Week 5 Fundamentals of IE – Operations analysis and design – Operations control – Operations management Assignment to submit at week 6 (in group): – – – – Use the case you’ve presented at Week 3 Describe the implementation of IE fundamentals there Construct a paper Submit the paper via e-mail, no more than 24 hours before the Week 6 class What is IE fundamental? The basic to do IE Basically: a science of operations The main criteria: – Quality – Timeliness – Cost IE ensures that the goods and/or services are provided at the right quality at the right time at the right cost Right means: effective and efficient Combinations of soft (management) and hard (engineering) sciences Science vs intuition (1) Looks like spinning We sure that these are fixed because the grids help us to measure the position Science vs intuition (2) intuitive science Operations A job or task, part of an activity, consisting several work elements Activity Operation 1 Work element 1 Operation 2 Work element 2 Work element … Operation … Operation … Why do we need to know about “Operation”? Production System essentially is the sum of its individual operations Why we concern on quality, timeliness, and cost? Technology: advanced technology and Internet Customers: have a greater expectation – I need the product to be delivered on time – I need mobile phone that has many features, etc Competitor: intense competition Organizations winning the competition on above criteria will be survived www.clker.com The main aim of any industry is Relationship between Production System – Effective & Efficient to produce an item (or service) to sell at a profit. continue business = continue profit How can it be reached? an industry needs to become effective in whatever it does. Aim of Industrial Engineering www.clipartguide.com Efficient production system design Efficiency improvement of production system Need to find ways to make its process efficient IE learn some method to improved efficiency Effectiveness…? Efficiency…? Term Meaning Effectiveness Goal achievement Example of How to achieve action the target of producing 100 units/day Efficiency Resources usage How to reduce the overtime Give other examples…! Efficient Efficient office assistant www.clipartguide.com Most efficient way to solve www.tommcmahon.net Combination between soft and hard…? Remember this one: Analysis…? Design…? Control…? Management…? Let’s watch a short movie Note and discuss: – The analysis activities – The design activities – The control activities – The management activities 3 fungsi dasar pada suatu system terpadu yang terdiri dari 5m, 1 I, 2 e: 1. Fungsi Manufacturing –membuat produk - ---untuk industry jasa – menyediakan jasa 2. Sales – menjual produk / jasa 3. Finance dan accounting Berarti pada saat kita membahas tentang fundamental of IE, maka kita harus mengkaitkan fundamental of IE tadi dengan ke-3 fungsi dasar pada suatu perusahaan + humam resource management Fundamentals of IE Operations analysis, design, planning Analysis to find the opportunity of improvement Design to develop the system, based on analysis Operations control Operations management Control to make sure that the system performs as well as the design Management to organize and synchronize all parts of the system Operations analysis and design Method engineering Work measurement Ergonomics Facilities planning and design Material handling Quality Planning *fungsi manufacturing Production Planning Inventory Planning Operations control Production control Inventory control Quality control Operations management Team based Continuous improvement Operations analysis and design Method engineering Principle: to make a production system efficient, we have to make sure that the individual operations are efficient Done by analysis and design on: – value added and non-value added activities (OPC, motion and time study, etc.) – combination and timing of activities (human-machine chart, left-hand right-hand chart, crew chart, gang chart, etc.) – synchronization (eg.: DFM, DFA) Highlighted: timeliness and cost Work measurement Principle: performance could only be measured by developing the standard Done by analysis and design on: – the time required to do the job – the time required for allowance (personal time, fatigue, unavoidable delay) – the normal time – the standard time Highlighted: timeliness and cost Ergonomics Principle: process/machine/equipment/method must be match with human Done by analysis and design on: – human selection – process/machine/equipment/method design (skeletal/muscular, sensory, environmental, mental) Highlighted: quality and cost Facilities planning and design Principle: proper location, arrangement, and size of facilities will minimize the total cost Done by analysis and design on: – geographical location of factory – layout of facilities within factory (plant, water, tower, office, warehouse, power plant, etc.) – space grouping within facilities (departments arrangement) – equipments arrangement within groups Highlighted: timeliness and cost Material handling Principle: the best material handling is no material handling Done by analysis and design on: – the recent material handling – the possible reduction of material handling – the possible integration of material handling and value added activities Highlighted: cost Operations control Production control Goal: to make sure that the production process provide the right production quantity at the right place and at the right time as planned Concerns: – WIP – Line balancing – Due date Highlighted: timeliness and cost Inventory control Goal: to make sure that the inventories are available at the right quantity at the right place at the right time as required Concerns: trade-off between setup cost and holding cost Highlighted: timeliness and cost Quality control Goal: to make sure that the quality is met the standard Concerns – inspection – root cause analysis – process improvement Highlighted: quality and cost Operations management Team based Management must performed by a team, to control over process improvements, plans, and goals Examples: – Production management – Quality management – Information management – Human resources management Continuous improvement Incremental (may be partial) improvement, based on control and analysis Give examples…! Additional information Try to find by yourself: – Poka yoke – 5 S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) – Just-in-time – Kanban – Kaizen – Deming cycle These may appear in the midterm test
