ISE 195

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ISE 195 Fundamentals of Industrial Systems
Engineering BME 195 Fundamentals of
Biomedical Engineering
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Introduction to Industrial Systems
EngineeringFrank W. Ciarallo, Associate
Professor and Assistant Chair of ISE
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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

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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)

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Post WWII Disciplines

• Nuclear engineering
• Electronic engineering
• Aeronautical engineering
• Astronautical engineering
• Computer engineering
• Environmental engineering
• Biomedical engineering
• Industrial Systems Engineering

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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

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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

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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.

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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

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Level One Elements

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

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Level Two Elements

• Planning systems
• Forecasting systems
• Material and inventory planning and control
• Scheduling activities
• Cost control and analysis
• Quality control system

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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

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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

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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

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INFORMS
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Production Operations

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

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Production System

• Characterized by
• 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

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Facility Layout

• Process Layout

• U Shaped Cells

• Focused Factory Layout

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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

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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

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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

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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

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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

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Institute of Industrial Engineers
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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 dont apply what to do?

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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.

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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)

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ARENA Model of a Supply Chain
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ARENA Model of a Truck Assembly Line
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Example Traffic Simulators

• Vehicle Intersection Model with Pedestrians
  (VisSim)
• http//www.youtube.com/watch?vYq9IAzNTAz0feature
  related

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Example Agent Based Models

• Subway Station Simulation AnyLogic Subway
  Entrance Hall Model
• http//www.xjtek.com/anylogic/demo_models/44/

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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

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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

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Prod. Planning Control

• Design quality control system and inspection
  processes
• Shop floor control procedures
• Reports
• Cost
• Quality
• Labor
• Productivity

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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

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Policies and Procedures

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

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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

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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

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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

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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)

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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

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What are ISE graduates doing now?

• http//www.linkedin.com

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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.

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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)