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 Acc to American Institute of Industrial Engineers
(AIIE)
 Industrial Engineering is concerned with the
design, improvement and installation of
integrated system of men, materials and
equipments.
 Industrial engineering is a branch of engineering
which deals with the optimization of complex
processes, systems, or organizations.

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 The prime objective of industrial engineering
is:-
 To increase the productivity.
 Eliminating waste and non-value added
activities.
 Improving the effective utilization of
resources.
 To establish methods for improving the
operations and controlling the production costs.
 To develop programmes for reducing these
costs.
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 It is the ratio between output and input. Output
means the amount produced or the number of
items produced and inputs are the various
resources employed e.g. Land and building,
equipment and machinery, materials and labour,
etc.
 It is analogous to the efficiency of a machine.
 Higher productivity means accomplishing more
with the same amount of resources or achieving
higher output in terms of volume and quality for
the same input.
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 Plant A Plant B
No. of workers = 200 300
No. of items produced = 10 20
per unit time
Therefore productivity = 10/200 20/300
= 1/20 1/15

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For Management

• To make profits
• To clear debts acquired from loans
• To sell more
• To stand better in market

For Workers

• Higher wages
• Better working conditions
• Higher standard of living
• Job security and Satisfaction

For Customers
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• Reduced Price of articles unmodified, non-commercial and
non-sharable outside the Institute)
 Human Resources.
 Availability of workers.
 Type of workers (a) Educated (b) Uneducated
-Educated worker can easily learn and understand
technology to improve the productivity.
 Labour Unions may be problematic in negotiating pays
but can cooperative in enhancing productivity.

Technology and capital investment.

 Advanced technologies; use of automatic machines, use
of design and optimization software, lean manufacturing,
etc.
 For new machinery huge investment will be needed.
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 Government Regulation.
 Some unneeded regulations are imposed by Govt. can
reduce the productivity.
 An excessive regulations are detrimental to
productivity.

Product or System design.

 Proper design of product may result in reduction of
unnecessary parts and the machinery/labour required to
fabricated them.
 Waste can be reduced.

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Machinery and Equipments.
 Type of machinery used : manual, semi-automatic, fully-auto.

 Use of computers to design (CAD) and run the machines.

The skill and effectiveness of workers.

 Trained and experienced workers can do the same job in shorter
time with effectiveness.

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 Manufacturing, a branch of industry, is the
application of tools and processes for the
transformation of raw materials into finished
products.
 The manufacturing sector is closely connected
with engineering and industrial design.
 Some industries, such as semiconductor and steel
manufactures use the term fabrication instead.

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 Plant layout means the disposition of the various
facilities (equipment, materials, manpower, etc.)
within the area of the site selected.
 Plant layout begins with the design of the factory
building and goes up to the location and
movement of work.

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 For classroom education only (use
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 Material handling, movements made by the workers and
transportation is minimized and efficiently control.
 Bottlenecks and points of congestions are identified so that
material moves fast from one facility to another.
 Proper utilization of cubic space (length, width, and
height). Suitable spaces are allocated to production centres.
 Waiting time of the semi-finish products minimize.
 Working conditions are safer, better (well-ventilated
rooms, etc.) and improve.
 Increased flexibility for changes in product design and
future expansion.
 Plant maintenance is easy, increased productivity.

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 Product or line layout
 Process or Functional layout
 Combined or Group layout
 Fixed position or location layout

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 If all the processing equipment and machines are
arranged according to the sequence of operations of the
product, the layout is called product type of layout.
 It is used for continuous production i.e. continuous
flow of in-process material towards the finished
product stage.

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 Advantages offered by Product Layout:
 Smooth and continuous work flow.
 Product completes in lesser time.
 Less skilled workers may serve.
 Lesser material handling time and cost.
 Less floor area is occupied by material in transit and for
temporary storages.
Disadvantages
 Product change is difficult.
 Excessive idle times of some machines.
 Failure of one machine in the line may stop further
process.

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 It is characterized by keeping similar machines or
similar operations at one place.
 This layout is commonly suitable for job order
production and non repetitive jobs.

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 Advantages of Process Layout:
 Greater flexibility regarding work allocation to machine and
workers.
 Better utilization of equipment is possible.
 It offers better and more efficient supervision through
specialization at various levels.
 Product variety creates interest in worker.
 Break down of equipment can be easily handled by
transferring work to another machine/work station.
Disdvantages
 Automatic material handling is difficult. Material handling
cost is high.
 Process layout need more space.
 Need more inspection and efficient coordination.

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 Flexibility is a very important, so layout should be such
which can be molded according to the requirements of
industry, without much investment.
 A combined layout utilize the good features of both the
process and product layouts. Machinery is arranged in a
process layout but the process grouping is arranged in a
sequence to manufacture products of different types and
sizes.

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 This type of layout is the least important for today’s
manufacturing industries. In this type of layout the
major component remain in a fixed location, other
materials, parts, tools, machinery, man power and other
supporting equipment’s are brought to this location.
 This type of layout is used in the manufacture of
boilers, hydraulic and steam turbines and ships etc.
Advantages Offered by Fixed Position Layout:
 Material movement is reduced.
 Capital investment is minimized.

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 For classroom education only (use
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 Material handling is the movement, protection,
storage and control of materials and products
throughout manufacturing, warehousing, distribution,
consumption and disposal.
 The movement may be horizontal, vertical and
combination of both.
 Material handling is the art and science of moving,
packing and storing of substances in any form.

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 Reducing material handling labour.
 Reducing indirect labour expenses on activities
connected with storage, inspection, quality
control, repair, tool room, shipping etc.
 Reducing damage of materials during handling.
 Better utilisation of space.
 Reducing in process storage.
 Reducing expenditure on packaging and other
protective devices.
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 Transport equipments
 Positioning equipments
 Unit load formation equipments
 Storage equipments

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 Equipment used to move material from one location to
another. Conveyors, Cranes and Industrial Trucks
are the transport equipments.
Different types of Conveyors.

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Cranes Fork Lift
For classroom education only (use
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 Numerical Control is a technique for controlling machine
tools or processes using coded command instructions.
These coded command instructions are interpreted and
converted by NC controller into two types of signals
namely:- motion control signals and miscellaneous
control signals.

 Motion control signals are a series of electric pulse trains

that are used to control the positions and the speed of
the machine table and spindle, whereas miscellaneous
control signals are set of ON/OFF signals to execute the
spindle rotation and direction, control of coolant
supply, selection of cutting tools, automatic clamping
and unclamping etc.

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Components of NC system

For classroom education only (use

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Advantages of NC systems over manual methods of
production

 Better control of the tool motion under optimum

cutting conditions.
 Improved part quality and repeatability.
 Reduced tooling costs, tool wear, and job setup
time.
 Reduced time to manufacture parts.
 Reduced scrap.

Punched tapes had limited life and storage was

difficult.
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 Computer numerical control (CNC) is the
numerical control system in which a dedicated
computer is built into the control to perform
basic and advanced NC functions.
 CNC controls are also referred to as soft-wired
NC systems because most of their control
functions are implemented by the control
software programs.

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 Components of CNC system

For classroom education only (use

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Advantages of CNC systems
 CNC machines can be used continuously and only
need to be switched off for occasional
maintenance. No need to rewind the punch tapes.
 Large number of part programs can be stored
and reused again.
 These machines require less skilled people to
operate unlike manual lathes/milling machines
etc.
 Training for the use of CNC machines can be
done through the use of “virtual software”. This
saves time and money.
 High precision and accuracy
 CNC machines are generally more expensive and
require high maintenance.

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 Direct numerical simultaneously control the operations of a group of NC
machine tools using a shared computer.
 The main tasks performed by the computer are to program and edit part
programs as well as download part programs to NC machines.
 Machine tool controllers have limited memory and a part program may
contain few thousands of blocks. So the program is stored in a separate
computer and sent directly to the machine, one block at a time.

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(a) Get new ideas,
(b) Separate the good and feasible ideas,
(c) Evaluate ideas technically,
(d) Evaluate ideas from market's point of view,
(e) Take the final decision,
(f) Get into production
(g) Introduce product into the market.

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(a) New ideas can be obtained :
(i) By imitation.
(i) By adaptation.
(ii) By invention (ie., R and D).
(iv) From dealers and customers
(v) By advertising-- asking people to send their
ideas and announcing prizes for the best idea.

(b) Separate the good, meritorious and feasible

ideas from amongst the many, received in step (a).
 Screening of ideas may be done by a committee
consisting of managers of R & D, Production,
sales and other departments related with the
product development.
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(c) The selected ideas are evaluated technically
w.r.t.,
 The method of manufacture,
 Labour and equipment requirements,
 Performance characteristics of the product,
 Cost of manufacture, etc.

(d) Selected ideas are evaluated as regards their

acceptability by the customers.
 The first evaluation is simply a cursory survey by
salesmen.
 If the idea looks promising a nation wide market
survey can be conducted.

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(e) Based on the information collected on
technical and market aspects of the new product,
it is decided finally as whether to go ahead for
production or to forget the idea.

(f) If it is decided to take up the idea,

 The product is designed.
 Equipments are ordered.
 Materials are procured.
 Workers are selected and trained.
 Whether to manufacture the product on mass
scale or job-lot basis.

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(f) While the product is under manufacture,
preparations are done:
 to introduce the product into
 the market and to impress the market with the
developed product.
The following aspects are explored:
(i) Size, location and characteristics of market,
(ii) Advertisement policies,
(iii) Appealing packaging,
(iv) Channels of distribution,
(v) Price, discount and guarantees,
(vi) Service after sale, etc.

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For classroom education only (use unmodified, non-commercial and non-sharable
outside the Institute)
 Production planning involves what to produce,
when to produce it, how much to produce, and
more.

 Planning looks ahead, anticipates possible

difficulties and decides in advance as to how the
production, best, be carried out.

 The control phase makes sure that the programmed

production is constantly maintained.

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 Improved organization for regular and timely
delivery.
 Better supplier communication for raw materials
procurement.
 Reduced investment in inventory.
 Reduced production cost by increasing
efficiency.
 Smooth flow of all production processes.
 Reduced waste of resources.
 Production cost savings.
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 For classroom education only (use
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 Planning Phase
Prior Planning
 Forecasting: Estimation of type, quantity and quality of future
work.
 Order writing: Giving authority to one or more persons to
undertake a particular job.
 Product design: Collection of information regarding specifications,
bill of materials, drawings, etc.
Active Planning
 Process planning and routing: Finding the most economical
process of doing a work and (then) deciding how and where the
work will be done.
 Material control: It involves determining the requirements and
control of materials.
 Tool control: It involves determining the requirements and control
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 Loading: Assignment of work to manpower, machinery, etc.
 Scheduling: It is the time phase of loading and determines when
and in what sequence the work will be carried out. It fixes the
starting as well as the finishing time for the job.

Action Phase
 Dispatching: It is the transition from planning to action phase. In
this phase the worker is ordered to start the actual work.

Control Phase
 Progress reporting:
(i) Data regarding the job progress is collected.
(ii) It is interpreted by comparison with the preset level of
performance.

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Corrective action:
 (i) Expediting means taking action if the progress reporting
indicates a deviation of the plan
from the originally set targets.
 (i) Replanning: Replanning of the whole affair becomes essential,
in case expediting fails to bring the deviated plan to its actual
(right) path.

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 Ergonomics is the process of designing or
arranging workplaces, products and systems so
that they fit the people who use them.
 Ergonomic is a branch of science that aims to
learn about human abilities and limitations, and
then apply this learning to improve people’s
interaction with products, systems and
environments.
 Ergonomics aims to improve workspaces and
environments to minimise risk of injury or harm.
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 For classroom education only (use
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 Reliability is defined as the probability that a product,
system, or service will perform its intended function
adequately for a specified period of time, or will operate in
a defined environment without failure.
 Quality control is the determination, by measurements,
that production materials and processes are within specified
tolerances. It ensures that product is defect free.
 Reliability is a design function whereas Quality control is
manufacturing function.
 Both are essential for satisfactory product performances.

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 Work Study is a generic term for management
services and system engineering techniques, used to
investigate:
 Methods of performing work (Method Study).
 The time taken to do it (Work Measurement).

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Need:
 To improve productivity of system involving very less or no
cost.
 Give solution of complex problem in systematic way.
 Provide accurate means of setting standards for the industries
 It results in immediate savings.

Advantages:
 Increase productivity
 Optimum utilization of resources
 Reduce manufacturing cost
 Provide better working environments i.e. ergonomics

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Method study is the systematic recording and critical
examination of existing method and proposed ways of
doing work, as a means of developing and applying
easier and more effective methods and reducing costs.
Used to analyze:
 Movement of body, people, or material
 Activities of people & machines
Method Study approaches and tools of Method
Analyst:
• Flow Process Charts & Flow Diagrams etc.
• Critical questioning techniques.
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 To Improve of processes and procedures.
 To Improve in the design of plant and equipment.
 To Improve of layout.
 Improvement in the use of men, materials and
machines.
 Economy in human effort and reduction of
unnecessary fatigue.
 Development of better working environment.

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 Procedure to accomplish method study, called "SREDIM" shall be
as follow:-
 Select: job or operation that needs improvement.
 Record: all facts, how work is done by chart methods.
 Examine: every aspect of the job by asking; what, why, where,
when, who and how.
 Develop: review ideas, eliminate, simplify, combine, re-arrange,
make new method which more safe, chart new method, submit
for approval.
 Install: the new method, consider best time to introduce,
convince all, train users.
 Maintain: check frequently, match results, correct deviations.

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 Select
Record

Examin
e
OK
?

Develop
Install
Maintain
January 31, 2021 54
 A flow process chart is a chart of all the activities involved in a
process.
1. Transportations

2. Delays
3. Operations

4. Inspections,
5. and Storages
 Use of various symbols in chart to show the sequence of work..
 The distances and time may also be noted in chart .
 Operation duration (time to complete)
 Distance traveled (for transport operations)

Flow process charts are of three types

(a) Man-type (b) Material-type (c) Equipment-type
Lab # 6: Method Study January 31, 2021 55
Operation Delay

Transportation Storage

Inspection

Lab # 6: Method Study January 31, 2021 56

 Operation
 Occurs when an object is intentionally changed in one or
more of its characteristics.
 Usually occurs at a machine or a work station.
 Drilling, machining, welding, Painting, Data Entry, Cutting,
Sorting, etc

 Occurs when an object is moved from one place to another.

 except when the movement is part of an operation or an
inspection
 Using elevator, carrying, moving with material handling
devices
57
 Delay
 Occurs when the immediate performance or the next
planned action does not take place
 Work In Process inventory waiting to be processed,
Employee waiting for an elevator, Waiting for accumulation
of a certain quantity for packaging
Inspection
 Occurs when an object is examined for identification or is
compared with a standard as to quantify or quality
 Examine the quantity or quality, read steam gauge on boiler,
detect the defectives

Lab # 6: Method Study January 31, 2021 58

 Storage
 Occurs when an object is kept under control such that its
withdrawal requires authorization
 Bulk storage of raw material, finished products inventory,
archived documents

Operation and Inspection

Two symbols may be combined when two activities are

performed concurrently.

Lab # 6: Method Study January 31, 2021 59

Man Type Flow Process Chart records the activities of an operator, i.e., what an
operator does.

• Type of activities and their repetitions are recorded.

• Distance travelled by the man is recorded.
• Time taken in various activities may be recorded.

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Material Type Process Chart
records what happens to the
material, i.e., the changes the
material undergoes in location or
condition.

• Type of activities and their

repetitions are recorded.
• Distance travelled by the
material is recorded.
• Time taken in various activities
may be recorded.

Equipment type process chart

records the manner in which the
equipment is used. In the similar
manner to man and material
type, this chart can be made.

61
 A Flow Diagram is a drawing or a diagram which is
drawn to scale.

 It shows the relative position of production machinery,

jigs, fixtures, gangway, etc., and marks the paths
followed by men (workers) and materials.

 Flow Process charts indicate the sequence of events,

they do not illustrate the movements of men, material,
etc., while the work is being accomplished.

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 The number of movements if minimized, result in a lot of saving
both in cost as well as efforts required to do a job.

 The path of movement (ie., the movement between two locations

and the number of times a movement is repeated) can be better
visualised by drawing a flow diagram.

Steps involved in drawing a flow diagram:

(1) Draw to scale the plan (Top-View) of the work area.
(2) Mark the relative positions of machine tools, benches, store,
racks, inspection booths, etc.
(3) From the different observations, draw the actual (path)
movements of the material or the worker on the diagram and
indicate the direction of movement.
(4) Different movements can be marked in different colours (for
better understanding). Process symbols may also be added on to
the diagram.

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 Below figure shows a simple flow diagram, in which, raw material
from the store moves to station A where an operation is performed,
the semi-finished product is sent to place B where another
operation is carried out, then it moves to place C for inspection, is
further sent to bench D, where it halts for a short while and
ultimately goes out of the factory.

Top-View
of Factory

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