Industrial Engineering and Production Management

1160 Pages·2018·39.53 MB·English

by  Martand T. Telsang

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About the Author
Dr. Telsang Martand Tamanacharya
Professor Mechanical Engineering & Dean Academics of Sanjay Ghodawat
University, Dr. Telsang is B.E. (Mech.) First Class with Distinction from
Karnataka University Dharwad (1982), M.Tech (Industrial Engineering)
from National Institute for Industrial Engineering (NITIE), Mumbai (1992)
and Ph.D. in Mechanical Engineering from Dr. Babasaheb Ambedkar
Technological University, Lonere Maharashtra. He is also D.B.M (Post
Graduate Diploma in Business Mgt.), First Class, IMDR Poona (1985).
With five years of Industrial experience and thirty years of teaching experience at UG and PG
programs in engineering and management, Dr. Telsang is Fellow of Institution of Engineers
(FIE) India and Fellow of Indian Institution of Production Engineers (FIIPE), Bangalore as well as
Senior Member, IIIE Mumbai, Member of ISTE New Delhi and Life member and National Council
Member of ISTD New Delhi. He is Advisory Board member BIOINFO Mechanical Engineering.
He has contributed research papers at various National and International seminars and
conferences and Journals. And is the author of 3 Books and 2 Monograms.
Dr. Telsang has organized workshops for faculty and students in areas like educational
Technology, TQM, Business Process Reengineering, Industrial engineering and is a recognized
trainer of ISTD in the areas of Industrial Engineering and quality management. Awarded with
Outstanding Academic award ’98, Instituted by RIT, Rajaramnagar and Best Teacher Award
2004 by K.E. Society’s Kasegaon, he has also received ISTE Best Engineering College Teacher
Maharashtra 2011, Outstanding Engineering Educator Award 2016 by lndo-US collaboration for
Engineering Education (IUCEE) and the Shivaji University Gunawant Shikshak Award 2015.
His long association with Professional Bodies like ISTE, ISTD, Institutions of Engineers (IE)
and IUCEE coupled with international exposure through visits of US top-ranking universities
as a member of Indian delegation through lndo-Universal Collaboration for Engineering
Education (IUCEE) adds to his already varied portfolio. Dr. Telsang has worked as Member
of Board of Governance of RIT for 10 years, is member Finance and Planning committee and
Member Secretary of Academic Council of RIT apart from being a reviewer for many national
and international journals and Member of Editorial Board of Journal of Engineering Education
Transformation.
His areas of interests include Total Quality Management, Industrial Engineering and Operation
Research. Production Management and Educational Technology.
IInndduussttrriiaall EEnnggiinneeeerriinngg
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PPrroodduuccttiioonn MMaannaaggeemmeenntt
[Recommended text for Diploma, Undergraduate and Post Graduate Programs in
Mechanical, Production and Industrial Engineering. A useful reference for BBA,
MBA and Professional Engineers. A useful guide for GATE and UPSC and other
Competitive Examinations.]
Dr. MARTAND T TELSANG
M.Tech (Ind. Engg). PhD Mechanical Engineering
Fellow (IEI) India, Fellow (FIIPE) Bangalore,
IUCEE Fellow (2017)
Dean Academics, Sanjay Ghodawat University
Kolhapur
S Chand And Company Limited
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© S Chand And Company Limited, 1998
All rights reserved. No part of this publication may be reproduced or copied in any material form (including
photocopying or storing it in any medium in form of graphics, electronic or mechanical means and whether or not
transient or incidental to some other use of this publication) without written permission of the copyright owner. Any
breach of this will entail legal action and prosecution without further notice.
Jurisdiction: All disputes with respect to this publication shall be subject to the jurisdiction of the Courts, Tribunals
and Forums of New Delhi, India only.
First Edition 1998
Subsequent Edition and Reprints 2002, 2004 (Twice), 2005, 2006 (Twice), 2007, 2008 (Twice), 2009, 2010,
2011, 2012, 2013 (Twice), 2014 (Twice), 2015
Third Revised Edition 2018
ISBN: 978-93-525-3379-4 Product Code: H3IEP62PAQC10ENAC18O
This Book is dedicated
to the loving memory of
my beloved brother Late
Krishna Telsang and
Revered father
Late Tamanacharya
Telsang
Preface to the Third Revised Edition
Rapid changes in technologies are the driving forces for both the industry and business at
global as well as national levels. Customer still remains in focus and is king in the competitive
manufacturing environment. The increase in capabilities of manufacturing accompanied
by expectations of customer is building pressure on both speed and variety. Customers are
becoming more demanding and expect the product to be designed and manufactured in a tailor
– made fashion to meet individual requirements (mass customization). The ever increasing
demand and expectations have shortened product life cycle and also customer wanting more
personalized treatment.
One more noticeable change is the shift in strategy of companies to focus on their core
competencies and outsourcing has become more prominent demanding interconnectivity or
networking of manufacturing substantially. The implication of this is that companies are now
integrated as the customer of their suppliers and integrated with customers whom they supply.
This has created need to design and manage same very complex supply chains networks.
Information technology has helped to solve many of the enterprise issue and helps to integrate
all functions of the organization.
The response to changing manufacturing environment is two-fold. The organization of
the book has been changed and the contents have been adjusted to more closely to reflect the
current needs.
Organization of the book (Third Edition)
The book is reorganized into six sections:
Section 1: Work System Design
Section 2: Production System Design
Section 3: Manufacturing Planning and Control
Section 4: Quantitative Techniques for Operations Decisions
Section 5: Supply Chain Management
Section 6: Advances and Trends in Operations Management.
Special feature of the third edition
This edition of the book retains all the good features of the second edition with respect to
presentation, simplicity of the language and format. With due response to feedbacks both
from my fellow faculty, students and industry persons, the focus of the book is reorganized
to include the perspective and approach right from how the product idea is translated into
a physical product. All the aspects have been covered comprehensively and lucidly so that it
serves both students and practioners.
The salient features are:
1. Entire book is re-organized into six sections with 29 brand new chapters (with 5 free
chapters on the website).
2. Each chapter starts with chapter learning outcomes (it is mandatory for NBA accreditation
to write course outcome chapter outcomes to practice OBE).
3. More solved and illustrative examples to make concepts clear and case studies to include
practicing aspects.
4. Conceptual clarity helps students to prepare for competitive examinations like GATE, UPSC.
5. New and evolving concepts like Reconfigurable manufacturing, Green manufacturing
and Remanufacturing are added to acquaint readers with new and advanced trends in
manufacturing.
6. A special note on manufacturing cost concepts is added to give a focus on costing.
Dr. Martand T Telsang
Acknowledgement
Constructive criticism and feedback from students and faculty has worked as a great
motivation for revising the book and coming up with chapters that address the latest operation
management technologies around the globe. Special thanks to entire academic fraternity of
industrial Engineering and Production/operations Management for recommending the book
for the courses in Engineering and Management.
I am very much thankful to President Mr. Sanjay Ghodawat, Trustee Mr. Vinayak. Bhosale
and Hon. Vice Chancellor Dr. Venkatesh A Raikar, Er. Shripad S Adhyapak and Registrar
Dr. B.M. Hirdekar of Sanjay Ghodawat University Kolhapur for their support and encouagement.
I acknowledge with thanks to management and the contribution of my fellow teachers
at Rajarambapu Institute of Technology, all my M. Tech Students and special thanks to
Dr. S.K Patil Dean Academics of RIT and Dr. Anand Mishrikoti, Professor Dean VDRIT Haliyal.
My special thanks to my mother Padmavati, My Better half Mrs. Kshama, My Father in law
Er. Sripad Adhyak and Mrs. Sarala Adhyapak and My Beloved Trupti, Manoj and Madhurya for
their uncondional support and motivation.
Kolhapur Dr. Martand T Telsang
Disclaimer : While the authors of this book have made every effort to avoid any mistakes or omission and have used their
skill, expertise and knowledge to the best of their capacity to provide accurate and updated information. the author and
S.Chand does not give any representation or warranty with respect to the accuracy or completeness of the contents of this
publication and are selling this publication on the condition and understanding that they shall not be made liable in any manner
whatsoever. S. Chand and the author expressly disclaim all and any liability/responsibility to any person, whether a purchaser
or reader of this publication or not, in respect of anything and everything forming part of the contents of this publication.
S.Chand shall not be responsible for any errors, omissions or damages arising out of the use of the information contained in
this publication.
Further, the appearance of the personal name, location, place and incidence, if any; in the illustrations used herein is purely
coincidental and work of imagination. Thus the same should in no manner be termed as defamatory to any individual.
Contents
SECTION I: WORK SYSTEM DESIGN
1. Introduction to Industrial Engineering 9–21
1.1 Definition 9
1.2 History and Development of Industrial Engineering 10
1.3 Contributions to Industrial Engineering 11
1.4 Activities of Industrial Engineering 12
1.5 Industrial Engineering Approach 13
1.6 Objectives of Industrial Engineering 14
1.7 Functions of an Industrial Engineer 14
1.8 Techniques of Industrial Engineering 14
1.9 Place of Industrial Engineering in an Organisation 15
1.10 Industrial Engineering in Service Sector 16
1.11 Systems Approach 17
Summary 19
References for Further Reading 20
Review Questions 20
2. Productivity and Production Performance 22–48
2.1 Introduction 22
2.2 Concept 23
2.3 Definitions of Productivity 23
2.4 Production and Productivity 24
2.5 Expectations from Productivity 25
2.6 Benefits from Productivity 25
2.7 Dynamics of Productivity Change 25
2.8 Productivity Measures 26
2.9 Advantages and Limitations of Productivity Measures 27
2.10 Productivity Measurement Models 31
2.11 Factors Influencing Productivity 32
2.11.1 Controllable Factors (Internal Factors) 33
2.11.2 External Factors 33
2.12 Productivity Improvement Techniques 34
2.13 Levels of Productivity Measurements 35
2.14 Measuring Manufacturing Performance 36
2.14.1 Capacity Utilization 36
2.14.2 Labour Productivity 36
2.14.3 Re-Visit of Capacity Utilization 37
2.14.4 Yield 37
2.14.5 What is Visual Management? 38
2.15 Common Production KPIS 38
2.16 Quality, Cost and Delivery (QCD): Measuring Manufacturing Performance 40
Summary 46
References for Further Reading 47
Review Questions 47
3. Work-Study 49–58
3.1 Introduction 49
3.2 Importance of Work-Study 50
3.3 Advantages of Work-Study 50
3.4 Work-Study Procedure 51
3.5 Work Simplification and Work-Study 52
3.6 Human Considerations in Work-Study 52
3.7 Work-Study and the Management 52
3.8 Work-Study and Supervisor 53
3.9 Work-Study and the Workers 53
3.10 Work-Study Man 53
3.11 Influence of Method and Time Study on Production Activities 54
3.12 Concept of Work Content 54
3.13 Reasons for Excess Work Content 55
3.14 Techniques to Reduce Work Content 56
3.15 Work-Study as a Tool to Improve Productivity 57
Summary 57
References for Further Reading 58
Review Questions 58
4. Method Study 59–95
4.1 Introduction 59
4.2 Objectives of Method Study 60
4.3 Scope of Method Study 60
4.4 Steps Involved in Method Study 61
4.5 Selection of the Job for Method Study 62
4.6 Recording Techniques 63
4.7 Recording Techniques 64
4.7.1 Charts 65
4.7.2 Diagrams 73
4.8 Micro-Motion Study 75
4.9 Memo Motion Study 77
4.10 Cycle Graph and Chronocycle Graph 78
4.11 Critical Examination 78
4.12 Operation Analysis 80
4.13 Development and Selection of New Method 82
4.14 Principles of Motion Economy 82
4.15 Installation of the Proposed Method 92
4.16 Maintain the Proposed Method 92
Summary 92
References for Further Reading 93
Review Questions 93