This blog post provides an overview of the basics of industrial engineering, including topics from quality management to Machine Tools. Most academic and industrial job exams that i faced recently require applicants to have a basic understanding of these concepts, making this blog an excellent resource for job seekers in this field. You may also like: 
BASICS OF SUPPLY CHAIN MANAGEMENT
➼Lean
Is developed by Toyota ,Japan.
Lean is a manufacturing philosophy related to the concept of continuous improvement and core principle of lean is to eliminate activities that do not add value to final product.
>4 main goals of lean are :
1)Reduce cost
2)Reduce Ware
3)Improve Productivity
4)Improve Quality
>Some Lean Tools are :
- Value Stream Mapping (VSM): A visual representation of the entire process flow, highlighting value-adding and non-value-adding activities. VSM helps identify opportunities for improvement and visualize the ideal future state.
- 5S: A workplace organization method consisting of five principles: Sort, Set in Order, Shine, Standardize, and Sustain+Safety. 5S aims to create an organized, clean, and efficient work environment.
- Kanban: A visual scheduling system that uses cards or signals to manage inventory levels and control the flow of work. Kanban helps optimize production and inventory management based on actual customer demand.Pull System.
- Poka-Yoke: Also known as error-proofing , Poka-Yoke techniques aim to prevent mistakes or defects from occurring by designing foolproof systems or devices to prevent or minimize defects.
- Kaizen: A philosophy of continuous improvement, Kaizen encourages small, incremental changes and involves all employees in seeking and implementing improvements on an ongoing basis.It's reduced costs, maximized profits,improved efficiency and improved quality.
- Just-in-Time (JIT): JIT focuses on producing or delivering items at the exact time they are needed, minimizing inventory levels, reducing waste, and increasing efficiency.
- Total Productive Maintenance (TPM): TPM aims to maximize equipment effectiveness and minimize downtime by involving all employees in the maintenance and improvement of equipment and processes.
- A3 Problem Solving: A structured problem-solving approach that encourages teams to analyze problems, define root causes, and develop action plans on a single A3-sized sheet of paper.
- Standard Work: Creating and documenting the best-known method for performing a task, ensuring consistency, reducing variability, and providing a baseline for improvement.
- Root Cause Analysis: A systematic approach to identifying the underlying causes of problems or defects, enabling teams to address the root causes rather than just the symptoms.The main problem or effect is depicted as the "head" of the fish, while the potential causes are represented as the "bones”.
➼Jidoka (automation):
The term "Jidoka" can be translated from Japanese as "automation with a human touch”.Refer to automatic manufacturing & defect idenfication. Automatic manufacturing stopped automatically when defect are identified. So, It reduced breakdown time & downtime.
➼4M :
Man,Machine ,Method ,Material for cause and effect analysis
When analyzing a problem or seeking to improve a process, considering the Four Ms can help identify the root causes and determine areas for improvement
➼Muda,MURA,MURI (Also known as 3M)
Muda: Muda refers to any type of waste or non-value-added activity in a process. There are eight common types of muda identified in Lean thinking: overproduction, waiting, transportation, inappropriate processing, unnecessary inventory, unnecessary motion, and defects unutlilized human brain 🧠,.
Mura refers to variation or inconsistency in a process. It can be unevenness or imbalances in workload and production..
Muri: Muri refers to overburden or strain in a process. It occurs when tasks are excessively difficult, complex, or beyond the capacity of the people, equipment, or systems involved
➼6 big losses:Loss Hour : (6 big reasons )
Defect/ Reject, Breakdown, Slow speed, Idle, Adjustment/ setup and Start-up losses.
➼Pareto analysis:
also known as the Pareto principle or the 80/20 rule, is a technique used to identify and prioritize the most significant factors contributing to a problem or outcome.Pareto Analysis is used to identify the top defective items. Cause-Effect Analysis helped to identify the root causes of defects.
➼PDCA(Quality Circle)
PDCA stands for Plan-Do-Check-Act, It's problem solving and continuous improvement tool.
Plan: establish plan and expected results
Do: implement plan
Check: verify expected results achieved
Act: review and assess; do it again
➼Gamba:
( Also means real place). Visit the actual place where has happened problem or incident. To solve the problem Gamba is necessary.
➼SMED
(Single Munite exchange Die) : It's the process of reducing change over or setup time ( usually less than 10 minutes).It reduces flexibility, productivity & efficiency
The Steps of SMED:
Observe, Record, Analyze→Recognize Internal and External process steps →Move Internal to External→Streamline remaining activities→ Document improved process as
➼SMV
Standard Minute Value (also referred to as the “Standard Time” or “SMV”), is the time required for a qualified worker working at “Standard Performance” to perform a given task.
➼Tack
Time (actual production time/customer demands)
➼TPM
(Total Productive Maintenance): It focuses on proactive and preventative maintenance to maximize the operational time of equipment.
The key principles and objectives of TPM are as follows:
1.Overall Equipment Effectiveness
2.Autonomous Maintenance
3.Planned Maintenance
➼TQM:
TQM stands for Total Quality Management. It is a management philosophy and approach that focuses on continuously improving the quality of products, services, and processes within an organization.
>Total Impliess= Everything
>Quality implies= Degree of excilience
The key principles and concepts of TQM include:
Customer Focus: TQM places a strong emphasis on understanding and meeting customer needs and expectations.
Continuous Improvement: TQM promotes a culture of continuous improvement in all aspects of the organization.
Employee Involvement: TQM recognizes that employees are a valuable source of knowledge and expertise. It encourages their active participation of employee.
The seven tools of TQM are:
- Cause-and-Effect Diagram (also known as Fishbone or Ishikawa Diagram): (See previous)
- Check Sheet: A check sheet is a simple and structured form used to collect and record data in a systematic manner.
- Control Chart: Control charts are used to monitor process variations and determine if a process is in control or experiencing any special causes of variation.
- Histogram:A histogram is a graphical representation of data that shows the frequency distribution of a particular variable. It displays data in a bar chart format, with the horizontal axis representing the variable and the vertical axis representing the frequency or count. Histograms provide insights into the distribution pattern and help identify outliers or abnormalities.
- Pareto Chart: (See previous)
- Scatter Diagram: A scatter diagram is used to understand the relationship between two variables.
- Flowchart: A flowchart is a visual representation of a process or a workflow.
➼OEE
Overall Equipment Effectiveness (OEE): is a metric commonly used in manufacturing to achieve nearly zero (breakdown+defects) associated with equipment.
OEE = Availability × Performance × Quality
➼Andon
: Is a Visual feedback system .The primary purpose of an Andon system is to facilitate real-time communication and problem-solving.
➼Six Sigma :
is project base approach to provide reliable ,dependble and quality products to customers by mainly focusing on -Continious imprvmnet- Defects - Variability - Customer . (3.4 defects /million oppurtunity)
>lean six sigma is to achive both lean & 6¥ goals simultaneously
>The Six Sigma methodology follows a structured approach known as DMAIC (Define, Measure, Analyze, Improve, Control).
√Define (goals) √ Measure √ Analyze √ improve ,√ Control
>6 sigma is realted to the concept of standard deviation.
➼Productivity VS Efficiency:
Productivity | Efficiency |
Productivity = Output / Input | Efficiency = (Actual output / Standard output) * 100 |
Productivity refers to the amount of output produced by a given input | while efficiency refers to the utlilization of available resources to produce that output. |
Example: number of units produced per hour by a machine. | A production line is capable of producing 100units/Hr, but due to various inefficiencies, it only produces 80 units, the efficiency would be calculated as (80 / 100) * 100 = 80%. System Utilization=80%. |
➼SAM (Standard Allowed Minutes) :
is a measure used in manufacturing to determine the standard time required to complete a specific operation or task. It represents the time it should take an average worker, operating at a normal pace, to perform the operation.
>>Calculate the SAM using the following formula:
SAM = Lead Time / (1 + Allowances)➼Machine Tools and their operations:
- Lathe Machine:
- Turning: Used to remove material from a rotating workpiece to create cylindrical shapes.
- Facing: Used to create a flat surface perpendicular to the axis of rotation.
- Taper Turning: Used to create tapered surfaces on the workpiece.
- Drilling: Used to create holes in the workpiece.
- Milling Machine:
- Face Milling: Used to create flat surfaces on the workpiece.
- Slot Milling: Used to create slots or grooves on the workpiece.
- End Milling: Used to create profiles and contours on the workpiece.
- Grinding Machine:
- Surface Grinding: Used to create smooth and flat surfaces on the workpiece.
- Cylindrical Grinding: Used to create cylindrical shapes or remove excess material from cylindrical surfaces.
- Drilling Machine:
- Drilling: Used to create holes in the workpiece.
- Reaming: Used to enlarge and finish existing holes to precise dimensions.
- Counterboring: Used to create a recess at the end of a hole to accommodate bolts or other fasteners.
- Tapping: Used to create internal threads in a hole.
- Shaping Machine:
- Shaping: Used to remove material and create flat surfaces or linear profiles.
➼Chamfer, Facing & Turning on Lathe Machine:
There are various operations performed on the lathe machine apart than plain turning of the metal piece. These are Chamfer, facing, Turning. Grooving, Forming, Knurling, Drilling, Taper Turning and other operations are performed on the single lathe machine. Few of the operations are discussed here below:
1. Chamfering: Chamfering is the operation of beveling the extreme end of the work piece. The form tool used for taper turning may be used for this purpose. Chamfering is an essential operation after thread cutting so that the nut may pass freely on the threaded work piece.
2. Facing: Facing is the operation of machining the ends of a piece of work to produce flat surface square with the axis. The operation involves feeding the tool perpendicular to the axis of rotation of the work.
3. Turning: Turning in a lathe is to remove excess material from the work piece to produce a cylindrical surface of required shape and size.
➼Link to Important MCQs:
This link contains most common MCQs of private job exam:
➼A book for Common Job Viva Questions: (IEM.KUET)
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