Part 1 History and Perspective of Industrial Engineering 1
1 HISTORY OF ENGINEERING AND DEVELOPMENT OF INDUSTRIAL ENGINEERING 1
1.1．Introduction 1
1.2．Early Developments 2
1.3．The Modern Era 3
1.4．The Engineering Process 5
1.5．Engineering as a Profession 6
1.6．Professional Ethics 8
1.7．Professional Licensing 8
1.8．Engineering Education and ABET Accreditation 10
1.9．Chronology of Industrial Engineering 12
1.10．Industrial Engineering Organizations 15
Contents 17
PREFACE 17
1.11．Definition of Industrial Engineering 18
1.12．Industrial Engineering Education 18
1.13．Impact of Related Developments 19
1.13.1 Impact of Operations Research 19
1.13.2 Impact of Digital Computers 20
1.13.3 Emergence of Service Industries 21
1.14．Relationship to Other Engineering Disciplines 21
1.15．Challenges of the Future 23
2.1．Introduction 25
2 INDUSTRIAL AND SYSTEMS ENGINEERING 25
2.2．Industrial and Systems Engineering Design 26
2.2.1 Human Activity System 26
2.2.2 Management Control System 26
2.3．Typical I. S.E.Activities 28
2.3.1 Production Operations 28
2.3.2 Management Systems 30
2.3.3 Corporate Services 31
2.4．Relationship to Total Organization 33
2.5．Internal Organization of the I. S.E. Function 36
2.6．Effectiveness Measures for the I. S.E. Function 36
2.7．The Nature of“Systems” 36
2.7.1 Definitions 37
2.7.2 System Classifications 38
2.8．Feedback Control in Systems 38
Part 2 Industrial and Systems Engineering Methodologies 43
3 MANUFACTURING ENGINEERING 43
3.1．Introduction 43
3.2．Product-Production Design Interaction 44
3.3．Process Engineering 45
3.3.1 Defining Product Structure and Specifications 45
3.3.2 Assessing Manufacturability 48
3.3.3 Determining Processes Capable of Producing the Part 48
3.3.4 Evaluating the Cost of Each Process 50
3.3.6 Documenting the Process 55
3.3.5 Determining the Sequence of Operations 55
3.4．Industrial Processes 56
3.4.1 Refining and Alloying 56
3.4.2 Casting 58
3.4.3 Metal Forming 59
3.4.4 Metal Cutting 60
3.4.5 Welding 64
3.4.6 Assembly 67
3.4.7 Finishing 67
3.5．Ancillary Functions 68
3.5.1 Tool,Jig,and Fixture Design 68
3.5.2 Cost Estimating 70
3.5.3 Maintenance Systems Design 71
3.5.4 Packaging Systems 72
3.6．Example 73
3.7．Computer Applications 73
4 FACILITIES LOCATION AND LAYOUT 80
4.1．Introduction to Facilities Location 80
4.2．Considerations 81
4.3．Analytical Techniques 83
4.3.1 Transportation Method of Linear Programming 84
4.3.2 Multiple Objectives 88
4.3.3 Mathematical Programming(Optional) 89
4.3.4 Public-Sector Location Problems 96
4.4．Introduction to Facilities Layout 99
4.5．General Considerations 102
4.6．Systematic Layout Planning 102
4.7．Computerized Layout Planning(Optional) 113
4.8．Impact of Computers 118
5 MATERIAL HANDLING,DISTRIBUTION,AND ROUTING 125
5.1．Introduction 125
5.2．Material Handling 126
5.2.1 Equipment Concepts 127
5.2.2 Principles of Material Handling 131
5.2.3 Quantitative Techniques 134
5.3.2 Operations Management—Routing 137
5.3.1 Warehouse Location 137
5.3．Distribution 137
5.3.3 Routing in the Public Sector 145
6 WORK DESIGN AND ORGANIZATIONAL PERFORMANCE—WORK MEASUREMENT 151
6.1．Introduction 151
6.2．Methods Improvement 154
6.2.1 Flow Process Charts 155
6.2.2 Left-Hand-Right-Hand Charts 156
6.2.3 Other Charts 160
6.2.4 Principles of Motion Economy 163
6.2.5 Human Engineering 164
6.3．Work Measurement 165
6.3.1 Direct Time Study 167
6.3.2 Time Study Standard Data 171
6.3.3 Predetermined Times 173
6.3.4 Predetermined time Standard Data 174
6.3.5 Work Sampling 174
6.4．Organizational System Performance Measurement 175
6.4.1 Productivity Measurement Basics 175
6.4.2 Normative Productivity Measurement Model 176
6.4.3 Multifactor Productivity Measurement Model 178
6.5．Computers and Work Measurement and Design 178
7 OPERATIONS PLANNING AND CONTROL 183
7.1．Introduction 183
7.2.1 Demand Forecasting (Ⅰ) 184
7.2．Overview of Operations Planning and Control 184
7.2.2 Operations Planning (Ⅱ) 186
7.2.3 Inventory Planning and Control (Ⅲ) 187
7.2.4 Operations Scheduling (Ⅳ) 188
7.2.5 Dispatching and Progress Control (Ⅴ) 188
7.2.6 Interfaces 189
7.2.7 Integrating the Functions 190
7.3．Techniques for Demand Forecasting 190
7.3.1 Moving Average 190
7.3.2 Exponentially Weighted Moving Average 191
7.3.3 Regression Analysis 192
7.4．Techniques for Operations Planning 194
7.5．Techniques for Inventory Planning and Control 197
7.6．Techniques for Operations Scheduling 200
7.6.1 Purpose of Operations Scheduling 201
7.7．Dispatching and Progress Control 203
7.8．MRP Systems 203
7.9．Just-in-Time Manufacturing 207
8 QUALITY CONTROL 212
8.1．Introduction 212
8.2．A Bit of History 213
8.3．The Malcolm Baldrige National Quality Award 213
8.4．Deming's Thoughts on Continuous Improvement 216
8.5．Juran's Contributions to Quality Thought 217
8.6．Tools for On-line vs.Off-line Quality Control 218
8.7．Quality Function Deployment 218
8.8．Quality Cost Systems 220
8.9．Benchmarking 221
8.10．Tools of Statistical Process Control 223
8.10.1 Flowchart 223
8.10.2 Cause-and-Effect Diagram 226
8.10.3 Data Collection Form 227
8.10.4 Pareto Analysis 228
8.10.5 Histogram 230
8.10.6 Scatter Plot 232
8.10.7 Designed Experimentation 233
8.11．Background on Control Charts 234
8.12．Control Charts for Variables 236
8.13．Sensitivity Checks for Control Charts 241
8.14．Process Capability Analysis 241
8.15．Control Charts for Attributes 243
8.15.1 The P Control Chart 243
8.15.2 The c Control Chart 244
9 FINANCIAL COMPENSATION 252
9.1．Introduction 252
9.2．Job Analysis 253
9.3．Job Evaluation 254
9.3.2 Classification or Grade Description 256
9.3.1 Ranking Method of Job Evaluation 256
9.3.3 Factor Comparison 257
9.3.4 Point Rating 259
9.4．Wage Surveys 262
9.5．Wage Payment 266
9.5.1 Daywork 267
9.5.2 Measured Daywork 267
9.5.3 Piecework Incentive 267
9.5.4 Standard Hour 268
9.5.5 Group Plans 269
10.1.1 A Brief History of Manufacturing 275
10.1．The Second Industrial Revolution 275
10 CAD/CAM,ROBOTICS,AND AUTOMATION 275
10.1.2 Impact of Computers and Electronics 277
10.1.3 Other Recent Developments 277
10.1.4 The Factory of the Future 278
10.2．Computer-Aided Design 279
10.2.1 Computers in Product Design 279
10.2.2 Computers in Process Design 280
10.2.3 Computers in Electronics Design 281
10.3．Computer-Aided Manufacturing 282
10.3.1 Computer-Aided Process Planning 282
10.3.2 Numerical Control 283
10.3.3 The Concepts of Group Technology 285
10.3.4 Automated Storage,Retrieval,and Handling 286
10.3.5 Computer-Aided Testing and Inspection 288
10.3.6 Computer-Aided Factory Management 290
10.3.7 The Concepts of Flexible Manufacturing Systems 290
10.4．Robotics 291
10.4.1 Definition and Basic Concepts 293
10.4.2 Physical and Technical Aspects of Robots 293
10.4.3 Robotic Applications 295
10.5．Automation 296
10.6．The Promise of CIM 297
10.7．Opportunities for I.E.'s 298
11.1．Perspective 301
11 HUMAN FACTORS 301
11.2．Physiological Aspects of Human Performance 302
11.3．Psychological Aspects of Human Activities 304
11.4．Human Interface with the World of Work 305
11.4.1 Human Interface with the Work Environment 306
11.4.2 Human Interface with Machines 307
11.4.3 Human Interface with Information/Communication Systems 308
11.4.4 Human Interface with Organizationall Supervisory Structure 308
11.4.5 Human Interface with Robots and Intelligent Machines 309
12.1．Introduction 312
12.1.1 Energy Management 312
12 RESOURCE MANAGEMENT 312
12.1.2 Water Management 313
12.1.3 Hazardous Material Management 313
12.1.4 This Chapter 314
12.2．Energy Management 314
12.2.1 Why Bother? 315
12.2.2 Why Industrial Engineering? 315
12.2.3 Required Ingredients 315
12.2.4 Understanding Rate Schedules 316
12.2.5 Alternate Rate Schedules 319
12.2.6 Energy Management Opportunities 319
12.3．Water Management 322
12.4.1 Government Regulations 324
12.4．Hazardous Material Management 324
12.4.2 The Role of Industrial Engineering 325
12.5．Summary 327
13 FINANCIAL MANAGEMENT AND ENGINEERING ECONOMY 329
13.1．Introduction 329
13.2．Accounting 330
13.3．Cost Accounting 333
13.4．Engineering Economy 336
13.5．Interest Factors 337
13.5.1 Single-Payment Compound Amount Factor 338
13.5.2 Other Interest Factors 339
13.5.3 Examples 341
13.6．Back to Gadgets—Present Worth Calculations 343
13.7．Impact of the Computer on Accounting and Engineering Economy 345
14 DETERMINISTIC OPERATIONS RESEARCH 349
14.1．Introduction—Definition 349
14.2．Similarity to Industrial Engineering 350
14.3．Nature of Operations Research 351
14.3.1 Economic Order Quantity 351
14.3.2 Plant Location 351
14 3.3 Job Evaluation 352
14.3.4 Quality Control 352
14.3.5 Others 352
14.4．Categorization of Operations Research 352
14.4.2 Probabilistic Approach 353
14.4.1 Deterministic Approach 353
14.6．Mathematical Programming 354
14.5．Deterministic Operations Research 354
14.7．Unconstrained Optimization 355
14.8．Linear Programming 362
14.8.1 Assignment Problem 367
14.8.2 Transportation Problem 369
14.9．Other Techniques 372
14.9.1 Nonlinear Programming 372
14.9.5 Geometric Programming 373
14.10．Impact of Computers 373
14.9.6 Other Programming 373
14.9.4 Quadratic Programming 373
14.9.3 Zero-One Programming 373
14.9.2 Integer Programming 373
15 PROBABILISTIC MODELS 378
15.1．Introduction 378
15.2．Queueing Theory 378
15.2.1 Queueing System Structure 379
15.2.2 Queueing Notation 380
15.2.3 Single-Service Channel 381
15.3．Inventory Control 384
15 3.1 Single-Period Model—No Setup Cost 384
15.3.2 Lot Size-Reorder Point Models 387
15.3.3 Periodic Review Models 388
15.4．Markov Chains 389
15.4.1 Regular Markov Chains 390
15.4.2 Absorbing Markov Chains 392
15.5．Impact of Statistics and Computers 393
16 SIMULATION 396
16.1．Introduction 396
16.2．Simulation Examples 397
16.3．Random Number Generation 403
16.4．Time-Flow Mechanism 407
16.5．Simulation Languages 407
17.1．Introduction 411
17 PROJECT MANAGEMENT 411
17.2．Project Planning Networks 413
17.3．Critical Path Method 415
17.3.1 Forward Pass 417
17.3.2 Backward Pass 417
17.3.3 Total Activity Slack 419
17.3.4 Critical Path 419
17.4．Program Evaluation and Review Technique 419
17.5．Time-Cost Trade-offs 424
17.6．Resource Leveling 429
18.1．Introduction 432
18 SYSTEMS CONCEPTS 432
Part 3 Integrated Systems Design 432
18.2．Introduction to Systems Thinking 433
18.2.1 Origin ofSystems Thinking 433
18.2.2 Hierarchical Nature of Systems 434
18.3．Definitions and Terminology 436
18.4．Systems Engineering 440
18.4.1 Systems Analysis and Design 440
18.4.2 The Systems Design Process 440
18.5．System Representation 442
18.5.1 Block Diagrams 442
18.5.2 Transfer Functions 443
19.1．Introduction and Perspective 448
19 MANAGEMENT SYSTEMS DESIGN 448
19.2．A Systems View of an Organization 449
19.2.1 Gaining a Perspective 449
19.2.2 Finding a Starting Point 450
19.2.3 Universal Outcome Goals 452
19.2.4 Determining Goals and Objectives 453
19.2.5 A Unified Framework 454
19.3．Organization Design 456
19.3.1 Specification of Objectives 458
19.3.2 Determination of Functions 459
19.3.3 Grouping the Functions 459
19.3.6 Management Controls 460
19.3.4 Functional Objectives 460
19.3.5 Job Descriptions 460
19.3.7 Organization Design Is Continuous and Dynamic 461
19.3.8 Organization Structures 461
19.3.9 Coordination within the Organization 462
19.3.10 Keeping the Design Current 463
19.4．Providing Management Controls 463
19.5．The Organization Life Cycle 464
19.5.1 Life Cycle Stages of an Organization 464
19.5.2 Organizational Renewal and Redesign 465
19.5.3 The Learning Organization 466
20.1．Perspective 469
20 COMPUTERS AND INFORMATION SYSTEMS 469
20.2．Basic Concepts of Information Systems 470
20.3．The Process of Designing Information Systems 472
20.3.1 Feasibility Study 472
20.3.2 Systems Analysis 472
20.3.3 General Systems Design 474
20.3.4 Systems Evaluation and Justification 474
20 3.5 Detail Systems Design 475
20.3.6 Systems Implementation 475
20.3.7 Systems Operation and Maintenance 476
20.4．Data-Base Management Systems 476
20.5．Data Communications Networks 479
21 PERSONNEL MANAGEMENT 483
21.1．Introduction 483
21.2．Selection,Testing,and Placement 484
21.3．Performance Appraisal,Training,Education,and Promotions 486
21.4．Job Analysis and Description 490
21.5．Labor Relations 490
21.6．Safety Programs 492
21.7．Benefits and Services 493
21.8．Motivation,Supervision,and Communications 494
20.8.1 Motivation 494
20.8.2 Supervision 496
20.8 3 Communications 497
21.9．Engineering Management 498
Appendices 501
A PROBABITITY AND STATISTICS 501
A.1．Introduction 501
A.2．Basic Probability Theory 502
A.2.1 Sample Space 502
A.2.2 Events 502
A.2.3 Probability of an Event 503
A.2.4 Rules of Operation 503
A.2.5 Combinations 504
A.3．Random Variables 505
A.4．Estimating Probabilities 506
A.5．Some Important Probability Distributions 508
A.5.1 Discrete Distribution Properties 509
A.5.2 Binomial Distribution 509
A.5.3 Poisson Distribution 511
A.5.4 Uniform Distribution 513
A.5.5 Continuous Distribution Properties 514
A.5.6 Normal Distribution 514
A.5.7 Exponential Distribution 516
A.5.8 Rectangular Distribution 516
A.5.9 Distribution Summary 517
A.6.2 Variance 518
A.6.1 Mean 518
A.6．Expected Values and Variability 518
A.7．Populations and Samples 520
A.7.1 Population 520
A.7.2 Sample 521
A.7.3 Sample Statistics 521
A.7.4 Distribution of Sample Means 522
A.8．Central Limit Theorem 523
B TABLES 527
Table B.1．Poisson Distribution—Cumulative 528
Table B.2．Normal Distribution—Cumulative 531
INDEX 533