensive principles in the maintainability approach such
as measuring convention, standardization, build ability score and open system
practices among IBS building maintenance teams. The integrated decision-making
process with the maintenance strategy from the design stage to the installation of
components is needed that can significantly improve the repairing method of IBS
building maintenance projects (Wood, 2012).
The research is to develop an appropriate key feature of system for use by
engineers of complex and high-rise IBS buildings to generate effective maintenance
management approaches and to implement relevant process on system elements for
best practice in maintenance management. This paper reports the research leading
to the development of such a new key feature of maintenance system.
KEY FINDINGS FROM CASE STUDIES
There are eight case studies involved in this research to identify the
maintenance management problems, the approaches to address problems, ICT
implementation, use of emerging technologies and the maintenance management
system at the nominated IBS building to improve the maintenance management
practices for building facility and infrastructure. The findings involved a cross-case
analysis and have been grouped into five main “embedded units of analysis” that has
been identified which is (1) maintenance management problems, (2) approaches to
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address problems, (3) ICT implementation, (4) use of emerging technologies and (5)
maintenance management system.
RESULTS AND DISCUSSION
There were many problems related to the conventional method at the IBS building such as,
defect repetition (leaking, jointing and cracking) and less competent contractor. The
conventional method also led to inaccurate design and construction information, late updating
of the required information, lack of coordination and integration (Ismail, 2014). The high quality
of IBS building maintenance works level and the long-life span of services required an efficient
management to maintain the building structure and facility at the IBS building. Therefore, the
transformation of the conventional process into the computer-based systems using emerging
technologies is important to improve the maintenance management processes for complex
projects, in the works of defect diagnosis and to reduce the defects for structural component
especially during the post occupancy of a building. In the case studies, the engineers of
client/maintenance contractor revealed that a number of shortcomings in the conventional
method. The building defect information record was insufficient to facilitate the maintenance
management staff to handle the data analysis and diagnose the defects. The information
record were also inaccurate in order to assess the size of work done and other decision
making process. The repetition of defect was frequent at IBS building. The maintenance
inspection and assessment was not able to address the building defect problems at the
particular location due to the lack of knowledge transfer between all parties in maintenance
management. Furthermore, the less competent contractor caused the maintenance faults to
be increased to encourage the deterioration of the IBS building structure and facility
CONCLUSIONS
Maintenance management is one of the aspects neglected most by the top management of
complex and high-rise IBS buildings. New key features of system development is a method
whereby organizations can improve their maintenance management systems and making use
of a new key feature of system approach can assist maintenance managers to deliver
maintenance work effectively. “defect repetition” and “less competent contractor” was
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perceived to be the most maintenance management problems. By having regular assessment

and diagnosis (by well-trained inspection staff) of the IBS building and all its structures
facilities to identify defective work, maintenance work can be carried out before expensive
corrective maintenance is required. If the maintenance management staffs of buildings are
also made aware of the importance of ICT-based maintenance, they can assist the
organizations greatly by analyzing any defective items using emerging technology.
The performances of existing maintenance management system in complex and high-rise IBS
buildings are all below practice standards; this amplifies the need for an improvement in
maintenance management system. One-way of improving the whole maintenance
management system is by using an emerging technology (BIM). The implementation of a BIM
can assist maintenance managers greatly in managing all maintenance aspects. The
advantages of using a BIM are well documented and it may be necessary that providers of
BIM software should inform maintenance managers about the availability of the various
software packages and their advantages. Organizations may realize that a BIM is needed, but
do not know how to find the best approach that will improve the maintenance management
processes of the organizations. Maintenance managers at complex and high-rise IBS
buildings can confidently use the new key feature of maintenance system that has been
developed to improve their existing maintenance management systems. It is crucial that top
management should take a serious look at how the maintenance of IBS buildings and is
managed and realize the importance of maintaining their structure and facility to good
standards, make sufficient provision for competent contractor and realize the adverse long-
term effects of ignoring the importance of ICT-based maintenance using emerging
technologies for managing defect repetition or other major maintenance problems.
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References
Ismail, Z.-A. (2016). A Case Study of Maintenance Management Systems in Malaysian.

International Journal of Economics and Financial Issues, 6(S3) 28-35.

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Republic of the Philippines

POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

IEM 635- SPECIAL TOPICS IN INDUSTRIAL ENGG. AND MGT.

Engr. Elbenson P. Rescober

First Semester, S.Y. 2019-2020

1.1 Perform production planning, scheduling, and control functions;

Considering your professional experience coupled with supervisory/management immersion,

IEM Functions/Competencies Justification

 With this new focus and competency, IE

 Risk management is a subject of great depth and

demonstrate agile problem-solving skills and the

Special Topics Industry Applications Organizational Benefits

3.Management of The importance of quality cannot be 1. Create constancy of purpose

Operation Research is of great help to attain the optimization of

Cause-and-effect diagram (also called Ishikawa or fishbone

Check sheet: A structured, prepared form for collecting and

Control chart: Graph used to study how a process changes over

Histogram: The most commonly used graph for showing

Scatter diagram: Graphs pairs of numerical data, one variable on

Stratification: A technique that separates data gathered from a

IEM 635- SPECIAL TOPICS IN INDUSTRIAL ENGG. AND MGT.

Engr. Elbenson P. Rescober

First Semester, S.Y. 2019-2020

Maintaining the production capability of an organization is an important function in

 Avoid production or service disruptions

Maintaining the production capability of an organization is an important function in

Maintenance Management Theoretical Flow – Good Maintenance and

 The goal of preventive maintenance is to reduce the incidence of breakdown or failures

Preventive Maintenance Schedule

Preventive Maintenance: Frequency

Computerized Maintenance System

 Approaches to dealing with breakdowns:

 When breakdowns become frequent and/or costly:

Stevenson, W. J. (2015). Operations Management 12th Ed. . New York: McGraw-Hill

IEM 635: Special Topics in Industrial Engineering and

A Case Study of Maintenance Management Systems in

The selected of assessment or diagnosis tools on industrialized building system

The repairing method in maintenance through conventional method (paper-

Less understanding of building defect level and limited technology supports

KEY FINDINGS FROM CASE STUDIES

RESULTS AND DISCUSSION

perceived to be the most maintenance management problems. By having regular assessment

Ismail, Z.-A. (2016). A Case Study of Maintenance Management Systems in Malaysian.

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