HISTORY and PERSPECTIVE of INDUSTRIAL ENGINEERING

Transcription

1 October 5,

2 HISTORY and PERSPECTIVE of INDUSTRIAL ENGINEERING History of Engineering and Development of Industrial Engineering Industrial and Systems Engineering 2

3 Science and Engineering Engineering and science have developed in a parallel, complementary fashion, although not always at the same pace. 3

4 Whereas science is concerned with the quest for basic knowledge, engineering is concerned with the application of scientific knowledge to the solution of problems and to the quest for a better life. 4

5 Obviously, knowledge cannot be applied until it is discovered, and once discovered, it will soon be put to use. In its efforts to solve problems, engineering provides feedback to science in areas where new knowledge is needed. 5

6 Thus, science and engineering work hand in hand. 6

7 Although science and engineering each have distinguishing characteristics and are regarded as different disciplines, in some cases a scientist and an engineer might be the same person. This was especially true in earlier times when there were very few means of communicating basic knowledge. The person who discovered the knowledge also put it to use. 7

8 Is Engineering a Job, or an Occupation, or a Profession? What is the difference between a job, occupation and a profession? 8

9 Job- definition regardless of skill level and responsibility, any work for you are paid for. a piece of work; especially : a small miscellaneous piece of work undertaken on order at a stated rate (Merriam- Webster Dictionary) 9

10 Occupation- definition Being employed and making a living. An activity that serves as one's regular source of livelihood; a vocation. 10

11 Profession? We now know the difference between a job and an occupation so what makes up a profession? 11

12 Attributes of a Profession The profession requires extensive formal education 12

13 Attributes of a Profession Special organizations set and enforce various standards for members of the profession 13

14 Attributes of a Profession A significant service is provided to the public 14

15 Attributes of a Profession The work requires significant skill, Judgment, and Discretion 15

16 Professional or Not? Are professional athletes actually professional? What about carpenters? 16

17 Professional or Not? So what can we conclude? Athletes and carpenters DO NOT meet the standards required to be considered professions Medicine,Law, and Engineering ARE professions 17

18 ENGINEERING the profession in which a knowledge of the mathematical and natural sciences gained by study, experience, and practice is applied with judgement to develop ways to utilise, economically, the materials and forces of nature for the benefit of mankind 18

19 The Modern Era We choose 1750 as the beginning of modern engineering for two reasons: 1. Engineering schools appeared in France in the eighteenth century. 2. The term civil engineer was first used in

20 Principles of early engineering were first taught in military academies and were concerned primarily with road and bridge construction and with fortifications. This portion of academic training was referred to as military engineering. When some of the same principles were applied to nonmilitary endeavors, it was only natural to refer to these as civilian engineering, or simply civil engineering. 20

21 An important advancement was the development of a practical steam engine that could perform useful work. Once such an engine was available (approximately 1700), many mechanical devices were developed that could be driven by the engine. These efforts culminated in the emergence of mechanical engineering as a distinct branch in the early nineteenth century. 21

22 The first significant application of electrical science was the development of the telegraph by Samuel Morse (approximately 1840). Thomas Edison s invention of the carbon-filament lamp (approximately 1880) led to widespread use of electricity for lighting purposes. This, in turn, spurred very rapid developments in the generation, transmission, and utilization of electrical energy for a variety of laborsaving purposes. Engineers who choose to specialize in this activity were naturally labeled electrical engineers. 22

23 Along with the developments in mechanical and electrical technology were accompanying developments in the understanding of substances and their properties. The science of chemistry is concerned with understanding the nature of matter and in learning how to produce desirable changes in materials. The field of engineering endeavor naturally became known as chemical engineering. 23

24 As industrial organizations merged to capitalize on the rapidly developing array of technological innovations, the size and complexity of manufacturing units increased dramatically. Mass production was made possible through two important concepts: 1. Interchangeability of parts. 2. Specialization of labor. Through mass production the unit cost of consumer products was reduced dramatically. 24

25 During the early part of this movement it was recognized that business and management practices that had worked well for small shops and farms simply were inadequate for large, complex manufacturing organizations. The need for better management systems led to the development of what is now called industrial engineering. 25

26 This five major engineering disciplines (civil, chemical, electrical, industrial, and mechanical) were the branches of engineering that emerged prior to the time of World War I. These developments were part of the industrial revolution that was occurring worldwide, and the beginning of the technological revolution that is still occurring. 26

27 The Engineering Process Engineers solve problems, but so do mathematicians. Engineers analyze, but so do statisticians and economists. Engineers design systems. Do others? We can say that the distinguishing characteristic of engineering is that it is concerned with the design of systems. 27

28 What is design? Certainly, design involves a considerable amount of creativity. Is design then simply an art that one learns through experience? Or are there design principles that can be learned and applied? Synthesis is a term whose meaning is almost the same as design. Perhaps we can develop an understanding of design by discussing the two terms synthesis and analysis. 28

29 Analysis is concerned with resolving something into its basic elements; synthesis is concerned with combining elements into a whole. Typically, analysis is concerned with existing systems. Synthesis is usually concerned with a new or improved system. 29

30 Problem symptom or expression of need Problem definition, including statement of desired outcome Analysis Synthesis of alternative solutions Decision (selection of one alternative) Solution, system, or method Fig Basic engineering process 30

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32 Industrial Engineering emerged as a profession as a result of the industrial revolution and the accompanying need for technically trained people who could plan, organize, and direct the operations of large complex systems. The need to increase efficiency and effectiveness of operations was also an original stimulus for the emergence of industrial engineering. 32

33 Evolution of Operations Management Craft production process of handcrafting products or services for individual customers Division of labor dividing a job into a series of small tasks each performed by a different worker Interchangeable parts standardization of parts initially as replacement parts; enabled mass production 33

34 Evolution of Operations Management (cont.) Scientific management systematic analysis of work methods Mass production high-volume production of a standardized product for a mass market Lean production adaptation of mass production that prizes quality and flexibility 34

35 Historical Events in Operations Management Era Events/Concepts Dates Originator Industrial Revolution Scientific Management Steam engine 1769 James Watt Division of labor 1776 Adam Smith Interchangeable parts 1790 Eli Whitney Principles of scientific management Time and motion studies Frederick W. Taylor Frank and Lillian Gilbreth Activity scheduling chart 1912 Henry Gantt Moving assembly line 1913 Henry Ford 35

36 Historical Events in Operations Management (cont.) Era Events/Concepts Dates Originator Human Relations Operations Research Hawthorne studies 1930 Elton Mayo 1940s Abraham Maslow Motivation theories 1950s Frederick Herzberg 1960s Douglas McGregor Linear programming 1947 George Dantzig Digital computer 1951 Remington Rand Simulation, waiting line theory, decision theory, PERT/CPM MRP, CIM 1950s 1960s, 1970s Operations research groups Joseph Orlicky, IBM and others 36

37 Historical Events in Operations Management (cont.) Era Events/Concepts Dates Originator Quality Revolution JIT (just-in-time) 1970s Taiichi Ohno (Toyota) TQM (total quality management) Strategy and operations 1980s 1990s W. Edwards Deming, Joseph Juran Wickham Skinner, Robert Hayes Business process reengineering 1990s Michael Hammer, James Champy 37

38 Historical Events in Operations Management (cont.) Era Events/Concepts Dates Originator Globalization Internet Revolution European Union, and other trade agreements Internet, WWW, ERP, supply chain management 1990s 2000s 1990s Numerous countries and companies ARPANET, Tim Berners-Lee SAP, i2 Technologies, ORACLE, PeopleSoft E-commerce 2000s Amazon, Yahoo, ebay, and others 38

39 Eli Whitney 1995 Corel Corp. Born 1765; died 1825 In 1798, received government 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 39

40 Frederick W. Taylor Born 1856; died 1915 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 40

41 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 41

42 Frederick W. Taylor is credited with recognizing the potential improvements to be gained from analyzing the work content of a job and designing the job for maximum efficiency. Taylor s methods brought about significant and rapid increases in productivity. 42

43 Frank & Lillian Gilbreth Frank ( ); Lillian ( ) Husband-and-wife engineering team Further developed work measurement methods Applied efficiency methods to their home & 12 children! (Book & Movie: Cheaper by the Dozen, book: Bells on Their Toes ) 1995 Corel Corp. 43

44 Frank B. Gilbreth extended Taylor s work considerably. Gilbreth s primary contribution was the identification, analysis, and measurement of fundamental motions involved in performing work. By classifying motions as reach, grasp, transport, and so on, and by using motion pictures of workers performing their tasks, Gilbreth was able to measure the average time to perform each basic motion under varying conditions. (THERBLIG) 44

45 Henry Ford Born 1863; died 1947 In 1903, created Ford Motor Company In 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!) 1995 Corel Corp. 45

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47 W. Edwards Deming Born 1900; died 1993 Engineer & physicist Credited with teaching Japan quality control methods in post-ww2 Used statistics to analyze process His methods involve workers in decisions 47

48 Another early pioneer in industrial engineering was Henry L. Gantt, who devised the so-called Gantt chart. The Gantt chart was a significant contribution in that it provided a systematic graphical procedure for preplanning and scheduling work activities, reviewing progress, and updating the schedule. 48

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50 W.A. Shewhart developed the fundamental principles of statistical quality control in This was another important development in providing a scientific base to industrial engineering practice. 50

51 Many other industrial engineering pioneers contributed to the early development of the profession. During the 1920 s and 1930 s much fundamental work was done on economic aspects of managerial decisions, inventory problems, incentive plans, factory layout problems, material handling problems, and principles of organization. Although these pioneers are too numerous to mention in this brief chronology, more complete historical accounts are available elsewhere. 51

52 ENM102, INTRODUCTION TO INDUSTRIAL ENGINEERING,

53 Definition of Industrial Engineering The following formal definition of industrial engineering has been adopted by the IIE: Industrial 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. 53

54 Industrial Engineering Education Topics that later evolved into industrial engineering subjects were initially taught as special courses in mechanical engineering departments. The first separate departments of industrial engineering were established at Pennsylvania State University and at Syracuse University in

55 Industrial Engineering Education An IE option in mechanical engineering was established at Purdue University in The practice of having an IE option within a mechanical engineering department was the predominant pattern until the end of World War II. Following the World War II, separate IE departments were established in colleges and universities throughout the country. 55

56 The American Institute of Industrial Engineers was founded in The AIIE provided, for the first time, a professional organization devoted exclusively to the interests and developments of the industrial engineering profession. 56

57 Impact of Related Developments The evolution of the industrial and systems engineering profession has been affected significantly by a number of related developments. Operations Research Digital Computers Emergence of service industries 57

58 Impact of Operations Research (OR) This approach originated in England and the United States during World War II and was aimed at solving difficult war-related problems through the use of science, mathematics, behavioral science, probability theory, and statistics. Following World War II the concepts of OR were extended to problems in industry and commerce. 58

59 Impact of Digital Computers Another development that has had a significant impact on the IE profession is the digital computer. Digital computers permit the rapid and accurate handling of vast quantities of data, thereby permitting the IE to design systems for effectively managing and controlling large, complex operations. 59

60 Computer simulation is emerging as the most widely used IE technique. A recent development that is having a profound (although still uncertain) impact on industrial engineering is computeraided design (CAD) and computer-aided manufacturing (CAM). 60

61 Emergence of Service Industries In the early days of the industrial engineering profession, IE practice was applied almost exclusively in manufacturing organizations. After World War II there was a growing awareness that the principles and techniques of IE were also applicable in nonmanufacturing environments. 61

62 Relationship to Other Engineering Disciplines Mathematics and Physics Military Engineering Civilian Engineering Chemistry Electrical Engineering Mechanical Engineering Industrial Engineering Chemical Engineering Psychology Social Sciences Computer Science Industrial and Systems Engineering Operations Research Early Management Philosophy Statistics 62

63 Challenges of the Future The world has a finite amount of nonrenewable resources. One of the major challenges for future engineers is to learn to accomplish the engineer s mission in recognition of these constraints. Another major challenge facing the engineering profession is to design systems and processes that are compatible with our natural environment. 63

64 A major challenge that future engineers will encounter is that of designing products that are safe and reliable. There is also an icreasing emphasis on improved quality. Perhaps the greatest challenge facing the engineering profession is to become involved in political issues and to provide assistance to lawmakers in the design of social systems. 64