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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. Overview. Brief History and Context for ISE - PowerPoint PPT Presentation
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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 ISEDiscuss Some Major Areas of Study in ISE Mathematical Optimization Production & Service System Design Simulation Modeling & Analysis
Overall Course Structure of the ISE MajorSome Examples of What Recent Graduates in ISE are DoingAssignment on “Podium Design”
4
Modern Engineering Disciplines
Civil engineering emerging from military engineeringMechanical engineering emerging from growth of mechanical devices after steam engineElectrical engineering after the telegraph (and other products) appearedChemical engineering (petroleum products, lubricants, etc)
5
Post WWII Disciplines
Nuclear engineeringElectronic engineeringAeronautical engineeringAstronautical engineeringComputer engineeringEnvironmental engineeringBiomedical engineeringIndustrial & Systems Engineering
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Chronology of ISE
The industrial revolution in large part led to the emergence of industrial engineering as a professionBabbage thought to specialize labor by skill requiredTaylor 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 workHenry Gantt developed his chart to preplan, schedule, and monitor work activityShewhart developed the fundamental principles of statistical process control Disciples became big names in quality
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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.
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Design Impacts
Industrial and systems engineers design systems at two levelsThe first level is called the human activity level and is concerned with how work gets accomplishedThe second level is called the management control system level and addresses the planning, measurement, and control of organizational activities
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Level One Elements
Processes within the organizationLayout of facilities and machinesDesign of the workplaceStorage space and locationWork methods
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Level Two Elements
Planning systemsForecasting systemsMaterial and inventory planning and controlScheduling activitiesCost control and analysisQuality control system
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“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 contentISEs try to use the correct technique to improve the integrated system under investigation, including OR when appropriate
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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 variablesSolutions 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
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INFORMS
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Production Operations
Analysis of proposed product or serviceAnalysis of manufacturing processFacilities issuesWork methods and standardsProduction planning and control
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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
• Ass
embl
y
• War
ehou
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 profitCoordinate 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
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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
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Manufacturing Process
What is the best process by which to manufacture and assemble the productWhat is the mix of equipment, robots, or personnelHow can the assembly lines best be balancedWhat 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 inspectionUtilities requiredSecurity and emergency planning
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Prod. Planning & Control
Forecast potential salesAre capacity and resources being utilized to their capabilitiesEstablish inventory proceduresPlan for any materials requirement planningScheduling
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Institute of Industrial Engineers
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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?
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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 componentsThe “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” approachSystems consist of: Entities (Customers, Parts) Resources (Machines, People) Routings (Logic, Networks) Input Data (Times, Probabilities) Performance Measures (Times, Utilizations)
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ARENA Model of a Supply Chain
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ARENA Model of a Truck Assembly Line
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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 standardsPerform work improvement studiesValue engineering studies to determine and eliminate sources of waste and excess cost
33
Personnel Systems
Employee testing, selection and placementTraining and education programsJob evaluation and incentive programsErgonomics and human engineering applied to jobs, workplaces and workplace in generalQuality improvement activities
34
Prod. Planning & Control
Design quality control system and inspection processesShop floor control proceduresReports Cost Quality Labor Productivity
35
Planning
Support corporate strategic planning to include national and international planningPerform enterprise modelingSupport and perform system integration activitiesProvide support to major decisions and participate in major decisionsQuality management activities
36
Policies and Procedures
Study organizational analysis and designPerform analyses of functional groupingsPolicy manualsProcedures
37
Performance Measurement
Identify meaningful performance measures for those areas of interest key to the firm successIdentify critical success factorsSpecify and design corrective action proceduresDesign reports for all levels of management
38
Projects and ISE might take on
Analyze systems and construct modelsApply appropriate solution methodologiesPerform simulation studiesPerform operations research studiesPerform statistical analysisConduct designed experimentsAnd more…
39
ISE and Systems
Industrial engineering really takes a system-level perspectiveThe 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 systemAn 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 ProjectCalculus, Physics and ChemistryWSU Core
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, stakeholdersDevelop a list of customer needs (15 to 25)Develop a set of metrics for the podiumDevelop a set of specifications for the podium (15 to 25)