ISE 195 – Fundamentals of Industrial & Systems Engineering BME 195 – Fundamentals of Biomedical Engineering

Introduction to Industrial & Systems Engineering Frank W Introduction to Industrial & Systems Engineering Frank W. Ciarallo, Associate Professor and Assistant Chair of ISE

Overview Brief History and Context for ISE Discuss Some Major Areas of Study in ISE Mathematical Optimization Production & Service System Design Simulation Modeling & Analysis Overall Course Structure of the ISE Major Some Examples of What Recent Graduates in ISE are Doing Assignment on “Podium Design”

Modern Engineering Disciplines Civil engineering emerging from military engineering Mechanical engineering emerging from growth of mechanical devices after steam engine Electrical engineering after the telegraph (and other products) appeared Chemical engineering (petroleum products, lubricants, etc)

Post WWII Disciplines Nuclear engineering Electronic engineering Aeronautical engineering Astronautical engineering Computer engineering Environmental engineering Biomedical engineering Industrial & Systems Engineering

Chronology of ISE The industrial revolution in large part led to the emergence of industrial engineering as a profession Babbage thought to specialize labor by skill required Taylor really started ISE Analyze and improve the work method Reduce the times required for the work Set standards for the times required

Chronology of ISE (cont.) Gilbreth extended work of Taylor to consider the human aspects of work to include motion involved in work Henry Gantt developed his chart to preplan, schedule, and monitor work activity Shewhart developed the fundamental principles of statistical process control Disciples became big names in quality

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.

Design Impacts Industrial and systems engineers design systems at two levels The first level is called the human activity level and is concerned with how work gets accomplished The second level is called the management control system level and addresses the planning, measurement, and control of organizational activities

Level One Elements Processes within the organization Layout of facilities and machines Design of the workplace Storage space and location Work methods

Level Two Elements Planning systems Forecasting systems Material and inventory planning and control Scheduling activities Cost control and analysis Quality control system

“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

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 content ISEs try to use the correct technique to improve the integrated system under investigation, including OR when appropriate

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 variables Solutions 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

INFORMS

Production Operations Analysis of proposed product or service Analysis of manufacturing process Facilities issues Work methods and standards Production planning and control

Production System Characterized by Interested in: Decisions include: 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 parts Interested in: Lead time for products Cost of processing Decisions include: System configuration Scheduling methods Inventory Control

Facility Layout Process Layout “U” Shaped Cells Saw Mill Grind Lathe Paint Drill Assembly Warehouse Stores “U” Shaped Cells Inbound Stock Outbound Stock “Focused Factory” Layout Saw Grind Weld Lathe Mill Drill Paint Stores Assembly Warehouse

Inventory/Supply Chain Management Plan production quantities to meet customer demands on time with a high level of certainty at a minimum cost/maximum profit Coordinate 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

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

Manufacturing Process What is the best process by which to manufacture and assemble the product What is the mix of equipment, robots, or personnel How can the assembly lines best be balanced What is the best material flow and material handling procedures

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 inspection Utilities required Security and emergency planning

Prod. Planning & Control Forecast potential sales Are capacity and resources being utilized to their capabilities Establish inventory procedures Plan for any materials requirement planning Scheduling

Institute of Industrial Engineers

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?

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 components The “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.

Process Flow Description of Systems To build the model on the computer, use a “process-flow” approach Systems consist of: Entities (Customers, Parts) Resources (Machines, People) Routings (Logic, Networks) Input Data (Times, Probabilities) Performance Measures (Times, Utilizations)

ARENA Model of a Supply Chain

ARENA Model of a Truck Assembly Line

Example: Traffic Simulators Vehicle Intersection Model with Pedestrians (VisSim) http://www.youtube.com/watch?v=Yq9IAzNTAz0&feature=related

Example: Agent Based Models Subway Station Simulation: AnyLogic Subway Entrance Hall Model http://www.xjtek.com/anylogic/demo_models/44/

Work Methods and Standards Perform work measurement studies and establish time standards Perform work improvement studies Value engineering studies to determine and eliminate sources of waste and excess cost

Personnel Systems Employee testing, selection and placement Training and education programs Job evaluation and incentive programs Ergonomics and human engineering applied to jobs, workplaces and workplace in general Quality improvement activities

Prod. Planning & Control Design quality control system and inspection processes Shop floor control procedures Reports Cost Quality Labor Productivity

Planning Support corporate strategic planning to include national and international planning Perform enterprise modeling Support and perform system integration activities Provide support to major decisions and participate in major decisions Quality management activities

Policies and Procedures Study organizational analysis and design Perform analyses of functional groupings Policy manuals Procedures

Performance Measurement Identify meaningful performance measures for those areas of interest key to the firm success Identify critical success factors Specify and design corrective action procedures Design reports for all levels of management

Projects and ISE might take on Analyze systems and construct models Apply appropriate solution methodologies Perform simulation studies Perform operations research studies Perform statistical analysis Conduct designed experiments And more…

ISE and Systems Industrial engineering really takes a system-level perspective The 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 system An ISE seeks to optimize systems

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)

ISE Course Coverage Computation (ISE 3540, ISE 4510) Engineering Science (BME 3211, BME 3212, BME 3511) Senior Design Project Calculus, Physics and Chemistry WSU Core

What are ISE graduates doing now? http://www.linkedin.com

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.

Podium Specification Assignment Form a team 4 students per team preferred, 3 students acceptable Understand the product, customer, stakeholders Develop a list of customer needs (15 to 25) Develop a set of metrics for the podium Develop a set of specifications for the podium (15 to 25)