INDUSTRIAL &

SYSTEM ENGINEERING
(MMV 14003)
C1 : INTRODUCTION
By
Ts. Mohd Fairuz Bin Marian
Faculty of Technical and Vocational Education
Sem 2 | 20182019
Syllabus

• INTRODUCTION: (6 Hours)
• Industrial Engineering: Basic Techniques involved.
• Method Study: Need for recording the activities, Symbols used in charting,
various charts, Questioning Technique, Process Improvements, Installation of
Improved Processes.
• Work Measurement: Aim, Time Study, Work / Activity Sampling,
Predetermined Time Standards, computer applications in industrial engineering.
Chronology of IE
§ Charles Babbage visited factories in England and the United States in the
early 1800’s and began a systematic recording of the details involved in
many factory operations.
§ He carefully measured the cost of performing each operation as well as the
time per operation required to manufacture a pound of pins.
§ Babbage presented this information in a table, and demonstrated that
money could be saved by using women and children to perform the lower-
skilled operations.
§ The higher-skilled, higher-paid men need only perform those operations
requiring the higher skill levels.
cont…
§ Frederick W. Taylor is done potential improvements to be gained through analyzing the work content (minimum
amount of work required to accomplish the task) of a job and designing the job for maximum efficiency.

§ Frank B. Gilbreth extended Taylor’s work considerably. Gilbreth’s primary contribution was the identification, analysis
and measurement of fundamental motions involved in performing work.

§ Henry L. Gantt, developed the Gantt chart. The Gantt is a systematic graphical procedure for pre-planning and
scheduling work activities, reviewing progress, and updating the schedule.

§ During the 1920s and 1930s much of fundamental work was done on
• economic aspects of managerial decisions,
• inventory problems,
• incentive plans,
• factory layout problems,
• material handling problems,
• principles of organization.
Definition
§ Fierce Competition in Economy.
§ Customers demands are rising.
§ Challenge for industries to produce goods of right quantity, quality , in
time and at minimum cost.
§ Industrial Engineering plays a pivotal role in meeting these challenges.
§ We have various techniques in Industrial Engineering to analyse and
improve the work methods, to eliminate waste, proper allocation and
utilization of resources.
Definition (cont…)
§ The formal definition of industrial engineering has been adopted by
the Institute of Industrial Engineers (IIE):

“Industrial Engineering is concerned with the design, improvement,

and installation of integrated systems of people, materials,
information, equipment and energy. It draws upon specialized
knowledge and skill in the mathematical, physical, and social
sciences together with the principles and methods of engineering
analysis and design to specify, predict, and evaluate the results to
be obtained from such system”.
Who is IE Engineer?
§ Any fool can devise a process that works, but it takes an industrial
engineer to design one that barely works.

§ Industrial engineers are the duct tape of industry because they are
expected to fix anything for almost nothing.

§ If you mixed together a computer expert, a production manager, and a

financial guru, threw in a heaping portion of salesmanship and a dash of
investigative reporter, marinated it in a rich solution of leadership and
the ability to impact change, and topped it off with a desire to learn and
do whatever it takes, you’d have the recipe for an outstanding industrial
engineer.
Objective of IE
§ The prime objective of industrial engineering is;
1. To increase the productivity.
2. Eliminating waste and non-value added activities.
3. Improving the effective utilization of resources.
Techniques of IE
§ Following tools and techniques are used to improve productivity of the
organization by optimum utilization of resources.
1. Method Study.
2. Time Study (Work Measurement).
3. Motion Economy.
4. Financial and Non Financial Incentives.
5. Value Analysis/Engineering.
6. Production, Planning and Control.
7. Inventory Control.
8. Job Evaluation.
9. Material Handling Analysis.
10. Ergonomics (Human Engineering).
11. System Analysis.
12. Operations Research Techniques.
Position of IE in Organization
Industrial & Systems Engineering

§ An Introduction via Examples.

• What is Industrial Engineering (IE)?
• What is Systems Engineering (SE)?
• An Early and Modern Example about Manufacturing: Car Assembly
• A Modern Example about the Service Industry: Disneyland
• A Modern Example about the truck manufacturing company
• Current Multidisciplinary Research into Efficient and Safer Large-truck
Freight Operations
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!!
Cont…
• 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)
• …..
What is Systems Engineering?
• 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)
 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).
Early Moving Assembly Line at Ford
A Glimpse of a Car Assembly Line
Robots at Work in Car Assembly
Robots at Work in Car Assembly
A Modern Car “Assembly Line”
VW Phaeton in Dresden
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?
 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.!
FastPass
Disneyland – Splash Mountain
FastPass Machine
Disneyland
FastPass Ticket
Disneyland
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
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
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
 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
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
…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
Assignment 1 (video review)
https://www.youtube.com/watch?v=WLxPzarbP8A
https://www.youtube.com/watch?v=_apjVS0ZAPA
https://www.youtube.com/watch?v=wnSz4hIyNVI

• Watch the YouTube links given. Write a report based on instructions

below:
• Observations: what you can understand and experience by watching given videos.
• Thought and lesson learned: What are your thoughts reflect to subject study in
chapter 1. How the videos relates to the dissertation you’d read. How to apply
them?
• Other points (if any).
cont…
• Report Matters
• Report is in English only.
• Margins of 0.5" (for top, bottom, right) and 1" (for left).
• Times New Roman font type, sized 10.
• Infographics presentation is also acceptable.
• 6-8 pages only (exclude cover, table of contents and reference).
• All sources of information must be properly cited in APA style.
• Submission format: Hard and soft copy.
• Deadlines: BEFORE 10th March 2019 (before 1200hrs)
Thank You