Lecture 1

Introduction to the course and the grading criteria

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Examples From the Following Companies Will Be Discussed in the Class.

Dana Corp., Eaton Corp., Emerson Electric, Fedders, Jostens, Lennox Industries, Maytag, Miller Brewing co., W L Gore, Weyerhaeuser Co, Becton-Dickinson, Heatcraft, Cooper Lighting, Woodstream Corp., Thomas Industries Inc., Toastmaster, Engelhard Corp., Dupont Photomasks, Cardinal IG, Lucas Novasensor, Engineered Fabrics, Indy Lighting, Medeco Security Locks, Nordyne, Monroe Auto Equipment Co, Rexnord Corp, Osram Sylvania, Phillips Display Components, Signet Systems, Mueller Co., Southwest Mobile & Systems, Technotrim, The Metalloy Corp, Z F Industries Inc., Rubbermaid Commercial Products, Pella Corporation, Modine Manufacturing Co, Kraft Foods, Kellogg's, Harley Davidson, Georgia Pacific, Frigidaire Home Products, Berwick Industries.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Today s discussion
1) Critical issues in the marketplace 2) Role of IE s, ME s & HFE s in the industry 3) How will this course help BME s 4) Grading criteria for in-class students 5) Grading criteria for distance students
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Critical issues in the marketplace

Workers Compensation costs Health & Safety issues Employee productivity Injuries such as back pain, Carpal tunnel syndrome etc. Morale in the workplace Occupational stress & its effects on: absenteeism's turnovers eye strain wrist/shoulder pain
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Role of Industrial Engineers in today s economy

IEs are being eliminated due to downsizing, lean management approach, & employee empowerment. Loss of union plants & time-study needs. Typical role of IE s such as line balancing, layouts, methods improvements, workstation design is being incorporated into ME s job. Emphasis is changing from labor efficiency to JIT, Continuous Improvement & waste elimination. Many companies are taking non-degreed employees & sending them for time-study training to maintain labor standards & methods improvement.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Potential of Manufacturing Engineers in today s environment

Manufacturing and Process Engineers are becoming very important in today s environment. Very few universities have courses in practical Manufacturing and Process Engineering. Manufacturing Engineer = IE + Ergonomics Many companies are hiring IEs and training them to become Manufacturing and Process Engineers Ergonomics education & training will help IE s improve their potential for good jobs & benefits. Ergonomics will give IE s an edge over Copyright 2002 with work Wright State University traditional ME s by Dr. Govind Bharwani,experience.

Weakness of Manufacturing Engineers

Lack of understanding of Ergonomics is causing problems to ME s in today s environment of JIT & Continuous productivity improvement approach. Many companies are seeing this weakness and are providing ergonomics training to ME s. There is a major effort in manufacturing to improve safety, reduce injuries & reduce Workers Comp. costs which is foreign to traditional ME s. Traditional ME s role has been in capital investment & automation without regards to Ergonomics. Many companies are demanding ergonomics application in the design of equipment's, workstations, hand-tools & methods of operation.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Role of Human Factors Engineers in today s environment

Very few industrial & manufacturing companies understand the role of Human Factors Engineers. Human Factors is being utilized more effectively in Aerospace, Defense & Operations Research. Understanding of Ergonomics will enhance the opportunities for Human Factors Engineer in industrial as well as office environment. Please note, that there is no job as Ergonomics Engineer . It must be complemented with Engineering position such as HFE w/ergonomics.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

How can Ergonomics help Biomedical Engineers?

Designing instrumentation & devices for medical care. Developing health & safety procedures to improve productivity. Reducing Workers Comp. cost & back injuries during patient care. Working with vendors to incorporate ergonomics during the installation of medical equipment. Applying ergonomic techniques in bioinstrumentation, biomechanics, clinical engineering & rehabilitation engineering. Establishing performance testing & maintenance of medical equipment.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

What causes frustration in first manufacturing jobs?

Many newly hired Engineers get frustrated during the first two years of their job. The turnover rate is very high during the first two years of a new job. The reason for this turnover is that Engineers do not understand the real manufacturing environment, expectations & challenges. Many Engineers are analytically strong & look at issues as black & white. In real world most issues are gray. This course will help you understand the real Industrial environment through case studies and video films.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading criteria for the course

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Course grade
A = 90 100% B = 80 89% C = 70 79% D = 60 69% F < 60%
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Tips to Get A in This Class

Since it will be an open book test, make sure that you understand the options and high priority items. Read the chapter & lecture notes before coming to the class Take good notes in the class & identify high priority items. Participate in the class discussions & case studies. In-class grade will be based on the participation (not on right or wrong answers only) Midterm and Final exams will include problem solving and ability to select course of action from various alternatives. Lecture notes can be downloaded from WebCT.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Key points to remember in the class

Always correlate your solutions to key objectives of the plant such as productivity improvement, Workers Compensation cost reduction, reduced absenteeism, improved efficiency, reduced inventory, manufacturing cost reduction etc. You will be judged on your selection criteria and how you can explain that selection. This course will emphasize team concept and team interaction through in-class problems

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading criteria for in-class students

Copyright 2002 by Dr. Govind Bharwani, Wright State University

In-class grading criteria

In-class discussions In-class case studies Term Paper Midterm exam Team lab project Final exam (in-class) 10% 15% 5% 25% 20% 25%

Copyright 2002 by Dr. Govind Bharwani, Wright State University

In class discussions (10%)

Surprise questions from the book Bonus questions from the book Read the chapter before coming to the class Participate & ask questions Grades will be more for participation rather than correct answers initially.

Copyright 2002 by Dr. Govind Bharwani, Wright State University

In-class case studies Group and individual

20%
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading for group case studies

Grading will be based on the quality of answer as well as group dynamics. All team members will get the same grade. Group interaction will be critical for your grade. It is the group s responsibility to create the environment where every team member is able to participate effectively. Group case study will take place in the class under my observation.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading criteria for individual case-studies

1. Basic mistakes -2 points 2. Major mistakes -3 or -4 points Major mistakes: Mistakes occurred after case-study feedbacks. Answering more questions than asked. Overlooking the case-study instructions Case study feedback will be given in the class

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Team lab project (20%)

Details of the ergonomics lab project will be given later in the class

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Midterm exam (25%) and Final Exam (25%)

Midterm exam will be from lectures 1-9. Final exam will be from lectures 10-16. Both exams will be open book & open notes. Do not answer more than what is required. It will be in-class exams. The questions will be in the same sequence as the lectures in the course outline.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading criteria for distance students

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Grading criteria for distance students

Four case studies Case study #1 Case study #2 Case study #3 Case study #4 Midterm exam Final exam Term paper 30% lectures 1-5 lectures 6-9 lectures 10-13 lectures 14-17 25% 25% 20%

Please note: Due to copyright protection, the video films will only be shown to in-class students. No questions will be asked to distance students from the films.
Copyright 2002 by Dr. Govind Bharwani, Wright State University

Lecture notes and lecture video recordings will be posted on pilot.wright.edu. The in-class presentations will be posted within 3 business days.

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Distance assignments
You will receive all your case studies by email with due dates. You will submit your assignment by email to me. The graded hard copy of your assignments will be mailed to you by US Postal Service. The feedback on the assignments will be discussed in the class. Please note that the case studies for in-class Students will be different from the case studies for Distance Students.

Copyright 2002 by Dr. Govind Bharwani, Wright State University

Good luck in the course

Copyright 2002 by Dr. Govind Bharwani, Wright State University