Module 1: Introduction to Industrial
Engineering
Definition
Industrial Engineering (IE) is the discipline
concerned with the design, improvement, and
installation of integrated systems of people,
materials, information, equipment, and energy.
It draws upon specialized knowledge of
mathematical, physical, and social sciences
together with the principles and methods of
engineering analysis and design, to specify,
predict, and evaluate the results obtained from
such systems.
Scope
System Optimization: Enhancing efficiency
in manufacturing, services, supply chains,
and organizational processes.
Process Design & Analysis: Streamlining
workflows to reduce waste and maximize
value.
Operations Management: Planning,
scheduling, and resource utilization.
Quality and Reliability: Ensuring standards,
compliance, and customer satisfaction.
Human Factors and Safety: Improving
working conditions and ergonomics.
Evolution
Early Stage: Originated with Taylor’s
Scientific Management and Gilbreths’
Motion Studies in the early 20th century.
Mid-20th Century: Expanded into
production planning, quality control, and
systems engineering.
Modern Era: Integrated lean, Six Sigma, and
digital technologies.
4IR Transformation: Incorporation of AI,
IoT, cyber-physical systems, and digital
twins to achieve smart manufacturing.
IE’s Role in Productivity, Competitiveness, and
4IR
Productivity: IE techniques optimize
resources, reduce cycle time, and improve
efficiency.
Competitiveness: Ensures cost reduction,
better quality, and faster delivery in global
markets.
4IR Integration: Industrial engineers play a
key role in digital transformation, leveraging
automation, data analytics, and Industry 4.0
technologies for sustainable growth.
Module 2: Productivity and Performance
Metrics
Productivity Models
1. Partial Productivity: Ratio of output to a
single input (e.g., labor productivity =
output/labor hours).
2. Total Productivity: Ratio of total output
to the sum of all inputs.
3. Multifactor Productivity (MFP):
Considers multiple input factors such as
labor, capital, and materials simultaneously.
Performance Metrics in Industry
Overall Equipment Effectiveness (OEE):
Measures machine efficiency considering
availability, performance, and quality.
Total Effective Equipment Performance
(TEEP): Extends OEE by including utilization
relative to total calendar time.
Benchmarking: Comparing organizational
performance with best practices or industry
leaders.
Lean KPIs: Metrics such as cycle time, takt
time, lead time, first-pass yield, and
inventory turns to monitor lean
transformation.
These indicators provide a data-driven
foundation for decision-making, continuous
improvement, and competitiveness in industrial
and service sectors.
Module 3: Work Study and Ergonomics
Work Study
Work study is the systematic examination of
work processes to improve efficiency and
productivity. It comprises:
1. Method Study
o Analyzes work processes to eliminate
unnecessary activities.
o Tools: Flow process charts, value stream
mapping, workflow analysis.
o Objective: Simplify operations, optimize
resource utilization.
2. Time Study
o Establishes standard times for
performing tasks.
o Techniques: Stopwatch timing, work
sampling, predetermined motion time
systems (PMTS).
o Application: Basis for planning,
scheduling, costing, and performance
appraisal.
Principle of Motion Economy
Use of both hands simultaneously.
Minimize movements and avoid
unnecessary motions.
Arrange tools and materials within easy
reach.
Use mechanical aids where possible.
Promote rhythm, natural body movements,
and reduce fatigue.
Ergonomics and Human-Machine Systems
Ergonomics: The science of designing work
environments, tools, and systems to fit
human capabilities and limitations.
Human-Machine Interaction: Integration of
cognitive, physical, and organizational
ergonomics to enhance safety, comfort, and
efficiency.
Applications: Control room design,
workstation layout, safety engineering,
user-friendly interfaces, and occupational
health improvements.