Table Of Content

IDNUSTRIEANLG.I NEERING AND MANAGEMENT INDUSTRIAL ENGINEERING AND MANAGEMENT By Dr. Ravi Shankar PhD (IIT, Delhi), MBA (Systems & Operations), M.Sc. (Engineering), B.E. Moldmedalist) Revised By Dr. G. Kannan (7s61'GALGOTIA Publications Pvt. Ltd. 5, Ansari Road, Darya Ganj, New Delhi-110 002 Dr. Ravi Shankar INDUSTRIAL ENGINEERING AND MANAGEMENT © Copyright 2000 by Galgotia Publications Pvt. Ltd. All rights reserved. No part of this book may be reproduced in any form, by photostat, microfilm, xerography, or any other means, or incorporated into any information retrieval system, electronic or mechanical, without the written permission of the copyright owner. ·First Edition - 2000 ·Second Edition - 2009 ·Reprint - 2015 ·Reprint - 2016 2017 ·ISBN - 978-81-7515-605-0 Published by Galgotia Publications Pvt. Ltd., 5, Ansari Road, Darya Ganj, New Delhi- 110 002 Printed at- Earam Offset Printers, Delhi- 110053 Galgotia Publications pvt. ltd. - - - Dedicated to my respected Guru 314.guSHu5ClIchlt 01141 niUr.“111 itff mir dpd -9Tr:ii 0111.411 qmitt,tui stkw1-4-6-4 c 811.- tvAd h 11 -7-4-6rr livRE01: TA-F: Trrams-crt-4-4:r w4:4 i‘tk,Nd gr:11 (-14 qiiqaci 04 +iict 1,(0,111:i wi:r4 91:1:11 7 tv w.- • 7 iv 414-- : -9 .-01111:trt -fflzi‘ 91:1:11 PREFACTEO T HES ECONEDD ITION Thea ppearoaftn hcleea rnguem boefri nteraesntdii mnpgo rdteavnetl oppmreondtdmsee td o makaes ubstraenvtiiosantil ho Beno oTkhe.m ajaodrd ittoti hobeno oikas sfo llo,v�: HumaRne souMracnea gemAenndHt u maRne souPrlcaen nHiunmg:aR ne soMuarncaeg ement. FactCoornst ritbotu hGteri onwgIi mnpgo rotfHa RnMc.Oe r ganiBzeahtaivoTinhaoGeluo rao,lf s OrganizBaethiaovIninaodlri ,vG irdouuTapel.a, m H,u maRne source( HPRlPSa)tn.rn ai·tn egg ic PlananntidhnH egu mRaens oPulracnen ing Process. ·PurchaFsuinncgot:Pfi u orncsh DaespianrgDt umteoinPfetu s,r chOafftsci.eMnreg,t hooPfdu sr chasing, PurchParsoicnegs s/PPLrtorccehdausrDieen,cg i/asBsPiu eoyPrnir nogc ePduurrceRh,ea qsuei siiion ForPmu,r chParsoie:neTgde unrdNeeo,rt sIi.nc veiT teinnd.Cge o rmsp,ar�tivIem pSotroatftaenmceen t, MateMrainaalgse SmteoRnretec. oPrudrsc,h Si;iyssitnegm sT/eBcuhyniPinuqgru cehsa,s ing/Buying TechnVieqnuRdeaosty,i ng. LeaMna nufactuCroimnmgMo:en t hUosdeisdLn e aMna nufacMteucrhiannfogirE ,sn mvsi ronmental ImprovtehmreoLnuetga Ihnm plemeBnatrarttiioSeo urncs,c elsmspfulle m_eoannnt.Fd al teixible ManufaScytsutr(eiFmnMsgS ) GrouTpe chnolPorgoyd:u Fclt·oiA wonna l(yPsFiAPs)F ,AP roceOdbujreec.it nCi evlelsu lar Manufacturing. IndusPtsryicahlo Elvooglyou:ft linodnPu ssytcrhiPoarllio mRgaoyro,lyf e l ndPussytcrhioallo gists. ServOipceer atAinodSn esr vPircoed uScetrsvO:i pceer aMtainoangse SmeernvtPi,rc oedsau ncdts SerCvhiacrea ctOepreirsaMttaiincoasng,sei tmnhe Sene tr Sveiccteo r. ErgonoAmM iacns-:M aScyhsitnDeeem s,ai ngTdny poeCfso ntArnotlhsr,o pPormienticrtniyhp ,el es AppliocfAa nttihorno pDoamtAeant,tr hirco pfooWmroe rtkrpyl acEer gDoensioiCnmgo inmc,ps u ter WorkstPaotsiiotnti,hoM eno inniSgtc orreL eing,h VteinrtJigNl,oa itLsieeov nie,ntl hsCe o inputer WorkstCaotmipouIntn,ej ru ri·es. MarketMiannga gemMeanrtk:e CtoinncMgea prtk,eM tiixFn,ug n ctoifMo anrsk ePtriondLgui,cf te CycPlrei,cT iynpogePf,_r si cMianrgRk,ee ste arch. SiSxi gmSai:Sx i gFmraa mewFoirvke, Eolfte hmSeei Snxigt-msFa r ameDweofirnke,- Measure Analyze-Clomnpt(rrDooAMvlIe CP )r ocTeostsQa.ul a lMiatnya ge(m"TeQnMc1t)n Sdi Sxi gma, In tern_OartgiaonnifoazrlSa ttainodna r(dIiS9zO0a)0St 0ei raoinnSed isS x i gma. AgiMlaen ufactNueriefondrgA :gi -lMeanufacFtouuPrrri inngcC,io p1lnepsba,e1 t'wiLeseeoannn ManufacatnAudgr iiMlnaegn ufacDtiufrfiebnreget,nw cTeere and iatniCdou nrarPler natci tnice Manufacturing. Aut·h or PREFACE --------------------�-�---------- Wrtiian g biosaol ko naenltdyi retsaosImkrte.e quail rooetfrs e adwirnigtt,iy npgai,nne dgd iting. Befoyroegu e at boofoa kr oeuingdhh utn dpraegdael soo,tfr eviasnicdoh nasnh gaevasel retaadkye n plaactde i ffesrteanogtfte hsbe o opkr epaBrualtti iakonenoy .t hfei.rn ipsrhoedduu lctti,mw ahteenl y ·thbeo ocko moeusit st,h ocuolndt saoimrnee vaall fuoiert u ss eIrb se.l itehvtaehte e f ftohrhatat s be_epnu itns trucwtruirtaiinnpndgrg ,e setnhmteai tnegfr oairt a elx tlbiotkohekwi osu,bl edo fs ome reuaslte oi tisn ternedaedd·e rs. WHYT HIBS0 0.K InduEsntrgiianlae neMdra innagg ieosmn eoenf t i tnhaoets ttr sapcetciivaefl oMizrea cthiaoEnnnisgc ianle ering graduTahticesos ui.ras sl eas c oo croeu irnas lem aolstlthb .er anocfEh negsi neHeorwitnvagets.r o ,m e plaictnesas md,ei ffael ribsti tftloe,erx amEpnlgei:n eering ManEgceomnaeonnmMdtya , n aEgnegmiennete,ring IndusMtarniaaglee mteTcnh.t·ib , so oiksa imteocd a tteotr h nee eodft hecsoeu rses. Th�irrsee aald leyao rfatc ho mprehbeonotskhci aovtve be orttshh t er adiatn'idro enicaselsn ute s inI nduEsntgrianleW eirtihenoxgup.to tstouh .rere e dceevnetl ogprmaednuetanstg,ii nwngiec leelrr st ainly beo ff-guiantr hdieen dd ustTrhyib/sofi oiekasl n da .t tetmobp rtit dhggeea t ph maotso tft haev ailable booiknts h siusb jseecettmoi nhaenrfadii ttl ot hceo vreerc deenvte loipnams eynsttsem maantniecr . COV�RAGE Thbeo oiksc arecfurlalftytoc e odvt ehrte r ada,irteaiasows ne lalsr ecaernetca hsa,nm gaen agement areaasws e lalsI T-areas,m oqdueaalswns et lailstm aatniavgeea mreenatsa ,lt lha aanrtrde e levant forI ndusEtnrgiinaTelhe cero sv.e orfat ghbeio so ikn clmuadnefoysc aalr esausca hs : TradiAtrieoaFnsaa:lc iPlliatnMyna itnegHr,ai nadlIl ninvgeC,no tnotrPryro old,uP cltainaonnni··d n g ContQruoallC,io tnytR reolli,aS bcihleidtPuyrl,oi dnDugec,vt e loVpamleEunnetg ,i neWeorrSiktn ugd,y ,' WorMke asurJeo�be-netv,aa nlmdue artriiatot Wnia ngge,.e- nitnpiclvaen s, etc. RecAernetJa us:s t-iSnu-pCTphliaymMi ean,n ageVmaelCnuhteaM, ia nn ageTmheeonoCftro ,yn straints, etc. Change ManCaognemteinntu:o us (TIQmpMBr)eo,nv cehmmeaannrtRdk e ienngg _i.n eering IT-arMeRaP·sM, :R •P UJ E,R PE,m ergoefen -cbeu seitnce.'s..s , ' QuantiMtoadteiLlvisen:P e raorg raTmrmainnsgpM,oo rdtAeaslts,ii ogmnno mdeQenulte, u Miondge ls, CfM /PERSiTm,u leattci.o n, EngineEecroinnogBm rye:Ea vk.e A nnalRyespilsa,c aenmSdee nlted cetciiosnEi nognisn,e ering Econommoyd els. INDUSTERNIGAILN EEARNIDNM GA NAGEMENT ManageAmreenPatrs :i ncoifMp alneasg eOmregnatn,iL seaatdieoErnns,th riepp,r etnyoepfue r ship, BusiSnyesstse ms, etc. Thceo veorfta hgteeo pairpcels a ntnoie ndt ecgornactmeeop dtenslu,sm ,ee rxiaamlap nlided su strial applicSautffiioccniasehr.naeb ts e etna kteopn r estehrneet c deenvte loapnmtder netinsned asca hr ea. besptihtiieist sa, l wpaoysss tihbsalotem r ee letvoapnoituc tsl iintn hesedy lloaffb euUwsn iversities arset miilsls Wienw go.u alpdp reicfsi uacgthae pa srb er outgoth htae t teonftt hiaeou nt shoot rh at improvmeambye neutn sd eritnta h-kne.ee nxe td i..tW iewo onu alldas pop reacniadac tken owfloerd ge ancyo nstsruucgtgiefvsoettr hi ieom np rovoeftm heinst bowoikdc.eo vTeohrfeat ghbeeo omka kes iuts efofurml a ncyo uirMns. eT sec hM..,B .PAG.D,Ba Mn Dd. BP.rAo.g raMmCmAae nsBd,C AProgrammes, M.Com.I,C WCaAAn A,dM I PEr ograemt.mc.e s, ACKNOWLEDGEMENTS Durtihnpegr epaorfta htbiiosoo lnki ,t efrraovtmau rrijeoo uusrm naaglasz,ai nnoden s-,al ritniec les havbee erne ferIre exdp.rn e1gsyrs a ttioat lusldu eca hu thpourbsl,ia snihdne srtsi mtauntoyift o hnesm; havbee elni sitnre edfe reInfsc oemsae.r l ee oftu itn advIes retetlkhy ep,ia rr don. Ie xprmeyss isn gcrearteti Potr uoPdfre.eV mr (aItDI eTl Hhiies)x .c elilInen ndcueEs ntgriinaele ring i�sb enchHmeai rasrk o.l e-amnoiddn eslp ifromarat nilyoi mnke eI. w isthoa cknowmlyse idngcee re thatnoPk-rso Sf..GD .e shm(uIkDIheT l ahin)o,tr hoelre -fomroe dxecle lilnte enacceah nirdne gs earch ofI ndusEtnrgiianleI etir sni osn ugr.p trhimasaten o yfm yu nderstaarinend fliunegbnsywc headt . Ih avlee arfrnoemmd y p rofeasnssdot rusdI et nhtastn,hk ea mlT lh.e mrieg bhemt a ngya pisnt he boobku,at l tlh easrede u teo m yo wnl imitaant,ldi a oconkfps e rfection. Ia lesxop rmey·ss isn tcheartneP�k r so .fK.B. a Dn �aenPtdr oAfrn.'nK anfdoatr h ee�icro ur.sa.g ement It hamnyko thceorl leaangfdur eis,ef noidrns s piarnaedtn icoonu raIgt ehmamenynkp t u.b lishers, MrS.u nGeaellg aonthdii Pasr oduction AM.�SKn.ha afognrte hreg,'ri erMsa rut.p phoarrwtod,r a kn d heldpu rtihnpegr epaorfat htbiiosoo nk . Ib elitehtvahetoe n weh od esearltvlheb ese asdtj ecitnti hvaiecssk no�liesndo gnmoeet nhte r thamnyw ifDerP,.o onam. hWesirut phpoioutirts it m,p ostsowi rbilatbe e o ookft hmiasg nitude. Myt wloi tcthlielP drraetnay,nuM dse hg dheas esrpveemc einatloi fo'na pprDeecsiptaihttetieieo rnn d.e r aget,h eayri en telelniogutegounh nt d ertshttaahtnwi dos r hka sdo mpeu rpaonsuder geDnucryi.n g lacsotu oplfye e aarlstl.h t ei msep einnwt r ittihBniogso akc tubaellloytn ·ogt ehde m. DrR.A VSIH ANKAR Jun2e0 00 ·DepartomfMe annta gemSetnutd ies UT,D elhi NewD elhi0-11610 emaislm:7 [email protected]