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1. Industrial Engineering
Course Objectives:
1 To introduce the basic role of an industrial engineer starting from the
production
planning to the costing.
2 To have systematic and comprehensive understanding on various
aspects related with industrial engineering such as plant location and
plant layout, production planning and control, scheduling, forecasting,
statistical quality control, total quality management, work study, method
study and work measurement etc and its relevance in the industrial
environment

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Contents
Production Planning and Control (PPC): Introduction to functions of PPC-
Forecasting– Definition and Methods; Routing – Definition and Procedure;
Scheduling – Definitionfactors affecting scheduling- Gantt chart; Dispatching
Definition and orders in dispatching.
Concept of production and productivity, Methods for improving productivity
Types of Production: Mass Production, Batch Production and Job Order Production.
Plant Engineering: Factors for Selection of site of industry; Plant layout; Types;
Process;Product, Fixed position, Combination layout;
Principles of Material handling equipment; Types of material handling equipments –
AGV,forklift truck, cranes, conveyor, hoist (Introduction only)
Plant maintenance: Importance; Bathtub curve; Planned and Condition based
maintenance; Break down maintenance; Preventive maintenance, Predictive
maintenanceand Scheduled maintenance

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functions of PPC- Forecasting– Definition and Methods; Routing – Definition and
Procedure; Scheduling – Definitionfactors affecting scheduling- Gantt chart;
Dispatching Definition and orders in dispatching.
Concept of production and productivity, Methods for improving productivity
Types of Production: Mass Production, Batch Production and Job Order Production.
Plant Engineering: Factors for Selection of site of industry; Plant layout; Types;
Process;Product, Fixed position, Combination layout;
Principles of Material handling equipment; Types of material handling equipments –
AGV,forklift truck, cranes, conveyor, hoist (Introduction only)
Plant maintenance: Importance; Bathtub curve; Planned and Condition based
maintenance; Break down maintenance; Preventive maintenance, Predictive
maintenanceand Scheduled maintenance

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INDUSTRIAL ENGINEERING

Industrial engineering is concerned with design,
improvement and installation of integrated systems
of men, materials, equipment and energy. Main
concern of industrial Engineering is productivity
which implies
More efficient use of resources
Less wastage
Higher level of output for a fixed level of input

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Functions of an Industrial Engineer
1. Establishing the one best way of doing work (standard
method)
2. Establishing the standard time for doing work
3. Developing a sound wage and incentive scheme
4. Preparing a detailed job description and job
specification for each job and
evaluating them
6. Developing cost control Programs
7. Developing an optimal layout for smooth flow of work
8. Make economic analysis and justify their results

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Industry
It is the place where the raw materials are converted or
processed to finished product. Industry coordinates men,
materials, processes, machinery and methods effectively
to get the desired products.
Business is the practice of making one's living or making money by
producing or buying and selling products It is also "any activity or
enterprise entered .

Factory .is a place were two or more persons are working
with machines or more than 20 persons working without
machines ,as a business activity

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PRODUCTION PLANNING AND CONTROL
(PPC)

Production is achieved by transforming the raw material into desired finished
products as per the customer demand. Before starting the actual production
process, we must plan it properly. It is necessary to decide in advance
What to produce?
Where to produce?
When to produce?
Planning decides the means and ways by which the production in best way
be carried out. The control phase take the activities are done as per the
plans and it maintain a planned production. So production planning and control
function involves the planning of various production activities and making them
to happen as per the program.
Principle involved in production planning and control is

‚PLAN YOUR WORK AND THEN WORK YOUR PLAN‛

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Objectives of PPC
To find the demand for a new product
To forecast the demand for an existing
productTo execute in advance the cost of a
new product
To make the route sheet
To prepare the schedules for production
To control labour and material

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Functions of PPC
Preplanning–Forecasting,,Order,writingProduct Design
Planning.........Material, Method, Facility Planning
Routing.............Flow of Work
Scheduling-.......production time Table
Control Functions
Dispatching........authorizing the start of operations
Expediting...........Follow up progress
Inspection.......Ensure Quality

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FORECASTING
It is defined as the type, quantity and quality of future
work. It is a process of predicting in advance for
future work
Methods of Forecasting
Historic Estimate
This technique is based on the assumption that what happens in the past
willhappen in future.ie history repeats itself. For example if a company
sold 3500 fans in last summer, it expects to sell the same 3500 numbers
this year also. This method is simplest and cheapest method of
forecasting

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Trend Line Technique
This is a statistical method. This technique is more accurate than historic
estimate when large data of past sale is available. But this is a time
consuming method.
Sales Force Estimate
This technique is based on the principle that the marketing and sales
personnel know best about future sales. Information is gathered from future sales. Different
sales managers at region level may send their report to the company. This technique is
useful when an industry is making a limited number of products and there are a few large
customers.
Ex: Commercial diesel generator sets.
Co-Relation Technique
Co-relation technique can be used if a relationship between sales and other
product or other economic and non-economic phenomenon exists. For
examplethe sales of a lubricating oil is related to the sale of automobile vehicles.

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Break Even Analysis -It is a tool for finding minimum quantity of product for getting profit

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Routing – Definition and Procedure;
ROUTING

Routing may be defined as the selection of path which each part of the
product will follow while being transformed from raw materials to
finished products. Path of the product will also give sequence of
operation to be adopted while being manufactured.

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; Routing procedure
1. The finished product is analysed and broken into number of components
required for the product
2. Bills of material are prepared from the parts list and decide what is to be
produced in the plant and what is to be purchased from outside
3. Available machine capacities and machine characteristics are find out
4. Necessary operation through which raw materials has to undergone are
listed
5. Path of material is decided.
6. Prepare a route sheet
7. The economic lot size is determined
8. Determine the scrap factors and places where scrap is very likely to occur
are identified. The cost of each production of each component is estimated.

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SCHEDULING

Scheduling determines the starting and completion of various operations in
the manufacture of a product. A production schedule is similar to a railway
time table showing when the product will enter particular process and when
it leaves the same for next operation. On the basis of this the production
timecan be determined.

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Factors affecting schedule

Internal factors
a) Availability of equipment, machinery
b) Availability of material
c) Availability of workers
d) Stock of finished goods in the firm
External factors
a) Customers demand
b) Delivery dates
c) Dealers and retailers inventory

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Master scheduling
It is a weekly or monthly breakup of the production requirements for each
product. Whenever any order is received, it is accommodated first in the
master schedule considering the availability of the machines and labour.
Parts scheduling
It gives the number of units of different parts to be produced for a given
product.it is prepared on the basis of master schedule.
Machine loading scheduling
It gives the information of allocating load for various machines. It is a time
table for the working of various machines. This scheduling is prepared in the
basis of parts schedule

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Gantt chart;

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Gantt chart; Parts scheduling

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Gantt chart;

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DISPATCHING
Dispatching is concerned with getting the work
started. It ensures that plans are properly
implemented. It is the physical handling over of a
manufacturing order to the operating facility or
worker through release of orders.

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–orders in dispatching are Written orders for carry out
activities

Tool orders
Time ticket
Inspection order
Work orders
material release orders
Purchase orders

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Concept of production and productivity,

Production and Productivity
Production is a process developed to transform a set of inputs like
men, materials, money, machinery and energy into a specified set of outputs
like finished products and services in desired quality and quantity
Production is a transformation of some set of inputs into desired outputs. It
is the volume of output irrespective of the quantity and quality of resources
employed to achieve that level of outputs.
Productivity is regarded as efficiency in industrial system.it is the ratio between
outputs to input
Productivity = Output / Input

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Comparison between production and productivity
Production Productivity
Fact Concept
Changed by input Changed by effective utilisation of
resorcess
Refers to Quantity of product Refers to Efficiency of production system
Benefits of higher productivity are
Reduction in cost per unit leading to reduction in price of goods.
Increase in wages
Increase in profits to the company
Better standards of living of people

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Methods of increasing the productivity
by increasing the output for a given input
by right utilization of human resources through motivation and training
by reducing scrap to the maximum extent
by adopting preventive maintenance measures
by using correct tooling and equipment
by providing good working conditions
by adopting latest technology such as automation, robotics etc
by promoting Research and development activities
by providing Incentive schemes

28. .
Types of production
1. Job(Unit) Production
Job production includes production of special products and model products
such as boilers, Turbo Generator, Special design engines etc.
Characteristics ❖ Planning can be done only after the job order is obtained
-
e
❖ product design takes a lot of time
❖ job order for each product is different
❖ highly skilled supervision and high degree of control is required ❖
highly skilled workers are necessary
Advantages ❖ Meets individual requirements
❖ No managerial problems
❖ Flexibility in production with regards to demand

29. .
Types of production
1. Job(Unit) Production
Job production includes production of special products and model products
such as boilers, Turbo Generator, Special design engines etc.
Characteristics ❖ Planning can be done only after the job order is obtained
-
e
❖ product design takes a lot of time
❖ job order for each product is different
❖ highly skilled supervision and high degree of control is required ❖
highly skilled workers are necessary
Advantages ❖ Meets individual requirements
❖ No managerial problems
❖ Flexibility in production with regards to demand


Disadvantages
❖ Raw material cost is slightly high
❖ High labour cost
❖ Production stops if there is no order

30. .
Batch (Intermittent)Production
It consists of production of identical products in batches
of small quantity. But one lot is different from the other. Ex:
manufacture of machine tools, forging press etc.
Characteristics
❖ Products produced in a batch are identical
❖ Division of labour is possible
❖ Common types of production
❖ Flow of material is intermittent
❖ Process layout is well suited
Advantages ❖ Variety of products can be manufactured
❖ It is flexible and easily adaptable to changes in product design ❖ A hold up in one operation does not cause
disruption of others ❖ Well suited for medium scale industries
❖ Investment required for machinery and plant is small
❖ Since the operators handle a variety of jobs there is more job satisfac


Disadvantages
❖ Due to frequent changes in product design
production planning is complex and machine
set-ups need frequent changes.
❖ Optimum machine loading is difficult to achieve
❖ Raw material and work in process inventories are
high

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Continuous Production
In continuous production, manufacturing process goes on regularly throughout
the day continuously. Ex: Textiles, Paper, Chemicals, Cement, Automobiles etc.
Characteristics
❖ Raw material enters at one point and leaves as a finished product at
another end
❖ Modern control techniques can be applied
❖ Good plant maintenance is essential
❖ Skilled and semiskilled labour may be employed
Advantages ❖ Handling of materials is reduced. ❖ Increased production ❖ Better
quality of products ❖ Minimum wastage of material ❖ Cost per unit is less

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Disadvantages ❖ Heavy losses in the event of reduced demand
1
-
e❖ Any disruption in the process flow results in stoppage of all production at all stages leading to huge
losses.
❖ Because of repetitive work nature, workers get bored
Continuous production can be classified into two
⮚ Mass or line production
⮚ Flow or process production
In mass production identical articles are produced in very large quantities using automatic machines
and equipment
Ex: Manufacture of Bolts, Nuts, Automobile parts etc.
In flow production the plant, equipment and machinery and layout are designed to produce the
required product. The arrangement is not flexible. It is normally designed for only one product.
Ex: Cement factory, Paper mill

33. .



MATERIAL HANDILING

Material handling is the art and science of moving, packaging and storing the
material in any form, and includes the preparation, placing and positioning the
material to facilitate their movement or storage
The cost of material handling accounts for 30% to 65% of the total cost of
covering the raw material into finished product. Material handling adds to the
cost of the product. Therefore, reduction in material costs will make the
product more competitive. The material handling system should be so designed
as to maximize efficiency and minimize cost.

34. .



2. Material handling adds to the cost of the product. Try to eliminate
material handling wherever possible
3. Arrange the production sequence and plant layout in such a way that
the material handling is eliminated or reduced
4. Select the proper equipment for movement, loading, unloading and
storage
5. Select the shortest route of material movement
6. Select multipurpose handling equipment wherever possible
7. Make use of gravity based material movement equipment wherever
possible
8. Ensure safety of men, material and equipment during handling
9. Carry out handling cost studies and cost control and cost reduction
methods
10. Carry out preventive maintenance for reducing their down time

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Principle of Material Handling
The word principle can be defined as a prescribed guide to accepted
procedures established through past practice and is accepted as authorities by
practitioners and without which a system would be less effective.
Planning Principle -

System principle - Handling activities ie. Receiving, Storage, in process handling,
inspection, packaging, shipping, transportation be integrated and co-ordinated.

Simplification Principle - Reduce combine or eliminate un necessary movements
of transportation.

Material flow principle - Material flow pattern must be determined by operation
sequence and pattern of equipment arrangement.

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Gravity principle - Utilize gravity wherever is possible
Unit size principle - Increase size, quantity, weight of the load handled. Since
larger the load, lesser the cost per unit handled.
Space utilization principle - Optimum utilization of building space. Utilize height of
building and use rack to permit higher stocking.
Safety principle - safe handling methods and equipment for better working
conditions and to avoid unsafe conditions.
Mechanization principle - For increasing efficiency use mechanized handling
equipment but to the desired extent only.

Flexibility principle - Equipment capable of handling variety of tasks be used.
Equipment selection principle - Select equipment very carefully considering all
aspects of materials, movements and the method
Standardization principle - Standardize equipment as well as methods

Light weight principle - Reduce weight of equipment

Motion principle - The handling equipment should be kept in motion ie. minimum
period for loading, unloading or other idleness
Idle time principle - Reduce idle and unproductive time

Obsolescence principle - Obsolete methods and equipment be replaced by
efficient methods and equipment

Maintenance principle - Preventive maintenance practices be adopted for
handling
equipment

Dept. of ME

Module-1
35
Control principle - Control production and inventory through materials handling
equipment

Capacity principle - Production capacity should be fully achieved
Performance principle - performance of handling be measured in terms of cost
per unit handled, safe working condition, increase in production rate or
reduced manpower for handling