Industrial Engineering Techniques
is an on-site 40-hour program, normally presented in five consecutive
days, which provides new engineers, supervisors, non-IEs, and other
technical and non-technical personnel a grounding in classical
Industrial Engineering methods and procedures.
The program relies
heavily on interactive demonstrations, teamwork, video, and class
exercises. This program has been presented many times for automobile
manufacturers and OEM suppliers, and uses numerous video examples of
real plant scenes in fabrication and assembly operations. The overall
program consists of several "modules" that may added or deleted to
produce a custom program of 24 to 40 hour duration if desired.
1.0 Introduction to Industrial Engineering and Methods Analysis
1.1 Definition of Industrial Engineering
1.2 Relationship of Method to Time
1.3 IE History; Taylor and Gilbreth
2.0 Methods Analysis and Work Measurement
2.1 Manufacturing Systems and Concepts
2.2 Methods Analysis and the Methods Engineering Approach
2.3 Work Measurement
3.0 Manufacturing Systems Analysis
3.1 Methods of Organizing Information
3.2 Symbol systems
3.3 The Fabrication Chart
3.4 The Precedence Chart
3.5 The Flow Chart
3.6 The Process Chart
3.7 The Flow-Process Chart
4.0 The Analysis of Manual Methods
4.1 Components of job study; task, element, act, motion,
4.2 Purposes of job analyses
4.3 Effects on method
4.4 Variation in Output within Fixed Limits
4.5 The Acts
4.6 Review of analysis form and sample Act Breakdown
4.7 Progressive improvement
5.0 Methods Summary Charting
5.1 Definition and purpose of methods summary charting
5.2 Types of charts; man/man, man/machine
5.3 Review of methods summary chart
5.4 Video exercises
6.0 Ineffective Worker Movement Analysis
6.1 Definition
6.2 Causes of Ineffective Worker Movements
6.3 Video examples
6.4 Six steps of analysis
6.5 Analysis form--Ineffective Worker Movement
6.6 Team exercises
7.0 Motion Economy and Workplace Layout
7.1 Improving the motion path; barriers
7.2 Workplace layout principles
7.3 Motion Economy Check List; discussion of 20 Principles
8.0 Ergonomics (Human Factors)
8.1 Definition
8.2 Scope and history
8.3 Anthropometry
8.4 Discussion of body dimensions
8.5 Workplace design dimensions
8.6 NIOSH guidelines for manual lifting
8.7 Hand tool design
9.0 Work Measurement
9.1 Overview of work measurement concepts
9.2 The Standard Hour Concept
9.3 Time study
9.3.1 Stopwatches
9.3.2 Procedure
9.3.3 Work description
9.3.4 Elemental breakdown
9.3.5 Types of method description
9.3.6 Keywords, breakpoints
9.3.7 Irregular elements, foreign elements
9.3.8 Number of cycles to study
9.4 Evaluating operator performance
9.4.1 Definition
9.4.2 Characteristics of normal performance
9.4.3 Performance descriptors; skill, effort, pace, etc.
9.4.4 Benchmarks
9.4.5 Performance rating systems
9.4.6 Selection of an average operator
9.5 Recording the data
9.5.1 Snapback vs. continuous study
9.6 Time study exercises
10.0 Work Sampling
10.1 Introductory Video
10.2 Work Sampling Procedure
10.2.1 Statistical principles, randomness
10.2.2 Demonstration
10.2.3 Determination of sample size; alignment chart
10.2.4 Design of study elements
10.2.5 Taking the study; instantaneous observation
10.2.6 Tracking progress of the study
10.3 Work Measurement Sampling
10.4 Use of an electronic random reminder; time management
11.0 Line Balancing
11.1 Discussion--Use of powered lines
11.2 Factors influencing product assembly; design, equipment, precedence
11.3 Build methods; process or product orientation, fixed position
11.4 Line types; straight, circular, indexing or continuous
11.5 Requirements for the line balancing process
11.6 Line balancing procedure
11.7 Line balance-powered line operations
11.8 Line balance class problem (team exercise)
12.0 Summary and Critique
1.0 Introduction to Industrial Engineering and Methods Analysis
1.1 Definition of Industrial Engineering
1.2 Relationship of Method to Time
1.3 IE History; Taylor and Gilbreth
2.0 Methods Analysis and Work Measurement
2.1 Manufacturing Systems and Concepts
2.2 Methods Analysis and the Methods Engineering Approach
2.3 Work Measurement
3.0 Manufacturing Systems Analysis
3.1 Methods of Organizing Information
3.2 Symbol systems
3.3 The Fabrication Chart
3.4 The Precedence Chart
3.5 The Flow Chart
3.6 The Process Chart
3.7 The Flow-Process Chart
4.0 The Analysis of Manual Methods
4.1 Components of job study; task, element, act, motion,
4.2 Purposes of job analyses
4.3 Effects on method
4.4 Variation in Output within Fixed Limits
4.5 The Acts
4.6 Review of analysis form and sample Act Breakdown
4.7 Progressive improvement
5.0 Methods Summary Charting
5.1 Definition and purpose of methods summary charting
5.2 Types of charts; man/man, man/machine
5.3 Review of methods summary chart
5.4 Video exercises
6.0 Ineffective Worker Movement Analysis
6.1 Definition
6.2 Causes of Ineffective Worker Movements
6.3 Video examples
6.4 Six steps of analysis
6.5 Analysis form--Ineffective Worker Movement
6.6 Team exercises
7.0 Motion Economy and Workplace Layout
7.1 Improving the motion path; barriers
7.2 Workplace layout principles
7.3 Motion Economy Check List; discussion of 20 Principles
8.0 Ergonomics (Human Factors)
8.1 Definition
8.2 Scope and history
8.3 Anthropometry
8.4 Discussion of body dimensions
8.5 Workplace design dimensions
8.6 NIOSH guidelines for manual lifting
8.7 Hand tool design
9.0 Work Measurement
9.1 Overview of work measurement concepts
9.2 The Standard Hour Concept
9.3 Time study
9.3.1 Stopwatches
9.3.2 Procedure
9.3.3 Work description
9.3.4 Elemental breakdown
9.3.5 Types of method description
9.3.6 Keywords, breakpoints
9.3.7 Irregular elements, foreign elements
9.3.8 Number of cycles to study
9.4 Evaluating operator performance
9.4.1 Definition
9.4.2 Characteristics of normal performance
9.4.3 Performance descriptors; skill, effort, pace, etc.
9.4.4 Benchmarks
9.4.5 Performance rating systems
9.4.6 Selection of an average operator
9.5 Recording the data
9.5.1 Snapback vs. continuous study
9.6 Time study exercises
10.0 Work Sampling
10.1 Introductory Video
10.2 Work Sampling Procedure
10.2.1 Statistical principles, randomness
10.2.2 Demonstration
10.2.3 Determination of sample size; alignment chart
10.2.4 Design of study elements
10.2.5 Taking the study; instantaneous observation
10.2.6 Tracking progress of the study
10.3 Work Measurement Sampling
10.4 Use of an electronic random reminder; time management
11.0 Line Balancing
11.1 Discussion--Use of powered lines
11.2 Factors influencing product assembly; design, equipment, precedence
11.3 Build methods; process or product orientation, fixed position
11.4 Line types; straight, circular, indexing or continuous
11.5 Requirements for the line balancing process
11.6 Line balancing procedure
11.7 Line balance-powered line operations
11.8 Line balance class problem (team exercise)
12.0 Summary and Critique
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