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

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

3. 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”

4. 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)

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

6. 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

7. 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

8. 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.

9. 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

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

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

12. “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

13. 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

14. 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

15. INFORMS

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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. Institute of Industrial Engineers

25. 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?

26. 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.

27. 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)

28. ARENA Model of a Supply Chain

29. ARENA Model of a Truck Assembly Line

30. Example: Traffic Simulators
Vehicle Intersection Model with Pedestrians (VisSim)

31. Example: Agent Based Models
Subway Station Simulation: AnyLogic Subway Entrance Hall Model

32. 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

33. 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

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

35. 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

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

37. 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

38. 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…

39. 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

40. 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)

41. 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

42. What are ISE graduates doing now?

43. 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.

44. 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)