Applied Industrial Engineering & Engineering Management

Foreword 
Preface 

Chapter 1 Introduction to Industrial Engineering and Engineering Management 
1.1 Origins of Industrial Engineering and Engineering Management 
     1.1.1 The Advent of Scientific Management 
     1.1.2 Founders of Scientific Management and Industrial Engineering 
          1.1.2.1  Adam Smith, Frederick Taylor, and Others 
1.2 Data Analytics and Productivity 
References 

Chapter 2 Industrial Engineering Fundamentals 
2.1 Tactical Operations 
     2.1.1 Design for Manufacturing 
          2.1.1.1  Design for Manufacturing Guidelines 
     2.1.2 Computer-Integrated Manufacturing 
          2.1.2.1  Computer-Aided Design 
          2.1.2.2  Computer-Aided Manufacturing 
          2.1.2.3  Computer-Aided Process Planning 
          2.1.2.4  Flexible Manufacturing Cells and Systems 
     2.1.3 Material Requirements Planning 
          2.1.3.1  Master Production Schedule 
          2.1.3.2  Bill of Materials 
          2.1.3.3  Inventory Record File 
     2.1.4 Inventory Management 
          2.1.4.1  System Components of Inventory Management 
          2.1.4.2  Aggregate Inventory Item Classes 
          2.1.4.3  Economic Order Quantity 
2.2 System Definition Activities 
     2.2.1 Process Planning 
          2.2.1.1 Process Planning for Specific Industries 
     2.2.2 Plant Layout and Flow 
          2.2.2.1   Plant Layout Analysis 
               2.2.2.1.1 The From-To Chart 
               2.2.2.1.2 The REL Chart 
               2.2.2.1.3 Space-Relationship Diagram and Block Plan 
          2.2.2.2   Plant Layout Synthesis 
     2.2.3 Material Handling 
          2.2.3.1   Material Handling Equations 
          2.2.3.2   Automated Guided Vehicles 
     2.2.4 Automation 
          2.2.4.1   Automation Elements 
     2.2.5 Flexible Manufacturing Systems 
2.3 Reliability Engineering and Control 
     2.3.1 Reliability Fundamentals 
          2.3.1.1   General Approach to Reliability Improvement 
     2.3.2 Design for Reliability 
          2.3.2.1   Part Selection and Control 
          2.3.2.2   Part Derating 
          2.3.2.3   Design Simplification 
          2.3.2.4   Redundancy 
2.4 Safety Engineering and Control 
     2.4.1 Safety Assessment 
     2.4.2 Safety and The Workforce 
          2.4.2.1   Human Factors 
               2.4.2.1.1 Work Design and Measurement 
               2.4.2.1.2 Methods Engineering 
               2.4.2.1.3 Motion Time Study 
               2.4.2.1.4 Workflow Process Charts 
     2.4.3 Safety Program Planning 
2.5 Quality Engineering and Control 
     2.5.1 Statistical Process Control 
          2.5.1.1   The Normal Distribution 
     2.5.2 Process Capability Analysis 
          2.5.2.1   Process Monitoring 
          2.5.2.2   Control Charts for Variables 
          2.5.2.3   Control Charts for Attributes 
     2.5.3 Acceptance Sampling 
     2.5.4 Six-Sigma Fundamentals 
     2.5.5 Cost of Quality 
          2.5.5.1   Good Costs of Quality 
          2.5.5.2   Bad Costs of Quality 
     2.5.6 Total Quality Management 
2.6 System Maintenance 
     2.6.1 Reliability, Maintainability, and Availability 
     2.6.2 Maintenance Program Planning 
          2.6.2.1  Corrective and Preventive Maintenance 
          2.6.2.2  Maintenance Planning Process 
               2.6.2.2.1 Maintenance-Induced Problems 
               2.6.2.2.2 Maintenance Documentation
     2.6.3 Maintenance Strategy 
          2.6.3.1  Reliability-Centered Maintenance 
               2.6.3.1.1 The RCM Process 
     2.6.4 Maintainability Analysis 
          2.6.4.1  Maintainability Improvement 
               2.6.4.1.1 Automated Fault Isolation 
          2.6.4.2  Maintainability Levels and Prediction 
Questions 
References 

Chapter 3 Engineering Management Fundamentals 
3.1 Organizational Leadership 
     3.1.1 Motivation 
          3.1.1.1  Leadership Style 
               3.1.1.1.1 Organizational Psychology 
               3.1.1.1.2 Strategic Motivation Model 
     3.1.2 Teaming 
          3.1.2.1  Basic Assumption Theory 
          3.1.2.2  Team Effectiveness 
               3.1.2.2.1 Personality 
               3.1.2.2.2 Team Composition 
               3.1.2.2.3 Reactions to Group Situations Test 
     3.1.3 Strategic Human Resource Planning 
          3.1.3.1  Performance Appraisal 
          3.1.3.2  Organizational Development/Training 
               3.1.3.2.1 Stages of Development
               3.1.3.2.2 Technical Development Program 
     3.1.4 Succession Planning 
3.2 Economic Analysis 
     3.2.1 Time Value of Money 
     3.2.2 Selection of Alternatives 
          3.2.2.1  Initial Cost 
          3.2.2.2  Interest Rate 
          3.2.2.3  Annual Cost or Benefit 
          3.2.2.4  Economic Life 
          3.2.2.5  Salvage Value 
          3.2.2.6  After Tax Cash Flow 
     3.2.3 Proforma Development 
          3.2.3.1  Break-Even Analysis 
     3.2.4 Investment Decision Matrix 
          3.2.4.1  Time-to-Market 
          3.2.4.2  Initial Investment 
          3.2.4.3  Excess Present Value Index 
          3.2.4.4  Benefit–Cost Ratio 
          3.2.4.5  Investment Payback 
          3.2.4.6  Internal Rate of Return 
          3.2.4.7  Ownership 
          3.2.4.8  Asset Value 
          3.2.4.9  Purchase Investment Analysis 
3.3 Decision-Making Using Operations Research Modeling 
     3.3.1 Linear Programming 
     3.3.2 Constrained Optimization Modeling Illustration 
3.4 Project Management 
     3.4.1 Project Management Networking 
Questions 
References 

Chapter 4 Strategic Planning and Management 
4.1 Strategic Planning 
     4.1.1 Goals, Strategies, Objectives, and Tactics 
4.2 Innovation and Technology Transfer 
     4.2.1 Technology S-Curve and Technology Life Cycle 
     4.2.2 Strategic Implications on Technology Commercialization 
     4.2.3 Strategic Technology Transfer 
Questions 
References 

Chapter 5 Design for Optimization and Productivity 
5.1 Simulation 
     5.1.1 Simulation Walk-Through 
5.2 Lean Manufacturing 
     5.2.1 Minimize Waste 
     5.2.2 Perfect First-Time Quality
     5.2.3 Flexible Production Lines 
     5.2.4 Continuous improvement 
5.3 Just-In-Time 
     5.3.1 Inventory Exposure 
     5.3.2 Pull-Based Production 
     5.3.3 JIT Implementation 
     5.3.4 Pull-Based Startup 
5.4 System Effectiveness 
     5.4.1 Components of Se 
          5.4.1.1  Quality Capability 
          5.4.1.2  Operational Efficiency 
          5.4.1.3  Operational Availability 
     5.4.2 Performance Benchmark 
          5.4.2.1  Quality Capability Data 
          5.4.2.2  Operational Efficiency Data 
          5.4.2.3  Operational Availability Data 
     5.4.3 Business Decision-Making 
Questions 
References 

Chapter 6 System Modeling and Prediction 
6.1 Reliability Modeling 
     6.1.2 Reliability Prediction 
6.2 Maintainability Modeling 
     6.2.1 Maintainability Prediction 
6.3 Failure Mode Analysis 
     6.3.1 Failure Mode, Effects and Criticality Analysis 
     6.3.2 Fault Tree Analysis 
6.4 Human Reliability Analysis 
     6.4.1 The Human as a System Component 
          6.4.1.1  Probabilistic Risk Assessment 
          6.4.1.2  Performance Shaping Factors 
          6.4.1.3  Technique for Human Error Rate Prediction 
6.5 Growing Product Reliability Prior to Manufacture 
     6.5.1 Test Data Collection and Analysis 
     6.5.2 Manufacturing System Modeling 
          6.5.2.1  Defect Removal Planning 
          6.5.2.2  Manufacturing Degradation Analysis 
Questions 
References 

Chapter 7 Business Analytics 
7.1 Use of Predictive Analytics 
7.2 Big Data System Design 
     7.2.1 Data System Organization 
     7.2.2 Data System Structure 
     7.2.3 Data System Operation 
          7.2.3.1  Data Collection 
          7.2.3.2  Data Processing 
          7.2.3.3  Data Reporting 
     7.2.4 Data System Implementation 
7.3 Data Recording and Feedback 
     7.3.1 Organizational Data Communications 
     7.3.2 Types of Databases 
          7.3.2.1  Automatic Identification Technology 
          7.3.2.2  Bar Coding 
          7.3.2.3  Optical Character Recognition 
          7.3.2.4  Voice Entry 
          7.3.2.5  Radio Frequency 
          7.3.2.6  Vision 
          7.3.2.7  Magnetic Stripe 
     7.3.3 Programmable Logic Controller 
7.4 Failure Recording, Analysis, and Corrective Action 
     7.4.1 Elements of the FRACA System 
          7.4.1.1  Responsibility 
          7.4.1.2  Activity Architecture 
          7.4.1.3  Reporting 
7.5 Data Analysis 
     7.5.1 Basic Probability and Statistics 
     7.5.2 Statistics 
          7.5.2.1  Exploratory Data Analysis 
          7.5.2.2  Measures of Central Tendency and Dispersion 
     7.5.3 Probability 
          7.5.3.1  Axioms of Probability 
          7.5.3.2  Discrete and Continuous Distributions 
     7.5.4 Probability and Statistical Basis for Operational Analysis 
          7.5.4.1  Random Variables 
          7.5.4.2  Probability Density and Cumulative Distribution Function 
          7.5.4.3  Continuous Probability Distributions 
               7.5.4.3.1 Exponential Distribution 
               7.5.4.3.2 Normal Distribution
               7.5.4.3.3 Lognormal Distribution 
               7.5.4.3.4 Weibull Distribution 
               7.5.4.3.5 Other Continuous Distributions 
          7.5.4.4  Discrete Probability Distributions 
               7.5.4.4.1 Binomial Distribution 
               7.5.4.4.2 Poisson Distribution 
     7.5.5 Correlation and Regression Analysis 
     7.5.6 Distribution of Human Performance Data 
          7.5.6.1  Human Error Probability Database 
7.6 Performance Analytics 
     7.6.1 Key Performance Indicators 
               7.6.1.1  Production Analytics 
               7.6.1.2  Financial Analytics 
               7.6.1.3  Customer Service Analytics 
Questions 
References 

Chapter 8 Testing and Assessment 
8.1 Test Program Effectiveness 
8.2 Strategic Testing 
     8.2.1 The Research and Development Process 
8.3 Test Plan Structure 
     8.3.1 Test Types 
     8.3.2 Test Planning Decision Logic 
          8.3.2.1  Decision Logic Questions 
          8.3.2.2  Test Program Options 
     8.3.3 Field Test Sizing 
8.4 Test Program Specification 
8.5 Design of Experiment 
     8.5.1 Analysis of Variance 
     8.5.2 Full Factorial Design 
     8.5.3 Central Composite Design 
Questions 
References 

Chapter 9 Case Studies 
9.1 Introduction to Case Study Analysis 
9.2 Case Study One: Service Organization Strategic Plan 
9.3 Case Study Two: Research and Development Strategic Test Planning 
9.4 Case Study Three: Carbon Capture, Utilization, and Storage Financial Investment 
9.5 Case Study Four: AI-based Tool for New Technology R/D Test Program Definition 
9.6 Case Study Five: Application of the Reaction to Group Situations Test 
9.7 Case Study Six: Molding Manufacturing System 
9.8 Case Study Seven: Stress-Strength Product Analysis 
9.9 Case Study Eight: Technology Transfer with Maintenance Planning 
9.10 Case Study Nine: International Supplier Visit 
9.11 Case Study Ten: Creating a Reliability Specification 
9.12 Case Study Eleven: Manufacturing System Effectiveness Monitoring 

Glossary