Industrial engineering

Chapter 1

Production & Productivity

1. Define industry

Industry is a place where raw materials are converted or processed to finished product or services
in an organised manner. It can be defined as the place where some kind of value addition takes
place

2. Define industrial engineering

Industrial engineering is concerned with the design , development, improvement and

installation of an integrated system of men , material , method etc .It is concerned with improving
almost everything currently being planned or done for better management and productivity.

3. Differentiate between production and productivity

Production is a process or sequence of process to transform set of inputs (men, material, money)
into specified set of outputs or finished products or services of required quantity and quality. Here the
concern is only about the volume of production.

Productivity is the ratio of output to input. It indicates the efficiency of a production process.
Output means products manufactured and input means resources like land, money, material,
labour etc. Productivity depends on the reduction in wastage of resources like men , material,
machine, power, time etc

4. List the areas of application of industrial engineering

1. Plant layout and material handling
2. Inventory control
3. Operation research
4. Production planning and control
5. Value engineering
6. Network analysis
7. Work study

5. List the different methods for improving the productivity of a process or service

Employee based

 Financial incentives
 Quality circles
 Job rotation
 Promotion and recognition
 Education
 Material based

 Inventory control
 Material requirement planning
 Good material handling
 QC

TASK Based

 Method study
 Time study
 Job evaluation

Product based

 Product diversification

 Product standardisation

 R&D

 Advt and promotion

 Value analysis

Technology based

 CAD

 CAM

 Robotics

 Laser Beam Technology

6 List the important factors in an industry

Men, material, machine, method, money etc.

7. List the characteristics of job order production

Production planning starts after receipt of orders from customer. Each job order stands alone and
not likely to be repeated. It has maximum flexibility.

Characteristics

Planning after order

Mechanization, division of labor etc are difficult

General purpose machinery is used

Product design takes a lot of time

Skilled labor is needed

High supervision needed

Intermittent flow of material

Process type layout preferred

Small quantity of production

8. List the characteristics of batch type production

Identical products are manufactured in batches of small quantity. Products are produced in lots. One
lot may differ from other. Only an extension of job order production. Suitable for production of Fashion
goods, umbrellas, medicines.

Characteristics

Special and general-purpose machinery can be used

Semi-skilled and skilled labor can be used

Combination type layout is preferred.

Division of labor possible

Production control is necessary

Production starts after receiving a particular quantity in order

Each batch requires separate planning

9. List the characteristics of continuous production

Specialized manufacturing of identical products in large quantity. Products with high demand are
produced in large quantities continuously. There are two types of continuous production.

Mass production – production of identical articles in large quantity using automatic machines – bulb,
switches, nuts, bolts etc.

Flow production – plant, equipment, machinery etc. specially designed for a particular product- cement,
fertilizers, chemicals, paper etc.

Characteristics

Large quantity of production

Single purpose or Special purpose machinery required.

Line type layout

Unskilled labour is OK
Automation and division of labour possible

Routine supervision will be adequate.

Fixed path for travel of material

Low production cost

Short and repetitive work cycle

Highly standardized product

Chapter 2

Production Planning and Control

Define PPC. List the objectives and advantages of PPC

Production planning and control involves planning of various activities related to production and making
them happen as per plan. It maintains a balance between meeting customer demand and maintaining
economy in production. It involves management of work flow, inventories and changing the level of
operation. It is considered as the nervous system of a factory

Objectives

Find the demand of a new product

Forecast the demand of existing product

Costing

To make the route sheet

To prepare schedules

To prepare orders for execution

To control labor and material

Advantages

To increase productivity

To keep the delivery dates

To reduce conflicts

Minimize wastage

Reduce maintenance
Improved working condition

Better feedback

Reduced material handling

List the functions of PPC

a) Forecasting

b) Product Design

c) Process planning

d) Order writing

e) Material Planning

f) Manpower planning

g) Method planning

h) Routing

i) Scheduling

j) Estimating

k) Dispatching

l) Inspection

m) Expediting

n) Evaluation

List the different methods of forecasting.

1) Historic estimate

2) Trend line technique

3) Sales force estimate

4) Market survey

5) Correlation technique

6) Delphi method

7) Forecasting by past average

Define forecasting. List the factors affecting the forecasting of demand of a product

Forecasting is the scientific estimation of future demand of a product. Various factors affecting the
demand of a product are

1) Competitors strategy

2) Customer taste

3) Arrival of new products

4) Government policies

5) Economic condition of the country

Define scheduling. List the objectives of scheduling. how is it different from loading?

It determines starting and completion of various operations in manufacturing a product. A production

schedule is a time table which shows when the product should enter a particular process and when it will
leave the same for next operation. It is assigning the work to a facility with specification of times and
sequence.

Loading means assignment of work to manpower, machinery etc without specifying the time. It shows
the utilization of facilities in a plant. It shows the relationship between load and capacity.

Objectives

a) To deliver goods in time.

b) To make men, material and machine available for production.

c) Maximize the use of manpower and machine capacity

d) Prevent underloading and over utilization of men and machines.

e) Keep minimum material in process.

Advantages

a) Minimum production cost

b) Minimum material storage cost

c) Customer satisfaction

d) Prevent overloading of men and machines

e) Prevent underutilization of men and machines

f) Good control of production

g) Job satisfaction

h) Increased goodwill of the company

 1. . List the internal and external factors affecting scheduling

External Factors

Customer demand

Customers delivery date

Dealers and retailers’ inventory

Internal factors

Availability of equipment, machinery, material, skilled workers, manufacturing facilities

Economic batch size

Stock of finished goods

Process duration

Additional manufacturing facility required

Define routing. Give an example for a route sheet

Deciding the most economical path for the flow of material. Objective is to find the best and cheap
sequence of operation. Path depends on material handling systems used, layout, storage facilities etc.

A line production routing sheet is used by managers to monitor total production schedules.

It includes:

1. A description of the operation

2. The product rate in pieces per hour

3. The number of operators and machines needed

4. The cost of producing the product in standard units

 2. . Give the procedure for the routing function in PPC

a. Deciding on purchases and manufacturing on the basis of bill of materials

b. Available machine capacities, characteristics

c. List of operations to be performed

d. Deciding the path of material flow

e. Determining of Economic Order Quantity

f. Identifying the scrap points and factors

g. Estimating the cost of production

h. Analysis of finished product

List the different functions in dispatching. What are the documents prepared in dispatching for
doing

the listed functions?

Dispatching is the execution function in PPC. It involves releasing of various orders and other
documents for performing production activities.

a) Release schedule for production

b) Issue work orders for starting production

c) Release material issue order to store

d) Move order to move material from store

e) Issue tool order to tool room

f) Releasing inspection order

g) Recording time of beginning and completion of job

Different documents released in dispatching are

1. Work order

2. Material issue order

3. Move order

4. Tool issue order

5. Inspection order

6. Job time ticket

 7. Final delivery notification

Define expediting or follow up. List its objectives

Expediting involves keeping the product on schedule with daily product reports.

If the schedule is broken, corrective action might include Overtime, retraining workers, changing
operations to improve efficiency, holding a motivational meeting, etc. It is done for the following
purposes

a) To see the materials, reach the shop floor in time as per schedule.

b) To see if a particular product is passing through all the operations as per schedule.

c) To see if all the parts are ready for assembly in actual quantities and at the required time.

d) To see the major causes of delay.

e) To find the major causes of rejections.

f) To find the errors in routing, scheduling, dispatching, etc

Explain the different types of schedules

Master production schedule – weekly or monthly breakdown of production requirements. Based on the
route sheet, loading chart, promised delivery schedule, etc

Parts schedule – gives a number of units of different parts to be produced. It is prepared for a month with
weekly break up. It is based on MPS.

Machine loading schedule – gives information on allocating work load for various machines. The
schedule is prepared for a week with a daily break up. It gives the timetable of working of various
machines.

Note- Example of schedules provided on the PPT

Explain any four methods of forecasting

1. Historic estimation

It is the oldest method for forecasting. Here we assume that what happens in the past will
happen in future. Factors affecting demand remains unchanged. It is the simplest and cheapest method.
Not scientifically true and valid.

2. Trend line method

It is a statistical method used for forecasting. Employed when appreciable amount of historical
data is available. A Graph is plotted with sales in Y axis and years in X axis. Sales of different years are
marked and a straight-line fitting to most of the points drawn (trend line). Trend line is projected and
future demand is calculated.
3. Sales force Estimate

Persons in contact with consumers know best about future trends and taste. Forecasting is based
on the feedback of salesman Technique is reliable when the company is making limited number of
products and there are only a few large customers. Reports send by the salesman at regional level are
analyzed to formulate final estimate of sales.

4 Correlation technique

Used when a relationship exists between sales of a particular product and another product or any
other economic and non-economic phenomenon. Total sale of the related product is found out based on
the market conditions. From this demand for our product is estimated. If the product sales is related to any
phenomenon like national income, population growth etc an empirical relationship between the product
and the variables like the phenomenon should be established which will help in predicting the future
demand.

Chapter 3

Plant location and layout

Define Plant and plant layout. List the objectives of a good plant layout

Plant is the place where men, material, money, machinery etc. are brought together for production. Plant
location involves selection of geographical area and selecting a site in that area. Plant layout is a floor
plan indicating the location of machines, materials, men, supporting facilities etc inside a plant.

Objectives

a. Congestion reduction.

b. Elimination of unnecessary occupied areas.

c. Improvement on control and supervision.

d. Better adjustment to changing conditions.

e. Better utilization of the workforce, equipment and services.

f. Reduction of material handling activities and stock in process

g. Reduction on health risks and increase on workers safety.

h. Reduction on delays and manufacturing time, as well as increase in production capacity.

List the different types of plant layout

Process type layout, product type layout, combination type layout, fixed position type layout

List the factors affecting the selection of site for a plant.

a. Availability of raw material

b. Nearness to market

c. Transportation facilities

d. Availability of power, fuel

e. Availability of labor

f. Climatic conditions

g. Commercial facilities

h. Local laws

i. Attitude of local people

j. security

Compare the characteristics of a rural and urban site selected for locating a plant

Urban

a. Skilled Labour force is available

b. Small plant site

c. Good transportation facilities

d. Good communication facilities

e. Banking and health facilities are available

f. Pollution problems could be a problem

g. Strict regulations from the govt

Rural

a. Land available in plenty and is cheap

b. Unskilled labour available

c. Help from govt

d. Non availability of skilled labour

e. Lack of transportation

Explain process type layout. Give its advantages and disadvantages.

This type of plant layout is useful when the production process is organized in small batches.

Personnel and equipment to perform the same function are allocated in the same area. The different items
have to move from one area to another one, according to the sequence of operations previously
established.

Advantages

a. Best use of specialization of machines & employees

b. Flexible – variety of products can be manufactured

c. General purpose machines – less costly

d. Ability to follow diverse paths

e. Less vulnerable to shutdowns

f. Machine breakdown is less of a problem

g. Production in small batches

h. Suitable for incentive pay

i. More interesting for workers

Disadvantages

a. General purpose machines are slower

b. Work routing& scheduling are difficult

c. Material handling costs are high

d. Material moves slowly

e. Partially finished inventory high – requires large storage space

f. Communication between workers is difficult

g. Some limit to size of parts that can be manufactured

Explain product type layout. Give its advantages and disadvantages.

Machines are arranged in the logical sequence of operation along flow lines. Suitable for continuous
production.

a. High volume of production

b. Machines are arranged in sequence of operation

c. Continuous flow of material

d. Standardised work

Advantages

a. Reduced material handling activities.

b. Work in Process almost eliminated.

c. Minimum manufacturing time.

d. Simplification of the production planning and control systems.

e. Tasks simplification.

Disadvantages:

a. No flexibility in the production process.

b. Low flexibility in the manufacturing times.

c. High capital investment.

d. Every workstation is critical to the process. - The lack of personnel or shut down of a machine
stops the whole process.

e. Monotonous work.

Explain fixed position type layout. Give its characteristics and applications.

Men and equipment move towards the material and the product is completed in the place where the
material lies.

a. Skilled workers are required for continuity of work

b. Minimum movement of materials

c. Maximum flexibility

d. Number of projects can be handled simultaneously

e. Low work in progress

f. Low utilisation of labour

g. High equipment cost

Applications - ship building, aircraft manufacture, pressure vessel manufacturing etc

Explain the combination type layout with an example

This type of layout is preferred when an item is made in different types and size. Machinery is arranged as
in process layout but the group of machines are arranged in sequence inside each department. The
sequence of operation remains the same. It is also useful when a number of products are manufactured in
same sequence but in small quantities.

9. List the factors affecting the selection of a particular type plant layout

a. Type of production

b. Type of building

c. Type of production system used

d. Availability of area

e. Material handling system used

f. Scope of future expansion

List the principles of a good plant layout

a. Principle of integration

b. Principle of minimum movement

c. Principle of smooth flow of material

d. Principle of smooth cubic space utilization

e. Principle of flexibility

f. Principle of safe and improved environment

 Chapter 4

Plant maintenance

Define Plant maintenance

One of the most important function in production management. All activities needed to keep plant,
machinery, tool and equipment, services including building in standard condition. The main Objective is
to improve productivity of the industry.

List the main objectives of maintenance

Objectives

a. Protect plant and building.

b. Keep machines, equipment, building in good condition.

c. Prevent breakdown of machines, processes.

d. Improve efficiency of production system.

e. Meet scheduled date of production.

f. Profit maximization.

g. Safety.

h. Environment protection & pollution control.

i. Reduce wastages and accidents.

List the scope of maintenance activities in a plant

a. Plant and building

b. Machine and equipment

c. Supporting facilities

d. Factory premises and surrounding area

e. Housekeeping and safety

f. Wastage disposal and recycling

g. Environmental protection and pollution control

4. List the different methods of maintenance.

Breakdown maintenance, Preventive maintenance, condition-based maintenance, Reliability centered
maintenance, predictive maintenance, scheduled maintenance etc.

Explain the characteristics of Preventive maintenance.

It is also known as Planned or systematic maintenance. It is based on the principle ‘Prevention is better
than cure’. It reduces every chance of breakdown.

A PM programme includes cleaning, lubrication, servicing, overhauling, testing, inspection performed as

per pre fixed timetable. Success of PM depends on periodicity of inspection, replacement and proper
servicing at regular intervals. It has a system to report chances of defects in a structured manner and
involves systematic analysis of defective parts. A PM programme should ensure proper documentation
through history card to record details of inspection, repair, modification etc.

Advantages

a. Minimum breakdown

b. Make plants and equipment available for use

c. Optimum productivity

d. To keep quality standard

e. Safety

f. Reduced pollution

g. Reduced wastage & accidents

h. Increased life of equipment and machines

6. List the main causes of breakdown in machines

a. Carelessness towards minor repairs

b. Failure to replace worn out parts

c. Non application of lubricants

d. Careless operation

e. Mishandling of tools

f. Neglected cooling system

g. Overloading
Explain the features of breakdown maintenance.

Here the maintenance is done only when the machines become out of order and it cannot give its normal
function any longer. It is not suitable for critical machines. But it is considered economical for not so
critical machineries. The main disadvantages of breakdown maintenance are

a. Delayed production.

b. Poor quality.

c. Reduced life.

d. Increased cost of production due to delay and stoppage.

e. Increased accidents and wastages.

f. Increased pollution.

g. Reduced profit.
 Compare breakdown and Preventive maintenance

BREAK DOWN MAINTENANCE PREVENTIVE MAINTENANCE

DONE AFTER FAILURE DONE BEFORE FAILURE

UNPLANNED PLANNED

NOT SUITABLE FOR CRITICAL MACHINERIES SUITABLE FOR ALL EQUIPMENTS

COST DUE TO DOWNTIME NO DOWNTIME

PRODUCTION LOSS NO PRODUCTION LOSS