Introduction to Industrial Engineering

Define station time as the time to finish at a station and cycle time as the maximum station time; cycle time must exceed the largest station time in land balancing.

Explore key line balancing formulas, including line efficiency, balance delay, and smoothing index. Learn how zero smoothing index yields a perfectly balanced line and how efficiency relates to capacity.

Compute line efficiency as 0.8 (48 over 10×6), with a 20% balance delay and smoothing index 6; car wash needs five stalls for 60 cars per hour.

Apply work study to identify the optimal method and time, enabling smooth production, reducing waste, cutting costs, improving conditions, and establishing standard times for manpower and production planning.

Explore the four chart types—operation process, flow process, multiple activity, and simultaneous motion charts—and learn how they record movements of people, materials, and equipment on a common time scale.

Explore two diagram types: floor diagrams showing parts, materials, and equipment on a factory scale model, and string diagrams mapping movements on a time-scale model to study movement density.

Establish standard times for a skilled worker by measuring time. Compute normal time as the mean time multiplied by the rating factor, then add allowances and study work sampling.

Learn how random work sampling replaces continuous observation in stopwatch time studies to yield more realistic time estimates and improved data quality.

This lecture applies work study to numerical problems, deriving standard time from normal time and allowances, using observed times and rating factors to calculate the eight-hour production rate.

Explore four plant layouts—line (product), functional (process), fixed-position, and cellular (group technology)—and their trade-offs in mass production, just-in-time systems, and production planning.

Lean manufacturing is an operational system that maximizes value by reducing diverse activities in a value stream, classifies activities into production, inventory, motion, over-processing, and transportation, and uses just-in-time production.

Calculates kanban quantities for a 200 per hour demand with a 25-unit lot size. Demonstrates production times of 30 minutes and 1 hour in plant layout problems.

Explore production planning and control as the nerve of manufacturing, guiding routing, loading, balancing, scheduling, and dispatch to ensure shop floor operations and integrate aggregate planning with the supply chain.

Explore aggregate planning in the supply chain, balancing capacity, production, inventory, and backlog to meet demand and maximize profit through chase, level, and flexible strategies.

Explore seven quality control tools, including histogram, Pareto analysis, cause-and-effect (fishbone) diagrams, defect concentration diagrams, scatter diagrams, textures, and the control chart.

Examine the two errors in control charts: type I (producer risk) that rejects good lots, and type II (consumer risk) that accepts bad quality.

explore the operating characteristics curve and its link between lot quantity and probability of acceptance, illustrating consumer and producer risks, and control charts in total quality management.

Explore quality circles as voluntary worker groups to improve processes, and examine total quality management as a systematic, top-management driven, customer-focused approach with continuous improvement and poka-yoke, including Six Sigma.

Learn quality function deployment to translate voice of the customer into design specifications and align customer attributes with design, and examine Six Sigma's method to reduce defects per million opportunities.

Explore short-term and long-term process capability and the link between process capability and performance indices within specification limits. Explain bullwhip effect and postponement as ways to align supply with demand.

Explore queuing theory by defining arrival rate as customers per time unit (assumed Poisson) and service rate mu (exponential); queues form only if arrival ≤ service.

Explore customer attitude in queues, covering joking, balking, and reneging, and show how arrival rate versus service rate forms infinite queue formation and finite queue formation.

Explore Kendal notation and its use in queuing models, including probability distributions for the number of servers, service types, and system capacity and calling population.

Explore key queuing theory formulas, including the average utilization factor and the probability of different numbers of customers in the system, and apply Little's law to determine waiting times.

Explore little's law for stable systems: the average number of customers in the system equals the arrival rate times the average waiting time in the system.

Apply the M/M/1 queuing model to solve numerical problems, and compute the average queue waiting time using arrival rate and exponential service times.

Explores reliability by examining how product properties vary from expected working conditions, leading to failure. Identifies catastrophic failure and degradation or creeping failure, including sudden and gradual loss of function.

the bathtub curve shows three failure phases, with failure rate declining early due to initial defects, stabilizing at a low level, then rising during wear-out as aging affects reliability.

Explore key reliability terms: failure rate (lambda), mean time between failures, reliability and failure functions, and the density function, demonstrating how availability and time govern product performance.

We apply exponential reliability modeling to a machine with lambda equal to 1/9000 per hour, computing the probability of breakdown during a 4500-hour warranty using R(t) and F(t).

Explore inventory control techniques, including the ABC 80/20 principle and V-D analysis, and review Harris models, production-ordered inventory, and total inventory models with shortages.

Explore the Wilson Harris model, a model without shortage, to balance total ordering and holding costs and determine the economic order quantity, where ordering cost equals holding cost.

Explore the built-up inventory model in production, derive maximum inventory and production time from production rate and demand, and compute the economic order quantity and total inventory cost.

Explore inventory with shortage, backlog, or back orders by analyzing holding, ordering, and shortage costs to determine the optimal order quantity and total cost.