Introduction to

Industrial Engineering
Code: JQD 20702
Credit Value: 2 (1,1,0)

Hj.Mazlan Awang
Chapter 1
•What is Industrial Engineering ?
•Who is Industrial Engineers ?
•Who’s Who in Industrial Engineering?
•Evolution of Industrial Engineering.
•The Concept of Productivity.
•BPR
•Kaizen Program.
•Techniques of Kaizen.
•Housekeeping 5S
What is Industrial Engineering ?
Who is Industrial Engineers ?

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

What is Industrial Engineering ?
The Accreditation Board for Engineering and Technology defines industrial
engineering as: the profession in which a knowledge of the mathematical
and natural sciences gained by study, experience and practice is applied
with judgment to develop ways to utilize economically, the materials and
forces of nature for the benefit of mankind concerned with the design,
improvement and installation of integrated systems of people, materials,
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 systems

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

What is Industrial Engineering ?
The Accreditation Board for Engineering and Technology defines industrial
engineering as: the profession in which a knowledge of the mathematical
and natural sciences gained by study, experience and practice is applied
with judgment to develop ways to utilize economically, the materials and
forces of nature for the benefit of mankind concerned with the design,
improvement and installation of integrated systems of people, materials,
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 systems

…the branch of engineering that deals with the creation and

management of systems that integrate people, materials,
equipment and energy in productive ways.

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Who is Industrial Engineers ?
The Role and Career of the Industrial Engineers

IEs also known as:

• Manufacturing Engineers
• Management Engineers
• Improvement Engineers
• Process Engineers

•Increased ability to do more with less,

•Making work safer, faster, easier, and more rewarding,
•Reducing the costs associated with new technologies,
•Showing ways to improve the working environments
•To increase the productivity of processes, achieve quality products.
Industrial engineers (IEs) figure out how to do things better !!

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Who’s Who in IE
• Fredrick W.Taylor is the father of IE ..covered topics such as the
organization of work by management, worker selection and training.
• The Gilbreths (Frank & Lillian Gilbreths) .. accredited with the
development of time and motion studies.
• Henry L. Gantt … on topics such as cost, good incentive plans and
scheduling of work. Originator of the Gantt chart.

The Institute of Industrial Engineers (IIE)

is a professional society dedicated solely to
the support of the industrial engineering
profession and individuals involved with
improving quality and productivity

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Evolution of Industrial Engineering..
IEs & Productivity

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Higher Productivity !!!

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 What is Productivity?
The relationship between the output of goods and services
and the inputs of resources used to produce them

A measure of the amount of output per unit of input

Productivity = Output / Input [%]
= Output Allocated time / Input Consumed time

Which chef
having higher
productivity..
Why?

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Productivity Questions

A std time to produce one unit

of calculator is 3 minutes

Q1: If an assembly line of 7 operators produced 1000 units of calculators in a 8-hrs

shift, what is the productivity level of the assembly line?
Q2: If an operator works at 95% productivity level, how many units of calculator
he/she will produce in 10-hrs shift ?
Q3: How many operators are required to staff an assembly line that capable to
produce 2500 units of calculators within 8-hrs shift?

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Q1 : Briefly describe MPC's functions and activities.

Q2: Explain below commonly used Productivity Indicators

A) Added Value per Employee

B) Labour Cost per Employee
C) Added Value per Fixed Assets
D) Fixed Assets per Employee

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©
Productivity
Concept

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Productivity Improvement
through BPR
Business process reengineering (BPR) is an approach aiming at improvements
by means of elevating efficiency and effectiveness of the business process that
exist within and across organizations. The key to BPR is for organizations to look
at their business processes from a "clean slate" perspective and determine how
they can best construct these processes to improve how they conduct business.

• Developed in early 1990s

• Information technology (IT) played an
important role in reengineering concept.
• Successes stories at Dell Incorporated and
Ford Motors. [Inventory //Quality]
• More recently, the concept of Business
Process Management (BPM) -- striving for
process efficiency.

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

BPR examples contributed by
IT development

•Shared databases, making information available at many places

•Expert systems, allowing generalists to perform specialist tasks
•Telecommunication networks, allowing organizations to be centralized
and decentralized at the same time
•Decision-support tools, allowing decision-making to be a part of
everybody's job
•Interactive video conference, to get in immediate contact with customers.
•Automatic identification, scanning and tracking, allowing things to tell
where they are.
•High performance computing/ CAD system, allowing fast planning and
revisioning.

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Continuous Improvement
( KAIZEN )
'change' or 'the action to correct' 'good'

• Japanese philosophy that focuses on continuous improvement.

• Kaizen is based on making little changes on a regular basis.
• Kaizen aims to eliminate waste (Lean Manufacturing)

Kaizen is a system that involves every employee -

from upper management to the cleaning crew.
Everyone is encouraged to come up with small
improvement suggestions on a regular basis. This
is not a once a month or once a year activity. It is
continuous. Japanese companies, such as Toyota
and Canon, a total of 60 to 70 suggestions per
employee per year are written down, shared and
implemented.

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Techniques for activating a
KAIZEN Program
• 5-Key pillars of Kaizen: Quality, Effort, Involvement of all
employees, Willingness to change and Communication.. QEIWC

• 5-Foundation of Kaizen: Team-work, Personal Discipline,

Improved morale, Quality circles, Suggestions for improvement ..
T-DIQS
- Elimination of Waste
•3-Key Factors that support the foundation: - Standardization
- 5S (Housekeeping)

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Relationship between Kaizen’s Elements, Foundations and factors that
support the foundations depict as below..
The 5 Elements
QEIWC

The 5
FOUNDATION
T-DIQS

Factors that support the foundation (ex: sand, stone, soil)

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

 Measures of Kaizen
7 Wastes of Manufacturing

(Defect)
Q: Explain why Waiting
time is considered as
waste in manufacturing

These can be remembered easily by using the acronym "TIM WOOD".

Introduction to Industrial Engineering / JQB20302 / Mazlan2009©

Measures of Kaizen
Housekeeping 5S

-discipline

(Seiri) (Shitsuke)

-cleanliness

(Seiton) (Seiso)

(Seiketsu)
Introduction to Industrial Engineering / JQB20302 / Mazlan2009©