METHODS AND INDUSTRIAL ENGINEERING

Ph.D. JAIME HUMBERTO MENDOZA CHACÓN

FACULTAD DE INGENIERÍAS
PROGRAMA DE INGENIERÍA INDUSTRIAL
 Before Industrial Engineering

• Engineering history lies back to the beginning of civilization.

• Until the end of 17hundreds, production meant crafts (A craftsman
used to treat material and assemble the pieces)
• Until then a single person used to
• Plan
• Select and supply material
• Produce and control
 Industrial Revolution

• In 1776, James Watt invented the steam engine. (Turning steam

power into mechanical power)
• This is the beginning of industrial revolution.
• Since then, first factories started to be established in USA and UK
(United Kingdom)
• Earlier factories were textile and metal working plants.
Significant Events in IE
  In1798, received government
Eli Whitney contract to make 10,000 muskets
 Showed that machine tools could
make standardized parts to exact
specifications
 Musket parts could be used in any
musket
Frederick W. Taylor

Known as ‘father of scientific

management’
In 1881, as chief engineer for Midvale
Steel, studied how tasks were done
Began first motion & time studies

Created efficiency principles

Taylor: Management Should Take More
Responsibility for
• Matching employees to right job
• Providing the proper training
• Providing proper work methods and tools
• Establishing legitimate incentives for work to be accomplished
 Frank & Lillian Gilbreth
 Husband-and-wife engineering team
 Developed work measurement methods
 Applied efficiency methods to their home & 12
children!
 (Book & Movie: “Cheaper by the Dozen,” book:
“Bells on Their Toes”)
Henry Ford
 In 1903, created ford motor company

 1913, first used

moving assembly line
to make Model T
 Unfinished product
moved by conveyor
past work station

 Paid workers very well for 1911 ($5/day!)

Contributions From
• Human factors
• Management science
• Biological science
• Physical sciences
• Information science
Significant Events in IE
• Division of labor (Smith, 1776)
• Standardized parts (Whitney, 1800)
• Scientific management (Taylor, 1881)
• Coordinated assembly line (Ford 1913)
• Gantt charts (Gantt, 1916)
• Motion study (the Gilbreths, 1922)
• Quality control (Shewhart, 1924)
Significant Events in IE
• CPM/PERT (Dupont, 1957)
• MRP (Orlicky, 1960)
• CAD
• Flexible manufacturing systems (FMS)
• Computer integrated manufacturing (CIM)
• Lean manufacturing Taiichi Ohno 1937
• Six sigma Bill Smith 1988
• 4.0 Industries 2016
METHODS ENGINEERING

• Methods engineering is the analysis and design of work methods and

systems, including the tooling, equipment, technologies, workplace
layout, plant layout, and work environment

• Other names for methods engineering:

• Work study
• Work simplification
• Methods study
• Process re-engineering
• Business process re-engineering
Objectives in Methods Engineering

• Increase productivity and efficiency

• Reduce cycle time
• Reduce product cost
• Reduce labor content
Other Objectives
• Improve customer satisfaction
• Improve product and/or service quality
• Reduce lead times and improve work flow
• Increase flexibility of work system
• Improve worker safety
• Apply more ergonomic work methods
• Enhance the environment (both inside and outside the facility)
Operations Analysis
Study of an operation or group of related operations for the purpose of analyzing their
efficiency and effectiveness so that improvements can be developed relative to specified
objectives.

Objectives in operations analysis

• Increase productivity
• Reduce time and cost
• Improve safety and quality

• Methods engineering and operations analysis are very similar, except that methods
engineering places more emphasis on design.
HOW TO APPLY METHODS ENGINEERING
Systematic Approach in Methods Engineering
• has its basis in the scientific method used in science, research and development,
engineering design, and other problem areas.
• The systematic approach in methods engineering consists of the steps described
below.

Step 1: Define the Problem and Objectives. The problem in methods engineering study may be low
productivity, high cost, inefficient methods, or the need for a new method or a new operation.
The objective is the desired improvement or new methods design. Possible objectives are to
increase productivity, reduce labor content and cost, improve safety, or develop a new method
or new operation.
HOW TO APPLY METHODS ENGINEERING
Step 2: Analyze the Problem. Data collection and analysis activities for the type of problem being
studied.

• Activities often used in this step include the following:

• Identify the basic function of the operation.
• Gather background information.
• Observe the existing process or observe similar processes if the problem involves a new work
design.
• Collect data on the existing operation and document the details in a format that provides
itself to examination.
• Conduct experiments on the process.
• Develop a mathematical model of the process or utilize an existing mathematical model
• Perform a computer simulation of the process.
• Use charting techniques.
HOW TO APPLY METHODS ENGINEERING
Methods design is concerned with either of the following situations:
1. Design of a new method or process
• Required for new product or service and there is no existing standard
• Method must be designed from scratch, using best existing practice for similar
operations

2. Redesign of an existing method or process based on a previous methods

analysis.
HOW TO APPLY METHODS ENGINEERING
Step 3: Formulate Alternatives. There are always multiple ways to perform a task or accomplish a
process, some of which are more efficient and effective than others.

• The purpose of this step in the problem-solving approach that is not to identify the best
alternative but to formulate all of the alternatives that are feasible.

Step 4: Evaluate Alternatives and Select the Best. This step consists of a systematic assessment of
the alternatives and the selection of the best solution among them, based on the original
definition of the problem and objectives.
HOW TO APPLY METHODS ENGINEERING
Step 5: Implement the Best Method. Implementation means installing the selected solution: introducing
the changes proposed in the existing method or operation, or installing the new method or process.
• This may involve pilot studies or trials of the new or revised
• Implementation also includes complete documentation of the new or revised method and replacement of the
previous documentation

Step 6: Audit the Study. Perform an audit or follow-up on the methods engineering project.
• How successful was the project in terms of the original problem definition and objectives?
• What were the implementation issues?
• What should be done differently in the next methods engineering study?

For an organization committed to continuous improvement, answers to these kinds of questions help to fine-
tune its problem-solving and decision-making skills.
Basic Data Collection & Analysis Tools
1. Histograms
2. Pareto charts
3. Pie charts
4. Check sheets
5. Defect concentration diagrams
6. Scatter diagrams
7. Cause and effect diagrams
Histogram
• A histogram is a statistical graph consisting of bars representing
different values or ranges of values, in which the length of each bar is
proportional to the frequency or relative frequency of the value.

• A useful tool because the analyst can quickly visualize the features of
the data, such as:
(1) the shape of the distribution,
(2) any central trend exhibited by the distribution,
(3) approximations of the mean and mode of the distribution,
(4) the amount of scatter or spread in the data.
Histogram
Pareto Chart
Special form of histogram in which attribute data are arranged according to some criterion such as
cost or value

• Based on Pareto’s Law: “the very important few and the unimportant many”

• Often identified as the 80%-20% rule

• 80% of a nation’s wealth is owned by 20% of the population
• 80% of sales are accounted for by 20% of the Stock Keeping Units
• 80% of a factory’s production output is concentrated in only 20% of its product models.
Pareto Chart
Pie Charts
Cause and Effect Diagram
A graphical-tabular chart used to list and analyze the potential causes of a given problem

• Can be used to identify which causes are most significant and how to take corrective
action against them

• Also known as a “fishbone diagram”

• In application, cause and effect diagrams are often developed by worker teams who
study operational problems.

• The diagram provides a graphical means for discussing and analyzing a problem and
listing its possible causes in an organized and understandable way.
Cause and Effect Diagram
• As a starting point in identifying the causes of the problem, six general categories of causes are often used
because they are the factors that affect performance of most production and service processes. They are
called the 5Ms and 1P

• Machines. This refers to the equipment and tooling used in the process.
• Materials. These are the starting materials in the process.
• Methods. This refers to the procedures, sequence of activities, motions, and other aspects of the method used in
the process.
• Mother Nature. This is for environmental factors such as temperature and humidity that might affect the process.
• Measurement. This relates to the validity and accuracy of the data collection procedures.
• People. This is the human factor.

Does the worker bring the necessary skills to the process?

Cause and Effect Diagram
Operation Process Charts
• Chronological sequence of operations
• Show operations as a flow chart though the worksite.
• Show the types of operations:
• Operation
• Transport
• Inspection
• Delay
• Storage
• Decision
Flow Diagram
• Show layout of work area
• Show the flow of work through that area
• Show congestion areas, crossing worker paths, total travel.
• Identify how layout can be redesigned to reduce travel, motion,
collisions, etc.
• Store materials near where they are used.
• Increase efficiency and safety.
Flow Diagram
Process diagram
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Methods_Engineering_and_Operations_Analysis.ppt
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