A.B.M. Zohrul Kabir Ph.D. (Aston), M.Sc. (BHam), M.Tech (IIT/Kanpur), B.Sc. Engg (BUET) Professor, Mechanical Engineering Dept & Head, REASP Islamic University of Technology Board Bazar, Gazipur
Birth of IE dates back to early 1950s Since then, IE has emerged as an important engg. discipline. In early stage of development, primary focus was in manufacturing Main objective was: achieving maximum productivity, through the design, improvement and installation of integrated systems of human, machine and equipment. Later Stage : With the development of OR, cybernetics, modern control theory and computing power, field of IE expanded dramatically.
To-day, IE knowledge is being applied not only to manufacturing facilities, but also to hospital, consulting firms, sales, government, transportation, i.e virtually all types of industries - manufacturing as well as service).
IE is among the top ranking engineering professions in the developed and fast developing countries (West, Japan, Singapore and even in the Middle East). In B/Desh, IE appeared with the introduction of IPE Dept in BUET in 1981. Now, IPE exists in 5 universities - SUST, KUET, RUET, AUST (Mech & Prod. Engg) The demand for IE graduates is steadily increasing albeit at a much slower rate than expected. Many employers are still unaware of the contributions that IE graduates can make to their industries/organizations. What is IE discipline? What contribution does it make? How various industry or organizations in Bangladesh can benefit from employing IE graduates?
Customer Supplier 1 Supplier 1 Supplier 1 Distribution System Management
Distribution Network Distribution Channel Geographical Location of customer Transportation Management Production Management
Production Planning Production Control Production Scheduling MRP, Aggregate Planning etc. INVENTORY MANAGEMENT When to order How much to order Is the future predictable Supplier Supplier Selection. Limitation Diversification of Supplier.
STAFFING
Planning Hiring/ Firing Selection Procedure Performance Evaluation Reward System Motivation
Leading
Process Design Process Selection Capacity Planning Production System Design (factory Layout) Technology Management Maintenance
M a c h i n e
Financial Management Capital Investment Capital Budgeting Working Capital Cost Control, Standards Cash Flow Management Purchase Salary
Customer Focus QFD, Concurrent Engineering TQM, ISO 9000- 2000 etc. M o n e y
Q u a l i t y
M a n a g e m e n t
Wholesaler
Retailers
L a b o r
M a t e r i a l
Manufacturers
M M M M Product (if no wholesaler and retailer) Product Distribution System Information Flow Material Flow P r i m a r y
C o m p o n e n t s
Demand Forecasting STRATEGIC PLANNING (Expansion, Contraction, Status Quo, Budgeting)
ORGANIZING (Designing of structure)
SYSTEM PERFORMANCE (Productivity, Time Study) Customer Supplier 1 Supplier 1 Supplier 1 Distribution System Management
Distribution Network Distribution Channel Geographical Location of customer Transportation Management Production Management
Production Planning Production Control Production Scheduling MRP, Aggregate Planning etc. INVENTORY MANAGEMENT When to order How much to order Is the future predictable Supplier Supplier Selection. Limitation Diversification of Supplier.
STAFFING
Planning Hiring/ Firing Selection Procedure Performance Evaluation Reward System Motivation
Leading
Process Design Process Selection Capacity Planning Production System Design (factory Layout) Technology Management Maintenance
M a c h i n e
Financial Management Capital Investment Capital Budgeting Working Capital Cost Control, Standards Cash Flow Management Purchase Salary
Customer Focus QFD, Concurrent Engineering TQM, ISO 9000- 2000 etc. M o n e y
Q u a l i t y
M a n a g e m e n t
Wholesaler
Retailers
L a b o r
M a t e r i a l
Manufacturers
M M M M Product (if no wholesaler and retailer) Product Distribution System Information Flow Material Flow P r i m a r y
C o m p o n e n t s
Demand Forecasting STRATEGIC PLANNING (Expansion, Contraction, Status Quo, Budgeting)
ORGANIZING (Designing of structure)
SYSTEM PERFORMANCE (Productivity, Time Study) Industrial Engineering Functions by Category Category IE Functions Production Engineering Manufacturing processes Manufacturing systems Computerized process control Facilities planning and design Production planning and control Quality control Inventory control Product improvement Operational Science Management information and control systems Organizational analysis and design Economic analysis Operations research Project management Cost control and standards Preventive maintenance Ergonomics/ Human Factors Engineering Work Measurement Methods engineering Work system design Wage administration Safety programs Training programs IE DEFINITION BY IIE (USA) Industrial Engineering is concerned with the design, improvement, and installation of integrated systems of people, materials, information, 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 obtained from such systems.
Two distinctive features of IE from other engg disciplines. First: IE focuses on the human being in the design of the integrated systems and for this, it requires a thorough understanding of such behavioral and social sciences as psychology and sociology, as well as life sciences as biology, anatomy and human physiology (Ref. Biles). Thus, the Industrial Engineer is more broadly educated than other engineers who acquire skills in very specific areas.
Second: IE is the only engg discipline that focuses on productivity and quality improvement that is needed so much in this age of globalization and trade liberalization accelerated by the growing impact of information and communication technology.
Industrial Engineers by training figure out how to do things better. They work to eliminate waste of time, money, materials, energy, and other commodities.
IE CURRICULUM Objective: To provide sufficient breadth of knowledge Generally includes courses from: - General engineering sciences - Industrial engineering sciences - Mathematics - Life sciences - Physical sciences - Social sciences Variations exist from school to school depending upon the emphasis placed Program names: Industrial engg, Industrial & Systems engg, Industrial engg & Operations management, Production engg, Engg management, Manufacturing systems engg, etc
IE vs MBA Recent trend in B/Desh and elsewhere More and more engineers pursuing MBA program after first degree in engg discipline.
Such combination of education and training definitely prepares an engineer to perform certain managerial functions with confidence.
But highly debatable whether this can provide sufficient breadth of knowledge that IE program provides. Why is IE Necessary? IIE (USA) contends that the following benefits can be directly linked to the work of Industrial Engineers - Leaner, more efficient, and more profitable business practices while increasing customer service and quality, - Improved efficiency and as a result improved competitiveness and profitability, - Setting of labor and time standards, - Good organization and improving productivity essential for long term health of business, - Increased ability to do more with less focusing on optimization, - Making work safer, faster, easier, and more rewarding, - Providing a method for business to analyze their processes and try to make improvements, - Reducing costs associated with new technologies, - Designing safer and easier to use products, etc Putting simply Industrial Engineering is a philosophy that there is always a better way to do things. Industrial engineer takes what exists today and conceptualizes what should exist in the future.
IEs Role in Bangladeshi Industry and Organizations In almost every discussion forum on the state of industry in B/Desh, people talk about:
Low productivity, inefficient operation, inefficient management, low product product / service quality, higher price of local products, inability to compete in the global market, wastage, and so on.
What people often fail to realize, there is a built-in inefficiency in the local industry. Reason: Right persons are not put in the right job. Many jobs related to IE are being done by engineers /managers who are not trained in IE and the consequence we all witness. Some important roles IE graduates can play As a production planner: finding optimal production policy using tools like aggregate planning, MRP, MRPII, ERP, supply chain management, etc As a production cost controller: setting cost standards As a quality engineer: developing and implementing quality assurance programs As a works manager: developing labor and time standards using Time and Motion Study As a logistic support manager: developing inventory policy, supply chain management As a maintenance manager: developing and implementing maintenance management programs (TPM, RCM, TRM, etc) As a safety manager: making workplace safer and hazard free for employees, protecting physical assets As a manufacturing system engineer: determining suitable materials, manufacturing processes, planning capacity As a facility layout designer: determining appropriate factory layout As a technology assessor: identifying suitable new technology considering technical, economic, environmental and other relevant factors. Particularly important in setting up a new industry or for balancing, modernization, replacement and expansion (BMRE) of an existing industry.
IE Research Tremendous research works are being done and published every year. Some of the popular areas: Operations Research, Scheduling (Flow shop and job shop using techniques like genetic algorithm, simulated annealing, fuzzy algorithm, heuristic search, etc), Inventory policy (stationary, non-stationary processes), Supply chain management, Human factors, MCDM, Cybernetics, etc
Top grade journals: Management Science, Operations Research, European J. of Operational research, Naval Research & Logistics Quarterly, J. of Decision Sciences, IIE Transaction, etc.