ISE 195 – Fundamentals of Industrial & Systems Engineering

BME 195 – Fundamentals of Biomedical Engineering

Introduction to Industrial & Systems Engineering

Frank W. Ciarallo, Associate Professor and

Assistant Chair of ISE

3

Overview

Brief History and Context for ISE

Discuss Some Major Areas of Study in ISE Mathematical Optimization Production & Service System Design Simulation Modeling & Analysis

Overall Course Structure of the ISE Major

Some Examples of What Recent Graduates in ISE are Doing

Assignment on “Podium Design”

4

Modern Engineering Disciplines

Civil engineering emerging from military engineering

Mechanical engineering emerging from growth of mechanical devices after steam engine

Electrical engineering after the telegraph (and other products) appeared

Chemical engineering (petroleum products, lubricants, etc)

5

Post WWII Disciplines

Nuclear engineering

Electronic engineering

Aeronautical engineering

Astronautical engineering

Computer engineering

Environmental engineering

Biomedical engineering

Industrial & Systems Engineering

6

Chronology of ISE

The industrial revolution in large part led to the emergence of industrial engineering as a profession

Babbage thought to specialize labor by skill required

Taylor really started ISE Analyze and improve the work method Reduce the times required for the work Set standards for the times required

7

Chronology of ISE (cont.)

Gilbreth extended work of Taylor to consider the human aspects of work to include motion involved in work

Henry Gantt developed his chart to preplan, schedule, and monitor work activity

Shewhart developed the fundamental principles of statistical process control Disciples became big names in quality

8

What is “ISE”?

Industrial & Systems 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 to be obtained from such systems.

9

Design Impacts

Industrial and systems engineers design systems at two levels

The first level is called the human activity level and is concerned with how work gets accomplished

The second level is called the management control system level and addresses the planning, measurement, and control of organizational activities

10

Level One Elements

Processes within the organization

Layout of facilities and machines

Design of the workplace

Storage space and location

Work methods

11

Level Two Elements

Planning systems

Forecasting systems

Material and inventory planning and control

Scheduling activities

Cost control and analysis

Quality control system

12

“ISE” and “Operations Research”

“Industrial & Systems Engineering” = “Branch of Engineering Concerned with Integrating and Improving Systems” ISEs can use “OR” tools to do this, usually with

the help of a computer ISEs focus on problems in Logistics,

Scheduling, Healthcare, etc. that have an optimization focus and that have a “scale” large enough to utilize OR tools

ISEs use “OR” to formulate design problems and generate solutions

13

Why the Comparison?

Pure Operations Research has a heavy mathematical and computational orientation There are many mathematical details to formulating

problems successfully There are many computational (computer

programming, algorithmic) details to successfully finding “optimal” solutions to a stated problem

ISE applications of OR do not have as high a theoretical mathematical or algorithmic content

ISEs try to use the correct technique to improve the integrated system under investigation, including OR when appropriate

14

Model Formulation and Solution

Mathematical optimization model formulation and solution Represent the system or phenomena in some set of algebraic

structures Uses the “decision-makers” view, usually different from the “real-world”

view Simulation models have a closer mapping to real world details

Encode the resulting model in a computer via some modeling language GAMS, X-Press, Excel

Find a “solution” to the model (hopefully “optimal”)

Solution algorithms vary for linear, nonlinear and integer decision variables

Solutions generated suggest new designs for a system A “prescriptive” decision technique

Trying to find a “best” solution with which to prescribe how to make the best use of limited resources

15

INFORMS

16

Production Operations

Analysis of proposed product or service

Analysis of manufacturing process

Facilities issues

Work methods and standards

Production planning and control

17

Production System

Characterized by Number of machines Number of part types Part routings through the

system Processing times Machine setups Demand patterns Raw material/component

availability Equipment

layout/configuration Operator availability

Interested in: Lead time for products Cost of processing

Decisions include: System configuration Scheduling methods Inventory Control

•parts

18•18

Facility Layout

•Saw

•Saw

•Grind

•Weld

•Lathe

•Mill

•Mill

•Grind

•Mill

•Drill

•Drill

•Lathe

•Drill

•Paint

•Paint

•Drill

• Sto

res

• As s

emb l

y

• War

eho u

se

•Saw

•Mill

•Grind

•Lathe

•Paint

•Drill

• Ass

embl

y

• War

ehou

se

• Sto

res

•Process Layout

•“Focused Factory” Layout

•Inbound Stock •Outbound Stock

•“U” Shaped Cells

19•19

Inventory/Supply Chain Management

Plan production quantities to meet customer demands on time with a high level of certainty at a minimum cost/maximum profit

Coordinate production/inventories between stages of the “Supply Chain”

Issues Costs for production, inventory, shortages, setups, etc. Variability in demand, supply Lead times in production, transportation

20

Product/Service Analysis

Will it be profitable?

Is product compatible with production line?

Can it be manufactured?

Where are there opportunities for improvement?

Analyze distribution of product or delivery of service to customers

21

Manufacturing Process

What is the best process by which to manufacture and assemble the product

What is the mix of equipment, robots, or personnel

How can the assembly lines best be balanced

What is the best material flow and material handling procedures

22

Facilities Concerns

What is the best facility layout?

How should material and goods be stored?

What maintenance processes should be adopted to include preventative maintenance, test, and inspection

Utilities required

Security and emergency planning

23

Prod. Planning & Control

Forecast potential sales

Are capacity and resources being utilized to their capabilities

Establish inventory procedures

Plan for any materials requirement planning

Scheduling

24

Institute of Industrial Engineers

25

Studying Mathematical or Logical Models

If model is simple enough, use ISE mathematical analysis … get exact results, lots of insight into model Queueing theory Differential equations Linear programming

But complex systems can seldom be validly represented by a simple analytic model Danger of over-simplifying assumptions … model

validity? The simplified model can provide valid bounds

Often, a complex system requires a complex model, and analytical methods don’t apply … what to do?

26

Discrete Event Simulation

“A model of a system as it evolves over time where the state of the system changes at discrete points in time”

Necessary when systems involve humans and logical connections between components

The “engine” of common ISE simulation software is built on the discrete event approach: ARENA (used in ISE 4712), FlexSim, AnyLogic etc.

The “logic” for the common ISE simulation software is built on the “process flow” approach.

Add animation to help communicate the model to the people operating the system.

27

Process Flow Description of Systems

To build the model on the computer, use a “process-flow” approach

Systems consist of: Entities (Customers, Parts) Resources (Machines, People) Routings (Logic, Networks) Input Data (Times, Probabilities) Performance Measures (Times, Utilizations)

28

ARENA Model of a Supply Chain

29

ARENA Model of a Truck Assembly Line

30

Example: Traffic Simulators

Vehicle Intersection Model with Pedestrians (VisSim) http://www.youtube.com/watch?v=Yq9IAz

NTAz0&feature=related

31

Example: Agent Based Models

Subway Station Simulation: AnyLogic Subway Entrance Hall Model http://www.xjtek.com/anylogic/demo_mod

els/44/

32

Work Methods and Standards

Perform work measurement studies and establish time standards

Perform work improvement studies

Value engineering studies to determine and eliminate sources of waste and excess cost

33

Personnel Systems

Employee testing, selection and placement

Training and education programs

Job evaluation and incentive programs

Ergonomics and human engineering applied to jobs, workplaces and workplace in general

Quality improvement activities

34

Prod. Planning & Control

Design quality control system and inspection processes

Shop floor control procedures

Reports Cost Quality Labor Productivity

35

Planning

Support corporate strategic planning to include national and international planning

Perform enterprise modeling

Support and perform system integration activities

Provide support to major decisions and participate in major decisions

Quality management activities

36

Policies and Procedures

Study organizational analysis and design

Perform analyses of functional groupings

Policy manuals

Procedures

37

Performance Measurement

Identify meaningful performance measures for those areas of interest key to the firm success

Identify critical success factors

Specify and design corrective action procedures

Design reports for all levels of management

38

Projects and ISE might take on

Analyze systems and construct models

Apply appropriate solution methodologies

Perform simulation studies

Perform operations research studies

Perform statistical analysis

Conduct designed experiments

And more…

39

ISE and Systems

Industrial engineering really takes a system-level perspective

The tools and techniques of the ISE allow the ISE to examine the system, the interactions among the components of the system, all while keeping in mind the objective or purpose of the system

An ISE seeks to optimize systems

40

ISE Course Coverage

Optimization (ISE 4711)

Simulation (ISE 4712)

Human Factors and Usability (ISE 4300, ISE 4320)

Ergonomics (ISE 4310)

Production & Distribution Systems (ISE 4810, ISE 4820)

Statistical Analysis of Data (ISE 2211, ISE 2212)

Cost and Entrepreneurship (ISE 4400, ISE 4410, ISE 4420)

41

ISE Course Coverage

Computation (ISE 3540, ISE 4510)

Engineering Science (BME 3211, BME 3212, BME 3511)

Senior Design Project

Calculus, Physics and Chemistry

WSU Core

42

What are ISE graduates doing now?

http://www.linkedin.com

43

Assignment

Podium Specification Assignment A customer need is a statement

describing something needed by the “customer” of a design.

A metric is a measure used to quantify the fulfillment of a need.

A specification is a precise engineering statement of a goal to achieve during design. It includes a metric and value.

44

Podium Specification Assignment

Form a team 4 students per team preferred, 3 students acceptable

Understand the product, customer, stakeholders

Develop a list of customer needs (15 to 25)

Develop a set of metrics for the podium

Develop a set of specifications for the podium (15 to 25)