INTRODUCTION TO INDUSTRIAL ENGINEERING

- Process Engineering
- Optimize the productivity of man and machine systems and processes.
- Optimizing is the core of IE
- You need to be able to quantify
- W. Edward Deming “Without data you’re just another person with an opinion”
- The whole world: systems (noun) or processes (verb)
- Learn from Japanese (how they organize things)

Five Quadrants

1. Process Improvement
a. Bottom left
2. Manufacturing/ Process Industries
a. Bottom right
3. Operational and IT Systems
a. Top left
4. Management Applications
a. Top right
5. Analysis and Optimization
i. Operations research
ii. Statistics/ Forecasting
iii. Simulation

Project 2022

1. Get Data
2. Do the Calculations
3. Do the Figures
4. Do the Cost

Top Topics

- TRACK R1: Disruptive technology in the insurance sector (Research, literature, design a poster)

- TRACK R5: A dummy’s guide to data cleaning (Research literature, design a poster)

- TRACK I1: Improve the layout of [a workplace] (Practical project - mapcurrent state, analyse,
improve, map future state)
- TRACK I2: Improve the flow of work through [a system] (Practical project - map current state,
analyze, improve, map future state)
 History of Industrial Engineering

- Developed from:
1. Basic IE
2. Analysis and Optimization (analytics)
3. Operational Systems (computer systems)
4. Manufacturing and Processing
5. Management Applications

- Started in 1910
o Past the Anglo-world war
o 70’s
o 250 years ago
- A machine can do more work than a human
o Most significant machine: Steam Engine
 Provided a source of power to operate machines
- Development of standards (basis of repetitiveness)
o Standard gauging systems
 Lowered custom goods & increased factories
- Management theory: no progress
o Enlightened and more systematic approach management needed
- Fredrick Taylor:
o Father of Scientific Management
o Best way to perform a job
- Henry Gantt:
o Motivate people (nonmonetary awards)
o System for scheduling (visual- show charts)
- Henry Ford:
o First assembly line
o Not an IE
- The Gilbreths:
o The root of IE (by Prof Paul Kruger)
o Frank & Lillian (mother and father of IE)
o Made significant and innovative contributions to science
 Motion study
 Scientific management
 Ergonomics
 Human factors
 Continuous Improvement
 Psychology
 Therbligs
 18 fundamental motions of the hand (standard)
Frank’s Story
- Studied at Massachusetts Institute of Lilian’s Story
Technology
- Improved Bricklayers. - Interested in music & poetry
o Previously had different methods - Enrolled at the University of California
o Method: o Against parent’s wishes
 Eliminated unnecessary o Majored in:
motion  English
 Decreased from  Foreign languages
18 to 4  Philosophy
 Increased productivity
o Become a teacher
 Scaffold received:
 Shelf – for bricks
- Enrolled at the University of Berkley
 Mortar – no o First woman to make the
longer had to graduation speech
bend to pick up a - University of Purdue’s Engineering
brick School
- Consulting Firm o First female professor (70)
o After marrying Lillian - Became a full professor in 1953
o Equal partners - 22 honorary degrees
- Surgical nurse
o Princeton
o Caddy
o Brown
 Passing surgical
instruments to the o Michigan
surgeon - Working with General Electric
- Used IE tools o Good Kitchen design
o Activity charts  Best height for kitchen
o Work chart appliances
o Process charts o Invented:
 foot pedal dustbin
 shelves inside a
refrigerator (egg
holder)
- integrated psychology into concepts of
Industrial management
- Advisor:
o Hoover
o Roosevelt
o Elsenhower
o Kennedy
o Johnson

 Civil defense
 War production
 Rehabilitation of the
physically handicapped
- Died peacefully (94)

- Formidable team

- Difference between Taylor

o More concerned about the worker’s welfare than Taylorism

 Aimed to achieve higher productivity without negatively affecting working
conditions
 Make more profit
 Making the job easier for the worker
o Taylorism: increase profit at the worker’s expense
 The Human Relations Movement

- Emphasizes: importance of the human element in job design

- Gilbreths focused on the human factor in work.

Hawthorne Effect

- Elton Mayo (1930)

o Conducted studies at the Hawthorne division of Western electric
- Abraham Maslow (1940)
o Motivational theories
o Frederick Hertzberg refined (1950)

- Telephone
o Everyone should have one in their house
o Two groups (scientific experiment)
 One: control
 Two: experiments: to improve productivity
o Improved the lighting in the room (visibility)
o Improved the layout (better chairs & desks)
 Elton Mayo: Improve the working conditions of the worker and the
productivity will improve
o Decreased the lighting
o Downgraded the layout
 Production improved
 Due to the attention and care
 Felt special

- Definition: psychological phenomenon that produces an improvement in human behavior or

performance as a result of increased attention from superiors, clients or colleagues. In a
collaborative effort, the effect can enhance results by creating a sense of teamwork and
common purpose.
- Financial reward: less conducive to worker productivity
- Management valuing workers made them feel valued and aware that their concerns were taken
seriously (greater productivity.
 Decision Model and Management Science

- Application of statistics to processes

- During World War II

- Operations Research

o U-boats
o Battle of the Pacific
 How much protection should a plane have against an attacking cannon
 Added extra steel where the most bullets hit
 Missing population problem
 Planes with the most holes didn’t come back

The influence of Japanese Manufactures

- W. Edwards Deming
- Joseph Juran
- Japanese took manufacturing to the next level
o Toyota
- Eliyahu M. Goldratt
o Top twenty management books
- Prof Kris Adenhoff
o Bsc Electrical engineering
o Brought IE to SA
o Developed IE in SA