Industrial Engineering and Management......Page 0
Contents......Page 4
Preface......Page 14
Acknowledgement......Page 15
About the Author......Page 16
1.1 Introduction......Page 18
1.2 Historical Development of Concepts in Industrial Engineering and Management......Page 19
1.3 Production Systems......Page 21
1.4 Selection of Production Systems......Page 25
1.5 Productivity......Page 26
Summary......Page 36
Multiple-choice Questions......Page 37
Review Questions......Page 38
Exercises......Page 39
References and Further Readings......Page 40
2.2 Facility Location......Page 41
2.4 Centroidal Method......Page 43
2.5 Facility/Plant Layout......Page 47
2.6 Systematic Layout Planning......Page 51
2.7 Block Diagram......Page 53
2.8 Assembly Line Balancing......Page 54
2.9 Group Technology......Page 57
2.10 Cellular Manufacturing......Page 60
Multiple-choice Questions......Page 62
Exercises......Page 64
References and Further Readings......Page 66
3.1 Introduction......Page 67
3.2 Forecasting Methods......Page 69
3.3 Time-series Forecasting......Page 71
3.4 Forecasting Performance Measurement......Page 86
Multiple-choice Questions......Page 88
Exercises......Page 90
References and Further Readings......Page 92
4.1 Introduction......Page 93
4.2 Aggregate Planning Strategies......Page 94
4.3 Mixed Strategy......Page 99
Multiple-choice Questions......Page 103
Review Questions......Page 104
Exercises......Page 105
References and Further Readings......Page 106
5.2 Materials Requirement Planning......Page 107
5.3 MRP II......Page 116
5.4 Enterprise Resource Planning......Page 118
Multiple-choice Questions......Page 120
Exercises......Page 122
References and Further Readings......Page 123
6.1 Introduction......Page 125
6.2 Classifications of Inventory......Page 126
6.3 Inventory Costs......Page 128
6.5 Economic Order Quantity......Page 129
6.6 Reorder Point......Page 140
6.7 Order Quantity for Variable Demand......Page 142
Multiple-choice Questions......Page 143
Exercises......Page 145
References and Further Readings......Page 146
7.1 Introduction to Engineering Design......Page 148
7.2 Product Concept and Concept Selection......Page 151
7.3 Product Life Cycle......Page 153
7.4 Morphology of Design......Page 155
7.5 Standardization, Simplification, Differentiation and Diversification......Page 156
7.6 Interchangeability and Modular Design......Page 157
7.7 Concurrent Engineering......Page 158
7.8 Economic Considerations in Product Design......Page 161
7.10 Ergonomic Considerations in Design......Page 162
Multiple-choice Questions......Page 163
References and Further Readings......Page 165
8.1 Introduction......Page 166
8.2 Flexible Manufacturing System......Page 167
8.3 CAD/CAM......Page 171
8.4 Lean Manufacturing......Page 177
8.5 Agile Manufacturing......Page 183
Multiple-choice Questions......Page 185
Review Questions......Page 187
References and Further Readings......Page 188
9.2 Relationship between Material Handling and Plant Layout......Page 189
9.5 Principles of Material Handling Systems......Page 190
9.6 Types of Material Handling Equipments......Page 191
Multiple-choice Questions......Page 202
References and Further Readings......Page 204
10.1 Introduction......Page 206
10.2 Objectives of Production Planning and Control (PPC)......Page 207
10.3 Production Planning......Page 208
10.4 Factors Affecting PPC......Page 213
Multiple-choice Questions......Page 214
References and Further Readings......Page 216
11.1 Introduction......Page 217
11.2 Method or Motion Study......Page 218
11.4 Memo-motion Study......Page 228
11.5 Time Study or Work Measurement......Page 230
11.6 Work Measurement Techniques......Page 231
11.7 Predetermined Motion Time System......Page 237
11.8 Principle of Motion Economy......Page 238
11.9 Work Sampling......Page 239
11.10 Job Design......Page 241
11.12 Merit Rating......Page 242
Multiple-choice Questions......Page 248
Review Questions......Page 250
References and Further Readings......Page 251
12.1 Introduction......Page 253
12.2 Reliability Curves......Page 254
12.3 Failure Pattern......Page 256
12.4 Basic Reliability Models......Page 259
12.5 Evaluation of System Reliability (RS)......Page 265
12.6 Improvement in Reliability of a System......Page 272
12.8 Reliability Testing......Page 273
12.9 Maintainability......Page 274
12.10 Design for Maintainability......Page 277
12.12 Availability......Page 278
12.13 Serviceability......Page 279
12.14 Housekeeping and 5S Concepts......Page 281
Multiple-choice Questions......Page 282
Exercises......Page 284
References and Further Readings......Page 285
13.1 Introduction......Page 286
13.2 Cost Elements......Page 288
13.3 Cost Accounting......Page 289
13.4 Computation of Material Variances......Page 290
13.5 Break-Even Analysis......Page 291
13.6 Depreciation......Page 297
Multiple-choice Questions......Page 310
Exercises......Page 312
References and Further Readings......Page 314
14.1 Introduction......Page 315
14.2 Replacement of Items that Fail Completely......Page 316
14.3 Replacement of Items that Deteriorate......Page 324
14.4 Replacement of the Defender......Page 338
Multiple-choice Questions......Page 349
Review Questions......Page 351
Exercises......Page 352
References and Further Readings......Page 353
15.2 Types of Value......Page 354
15.3 Seven Phases of Value Analysis......Page 355
15.4 Application of Value Analysis......Page 356
15.6 Value Analysis of a Graphite Pencil by Matrix Method......Page 357
Multiple-choice Questions......Page 359
References and Further Readings......Page 362
16.1 Introduction to Linear Programming......Page 363
16.2 Simplex Technique......Page 365
16.3 Big-M Method......Page 368
16.4 Two-Phase Method......Page 372
16.5 Duality......Page 374
16.6 Graphical Method......Page 378
16.8 Tabular Method to find the Basic Feasible Solution of Transportation Model......Page 380
16.9 Test of Optimality using MODI or U-V Method......Page 391
Summary......Page 402
Multiple-choice Questions......Page 403
Exercises......Page 405
References and Further Readings......Page 407
17.1 Introduction to Assignment Problem......Page 408
17.2 Sequencing Problem......Page 413
Multiple-choice Questions......Page 419
Exercises......Page 421
References and Further Readings......Page 422
18.1 Introduction......Page 423
18.2 The Service Characteristics......Page 424
18.3 Mathematical Distributions......Page 426
18.4 Waiting Line Models......Page 428
Multiple-choice Questions......Page 442
Exercises......Page 444
References and Further Readings......Page 445
19.1 Introduction......Page 446
19.2 Classical School of Management......Page 448
19.5 Behavioural Approach......Page 452
19.7 Functions of Management......Page 453
19.8 Levels of Management......Page 455
19.9 Skills of Manager......Page 457
19.10 Managerial Roles......Page 458
19.11 Theory of Motivation......Page 459
19.12 Administration and Management......Page 460
Multiple-choice Questions......Page 461
References and Further Readings......Page 463
20.2 Sole Proprietorship......Page 464
20.4 Partnership......Page 465
20.5 Corporation......Page 467
20.6 Joint Hindu Family Business......Page 468
20.7 Joint Stock Company......Page 470
20.8 Multinational Corporation......Page 474
20.9 Departmentalization......Page 475
20.10 Classification of Organizations......Page 476
20.11 Delegation of Authority......Page 480
Multiple-choice Questions......Page 481
Review Questions......Page 483
References and Further Readings......Page 484
21.1 Introduction......Page 485
21.2 Project Life Cycle......Page 487
21.3 Project Appraisal......Page 488
21.4 Project Structure......Page 490
21.5 Terminology used in Project Scheduling......Page 493
21.6 Project Crashing (Optimization through CPM) 483......Page 500
21.7 Resource Levelling......Page 508
Multiple-choice Questions......Page 509
Exercises......Page 511
References and Further Readings......Page 512
22.2 Definitions of Quality......Page 513
22.4 Dimensions of Quality......Page 514
22.5 Quality Planning, Assurance and Control......Page 515
22.6 Costs of Quality......Page 516
22.7 Evolution of Quality Concepts......Page 518
22.8 Quality Gurus and their Philosophies......Page 519
22.9 Total Quality Management......Page 526
22.10 Seven Basic Tools for Quality Control......Page 528
22.12 Quality Awards......Page 533
Summary......Page 539
Multiple-choice Questions......Page 540
Review Questions......Page 541
References and Further Readings......Page 542
23.2 Sources of Variations......Page 543
23.3 Chart Techniques......Page 544
23.4 Control Charts for Variables......Page 545
23.5 Control Chart for Trends......Page 554
23.7 Process Out of Control......Page 555
23.8 Process Capability and Specification Limits......Page 557
23.9 Process Capability......Page 558
23.11 Control Charts for Attributes......Page 559
23.12 Count of Defect Chart......Page 566
23.13 Demerits Classification and Control Chart......Page 571
23.14 Lot-by-Lot Acceptance Sampling......Page 572
23.15 Sampling Plan......Page 573
23.16 Properties of OC Curves......Page 579
23.18 Sampling Plan Design......Page 581
23.19 Average Outgoing Quality......Page 585
23.20 Average Sample Number......Page 586
23.21 Average Total Inspection......Page 588
23.22 Sequential Sampling Plan......Page 589
Summary......Page 591
Multiple-choice Questions......Page 592
Review Questions......Page 593
Exercises......Page 594
References and Further Readings......Page 598
24.2 6s Measurement......Page 599
24.3 DMAIC Methodology......Page 601
24.4 Six-Sigma Belts......Page 602
24.5 ISO 9000 586......Page 603
24.7 Major Changes between the 1994 and 2000 Versions of the ISO 9001 Standard......Page 604
24.8 Implementing ISO 9000 QMS......Page 605
24.9 EMS: Introduction......Page 610
24.10 ISO 14000......Page 611
Summary......Page 613
Multiple-choice Questions......Page 614
Review Questions......Page 615
References and Further Readings......Page 616
25.1 Introduction......Page 618
25.2 Four Fundamentals of Supply Chain (4Fs of SCM)......Page 619
25.3 Drivers of Supply Chain Performance......Page 620
25.5 Bullwhip Effect......Page 621
25.6 Supply Chain Information Systems......Page 623
Multiple-choice Questions......Page 627
References and Further Readings......Page 629
26.1 Introduction......Page 631
26.2 Decision-Making Environments......Page 632
26.3 Decision Tree Analysis......Page 642
Summary......Page 644
Multiple-choice Questions......Page 645
Exercises......Page 647
References and Further Readings......Page 648
Appendix 1......Page 650
Appendix 2......Page 653
Appendix 3......Page 654
Appendix 4......Page 655
Appendix 5......Page 660
Index......Page 662