In the Introduction to Industrial Engineering, the global panorama of the career and a generic vision of the operation of the company are shown. So now a specific approach is required of how the company is organized according to its objectives and establishes the functions in direct relationship with the activities and the personnel in such a way that it is always oriented towards greater productivity.
The above responds to the fact that for an Industrial Engineer, it is essential to know the organizational structure of the company; how it starts its activities, the development of the organization, its operation and evolution; since it is precisely in the Productive Organization of goods and services where he exercises his professional activity optimizing resources.
industrial-engineering-career-overview-So we will answer the following questions throughout this investigation:
- Who are the fathers of Industrial Engineering? What is Industrial Engineering? What is a production system? What is meant by improving? Why accentuate the system? Is industrial engineering strictly »industrial«? Are industrial engineers directly involved with manufacturing? How does the Industrial Engineer view Engineering? How does industrial engineering compare with other engineering disciplines? What makes Industrial Engineering different from other engineering disciplines? What are the basic sciences for industrial engineering? Do all engineers use the same mathematics? Why is statistics important in industrial engineering? What is the influence of the computer on industrial engineering? What are the specialties of industrial engineering?
OF INDUSTRIAL ENGINEERING: FREDERICK WINSLOW TAYLOR (1856 -1915)
North American engineer and economist, promoter of the scientific organization of work. In 1878 he made his first observations on the labor industry in the steel industry. They were followed by a series of analytical studies on work execution times and remuneration. His main points were to scientifically determine standard work, create a mental revolution and a functional worker through various concepts that are intuited from a work of his published in 1903 called "Shop Management". The principles contemplated in said work are presented below:
- Study of Times Study of Movements Standardization of tools Planning department Principle of administration by exception Teaching card for workers Calculation rules for metal cutting Routing system Cost determination methods Selection Employees by tasks Incentives if work is completed on time.
HENRI FAYOL (1841-1925)
A mining engineer born in Constantinople, he made great contributions to the different administrative levels. He wrote "Administration industrielle et générale", which describes his philosophy and proposals. Fayol divided the industrial and commercial operations into six groups:
- TechnicalCommercialFinancialAdministrativeSecurityAccounting
BEGINNING:
- Subordination of particular interests: Above the interests of the employees are the interests of the company.
2. Unity of Command: In any job an employee should only receive orders from a superior.
3. Management Unit: A single boss and a single plan for any group of activities that have a single objective. This is the essential condition to achieve unity of action, coordination of efforts and focus. Unity of command cannot exist without unity of direction, but it is not derived from it.
4. Centralization: It is the concentration of authority in the upper ranks of the hierarchy.
5. Hierarchy: The chain of bosses goes from the highest authority to the lowest levels and the root of all communications goes to the highest authority.
6. Division of work: it means that the tasks to be developed and the staff must be specialized in their work.
7. Authority and responsibility: It is the ability to give orders and expect obedience from others, this generates more responsibilities.
8. Discipline: This depends on factors such as the desire to work, obedience, dedication, and correct behavior.
9. Personal compensation: You must have fair and guaranteed satisfaction for employees.
10. Order: Everything must be properly put in its place and in its place, this order is both material and human.
11. Fairness: Kindness and fairness to achieve loyalty of staff.
12. Stability and duration of staff in a position: You have to give staff stability.
13. Initiative: It has to do with the ability to visualize a plan to follow and to ensure its success.
14. Team spirit: Making everyone work within the company with pleasure and as if they were a team, makes the strength of an organization.
What is industrial engineering?
Industrial engineering refers to the design of production systems. The Industrial Engineer analyzes and specifies integrated components of people, machines, and resources to create efficient and effective systems that produce goods and services beneficial to humanity.
WHAT IS INDUSTRIAL ENGINEERING? (INDUSTRIAL ENGINEERING AND THE ENGLISH LANGUAGE)
Definition of Industrial Engineering - The Work of an Industrial Engineer
The field of engineering is subdivided in several major disciplines like mechanical engineering, electrical engineering, civil engineering, electronical engineering, chemical engineering, metallurgical engineering, and also industrial engineering. Certainly this disciplines can also be subdivided further. Industrial Engineering integrates knowledge and skills from several fields of science: From the Technical Sciences, Economic Sciences as well as Human Science - all these can also be supported with skills in Information Sciences. The Industrial Engineer comprehends knowledge in those sciences in order to increase the productivity of processes, achieve quality products and assures Labor safety.
What Industrial Engineers do
So what do industrial engineers do to increase productivity and assure quality?
An Industrial Engineer can perform several activities to fulfill its task:
Processes and Procedures of manufacturing or service activites can be examined through Process Analysis
He can Use Work Study comprehending Method Study and Time Study. Method Study is the Study of How a job is performed examining and recording the activities, operators, equipment and materials involved in the process. Time Study records and rates the times of jobs being performed. The mentioned activities are also called operations Management. Furthermore can Industrial Engineeringinvolve inventory management to make a manufacturing process more feasible and efficient. Industrial Engineers are also involved in design activities for Products, Equipment, Plants an Workstations. Here ergonomics and motion economy play a role. Last but not least is the Industrial Engineer playing an important role in developing Quality Management Systems (as they ie should comply with the ISO 9000 Standards). Here they often have job titles like Quality Engineer or Quality Manager.
CLASSICAL QUESTIONS FROM INDUSTRIAL ENGINEERING STUDENTS AT UPIICSA - IPN
What is a production system?
Wherever there is a »value-added« company, there is a production process. The Industrial Engineer focuses on "how" a product is made or "how" a service is provided. The goal of industrial engineering is to improve the »how«.
What is meant by improve?
Generally, the criteria for judging improvement are productivity and quality. Productivity means getting more from the resources that are expended, namely being efficient. Quality judges the value or effectiveness of the output.
Why accentuate the system?
industrial engineering focuses on the design of systems. Production processes are made up of many pieces that work together. Experience has taught that changes to one part cannot help improve the whole. Thus, industrial engineers generally work with tools that emphasize systems analysis and designs.
Is industrial engineering strictly »industrial«?
Since production systems are found wherever there is an attempt to provide a service, as well as to produce a part, the methodologies of industrial engineering are applicable. In that sense, the adjective "industrial" should be interpreted as "industrious", referring to the process of being skillful and caring. In many departments, industrial engineering is called "industrial and systems engineering" in an attempt to make clear that the adjective industrial is intended to be generic.
Are industrial engineers directly involved with manufacturing?
Every industrial engineer takes at least one manufacturing course, which deals with manufacturing processes, and other courses closely related to manufacturing. Every Industrial Engineer is therefore well informed about work machinery and processes. Additionally, related courses treat manufacturing as a system. The manufacturing industry has and continues to be an industrial engineering concern.
How does the Industrial Engineer consider Engineering?
In general, engineers deal with systems analysis and design. Electrical engineers deal with electrical systems, industrial engineers deal with mechanical systems, chemical engineers deal with chemical systems, and so on. Industrial engineers focus on production systems. In general, engineering is the application of science and mathematics to the development of products and services useful to humanity. Industrial engineering focuses on the "way" in which those products and services are made, using the same approaches that other engineers apply in product or service development, and for the same purpose.
How is industrial engineering like other disciplines of engineering?
The Industrial Engineer is trained in the same basic way as other engineers. They take the same foundational courses in math, physics, chemistry, humanities, and social science. It is thus also that it takes some of the basic physical sciences of engineering such as thermodynamics, circuits, statics and solids. They take courses in the specialty of industrial engineering in their later years. Like other engineering courses, industrial engineering courses employ mathematical models as the central device for understanding their systems.
What makes industrial engineering different from the other disciplines of engineering?
Fundamentally, industrial engineering does not have any basic physical science like mechanics, chemistry, or electricity. Also because an important component in any production system is people, industrial engineering has a person portion. The human aspect is called ergonomics, although elsewhere it is called the human factor. A more subtle difference between industrial engineering than other engineering disciplines is the concentration in discrete mathematics. Industrial Engineers deal with systems that are measured discretely, rather than metrics that are continuous.
What are the basic sciences for industrial engineering?
The fundamental sciences that deal with methodology are mathematical sciences, namely mathematics, statistics, and computer science. The characterization of the system thus employs mathematical, statistical, and computational models and methods, and gives direct enhancement to industrial engineering tools such as optimization, stochastic processes, and simulation. Industrial engineering specialty courses therefore use these "basic sciences" and IE tools to understand traditional elements of production such as economic analysis, production planting, resource designs, materials handling, processes and manufacturing systems, job analysis, and so on.
Do all engineers use the same math?
All engineers, including Industrial Engineers, take math with calculus and differential equations. Industrial engineering is different in that it is based on "discrete variable" mathematics, while the rest of engineering is based on "continuous variable" mathematics. Thus the Industrial Engineers emphasize the use of linear algebra and differential equations, in comparison with the use of differential equations that are often used in other engineering. This emphasis becomes evident in the optimization of production systems in which we are structuring orders, scheduling batch treatments, determining the number of manageable units of material, adapting factory layouts, finding sequences of movements, etc.Industrial engineers deal almost exclusively with discrete component systems. So Industrial Engineers have a diverse mathematical culture.
Why is Statistics Important in Industrial Engineering?
All Industrial Engineers take at least one course in probability and one course in statistics. Industrial engineering specialty courses include quality control, simulation, and stochastic processes. In addition, traditional courses in production planning, economic risk modeling, and facilities planning to use statistical models to understand these systems. Some of the other disciplines of engineering take some probability and statistics, but none have integrated these topics further into their study of systems.
What is the influence of the computer in industrial engineering?
No other aspect of technology probably has a greater potential impact on industrial engineering than the computer. Like the rest of the engineers, the Industrial Engineer carries computer programming. The industrial engineering specialty carries control and simulation that broaden the role of computer science principles within industrial engineering. Furthermore, most industrial engineering tools are now computerized, with the recognition that the computer-aided design and analysis of production systems has untapped new potential. Something special is that computer simulation involves the use of specialized programming languages to model production systems and analyze their behavior on the computer.before starting to experiment with the real systems. Furthermore, computer science and industrial engineering share a common interest in discrete mathematical structures.
What are the specialties of industrial engineering?
Industrial engineering, at the student level, is generally considered as a composition of four areas. First is operations research, which provides the methods for general systems design and analysis. Operations research includes optimization, decision analysis, stochastic processes, and simulation.
Production generally includes aspects such as analysis, production planning and control, quality control, resource design, and other aspects of world-class manufacturing. The third is manufacturing processes and systems. The manufacturing process deals directly with the formation of materials, cutting, modeling, planning, etc. Manufacturing systems focus on the integration of the manufacturing process, generally through computer control and communications. Finally ergonomics that deals with the human equation. Physical ergonomics views the human being as a biomechanical device while informational ergonomics examines the cognitive aspects of human beings.
INDUSTRIAL ENGINEERING AND OTHER AUTHORS IN ITS HISTORY
In 1932, the term "Engineering Methods" was used by HB MAynard and his associates, hence the techniques of methods, such as the simplification of work, had accelerated progress. It was in the Second World War where industrial management was promoted with a method of scientific rigor mainly due to the use of Operations Research. Likewise, industrial engineering has had contact with the fields of action of the production of goods and services, evolving from the engineering of metal-mechanical and chemical production to covering other production processes of other economic sectors.
The concepts of Man - Machine that initially set the action of Industrial Engineering, currently and in the coming years are being expanded to other great concepts such as: Man - Systems, Man - Technology; Man - Globalization, Man - Competitiveness; Man - Knowledge Management, Man - Information Technology, Man - Industrial Biogenetics, Man - Automation, Man - Environment, Man - Robotics, Man - Artificial Intelligence, and many more interrelationships which I call, «Systemic Fields of Industrial Engineering - CSII "that will be integrated into the vast field of its action and that due to the" Creative and Technological "development and its versatility, no limits are set to participate in any Terminal Production of any Economic Sector or Geographical Area of the Country,with a solid degree of responsibility towards the well-being of the Organization or Environment where it operates. That should be oriented to the search for IDEAls or levels of excellence, having as Basic Objectives: to seek the best optimal levels of economics, increase productivity and total quality as well as the profitability of the systems; Design, improve, develop comprehensive systems composed of men and SII concepts. using specialized knowledge, mathematical, physical, social sciences and other disciplines interrelated together with the principles and methods of engineering analysis and design to point out, produce and evaluate the results that will be obtained from said systems.That should be oriented to the search for IDEAls or levels of excellence, having as Basic Objectives: to seek the best optimal levels of economics, increase productivity and total quality as well as the profitability of the systems; Design, improve, develop comprehensive systems composed of men and SII concepts. using specialized knowledge, mathematical, physical, social sciences and other disciplines interrelated together with the principles and methods of engineering analysis and design to point out, produce and evaluate the results that will be obtained from said systems.That should be oriented to the search for IDEAls or levels of excellence, having as Basic Objectives: to seek the best optimal levels of economics, increase productivity and total quality as well as the profitability of the systems; Design, improve, develop comprehensive systems composed of men and SII concepts. using specialized knowledge, mathematical, physical, social sciences and other disciplines interrelated together with the principles and methods of engineering analysis and design to point out, produce and evaluate the results that will be obtained from said systems.develop comprehensive systems made up of men and SII concepts. using specialized knowledge, mathematical, physical, social sciences and other disciplines interrelated together with the principles and methods of engineering analysis and design to point out, produce and evaluate the results that will be obtained from said systems.develop comprehensive systems made up of men and SII concepts. using specialized knowledge, mathematical, physical, social sciences and other disciplines interrelated together with the principles and methods of engineering analysis and design to point out, produce and evaluate the results that will be obtained from said systems.
Only Man has gone from the Atomic explosion, to the Digital and Virtual explosion, hence a long way to the Universal explosions of Systems awaits him, where the "Man - Connectivity" already becomes real. And for this reason, the Industrial Engineer must direct his education, knowledge - training and experience, within the "Systemic Fields of Industrial Engineering - CSII" and technologies, he must be able to determine the factors involved in the Terminal Productions, in the Added Values, in Resources, related to Man and any economic field, continue to strengthen human institutions to serve humanity and the premises and priorities must be the common good of man, understanding the laws that govern the operation of the Systemic Fields of Industrial Engineering,and take it to a better standard of living, quality and well-being. And in terms of Necessity, Creativity, Causality, Competitiveness and Chance, a dynamic of new opportunities is achieved for future professionals in this branch.
THE IMPACT OF ENGINEERING ON SOCIETY
Human needs that gave rise to some engineering specialties and their main contributions to the well-being of humanity.
industrial engineering
At the end of the 19th century, the United States was already offering a degree in industrial engineering. For this reason, it will be necessary to ask what work should industrial engineers perform that could not perform any of the other engineering specialties that already existed? The answer is simple. While mechanical, electrical and chemical engineers, among others, were specialists in their area, and designed and operated the machines and devices of their specialty, there were no trained personnel who, apart from understanding the terms of the other specialists, could administratively control such processes. Control means providing all the necessary inputs for production, scheduling it, controlling operating personnel, maintaining equipment, and worrying about increasing work efficiency.In general, all these tasks were carried out by the industrial engineer, since its creation.
In this way, the industrial engineer is not mechanical, electrical or chemical, but rather the person in charge of the control and optimization of production processes, a task that other specialties do not normally perform. Day after day, the field of activity of the industrial engineer is more defined, and because of the versatility that he must have in his profession, in the sense of being able to understand the language of all other specialties, his training is interdisciplinary. This does not represent an advantage or a disadvantage, but simply a characteristic of this branch of engineering and its tasks within the company, which are clearly defined with respect to the different tasks performed by the other engineering specialties.
In this way, all activities related to an industry are the interference of industrial engineering, with the exception of the technologies used in production processes; Thus, the industrial engineer can be in charge from the determination of the optimal location of the industry, the optimization of the processes, the use of the machinery, and of the workforce, the design of the plant, the decision-making for automation from processes, up to production planning, which implies controlling inventories of both raw materials and finished products, it also plans the maintenance of all equipment.
Once again, there is an engineering field with an extensive application, so it was also subdivided into a series of specialties such as engineer in manufacturing processes, industrial administrator, industrial in administration and production planning, industrial in quality control, industrial in systems, industrial in pulp and paper, industrial in project evaluation and others. There is no need to emphasize that this is one of the engineering specialties that is not only related to other engineering in the same industry, but is in contact with all areas of the industry other than engineering, that is, engineering Industry is closely related to senior management, administrators, finance, etc.so it can be considered to have an interdisciplinary approach out of necessity.
INDUSTRIAL ENGINEERING AND BASIC SCIENCES
CALCULATION
Know and apply the Concept of Derivative and Integral
Fundamental Theorem of Calculus
Calculation Application (Optimization)
Fourier series
Laplace transform (Industrial Applications)
PROBABILITY
Distinguish between a random model and a deterministic model
Calculate event probabilities
Define Counting techniques and their Application
Define a discrete random variable
Define a continuous random variable
STATISTICS
Statistics is the science that makes sense of numerical data. When a group of managers of a company tends to decide how to make a new food product, they can be guided by their own tastes and intuition, or obtain data taken from a survey about the preference of consumers.
Parameter Estimation
Hypothesis Testing
PHYSICS FOR INDUSTRIAL ENGINEERING SCIENTISTS AND ENGINEERS
MECHANICAL AND ACOUSTIC WAVES
Analyze the physical phenomena related to rotational dynamics, the balance of bodies, oscillations, acoustics, electroacoustics
Apply the formulations corresponding to the problems proposed in the development with real application topics
Electromagnetism
Sources of the Magnetic Field
Ampere's Law
Magnetic Inductance
Magnetic Energy and Circuits
Magnetic properties of matter
Electromagnetic waves
Optics
Industrial Chemistry - Chemistry
The profile of the Industrial Engineer indicates that within their functions is to contribute to the efficiency and greater productivity of industrial processes, so it is necessary for them to have extensive basic knowledge of Engineering in general, to apply them to the solution of problems industrial and social. All this implies that the Industrial Engineer is involved with the human element, in the organization and administration of the industrial company.
The universal presence of Chemistry within the different branches of the industry, as well as the development of life in modern society, makes it necessary for the Industrial Engineer to have firm knowledge of the applicative aspects of physical and chemical phenomena and of the transformations of the materials that take place in its environment. Acquiring basic knowledge about this area is essential, since Chemistry aims to describe, explain and predict the transformations of matter that can take place when different situations are present and generate changes in it. Chemistry itself has a double interest: scientific and technological.
Apply ideal gas laws to predict the behavior of a gas or gas mixture
Ideal Gas Laws: Boyle, Charles, and Gay-Lussac
Relate the variables involved in the change from liquid to vapor phase, using the Clausius Clapeyron equation
Identify the different types of phase equilibrium
Thermodynamics
Thermochemistry
Chemical Balance
Ionic Balance
Electrochemistry
Basic Sciences Laboratory
Reaction Heats
Reaction in Chemical and Ionic Equilibrium
Chemical kinetics
EXPERIMENTAL PHYSICS
Apply the methods and / or techniques of acquisition and analysis of experimental data in the practical study of phenomena of an electromechanical nature.
Effects of Magnetism Phenomena of reflection and refraction of light by different means
INDUSTRIAL ENGINEERING AND THE COMPREHENSIVE OPTIMIZATION OF RESOURCES
Engineering Methods and Work Measurement
The study of work in its two branches; The study of methods and the measurement of work represent the origin of Industrial Engineering and currently facilitates the first professional exercises of the majority of graduates of the Industrial Engineering career, it is also the knowledge organizing scheme that allows students to accommodate The contents of the other disciplines of Industrial Engineering, Methods Engineering focuses on the study of the study technique of work methods that consists of the most specific application for the registration and critical examination of the ways in which the work is carried out by designing, installing and improving more simple and effective and reduce costs.
Methods Engineering as part of Industrial Engineering
History of Methods Engineering
Productivity Engineering and Management
Study of Methods: Selection and Registration
Registration Techniques: Synoptic and analytical course diagram
Stroke diagram
Bimanual Diagram
Diagram Man - Machine and Multiple Activities
Method Study: Method Design
Study of Methods: Techniques for method improvement
Study of Methods: Analysis of Methods
The Famous "Study of Movements"
Man-Machine Relations
Methods Study: Representation and installation of the Proposed Method
Work Measurement Engineering
General Methods for Measuring Standard Time
Applications of Standard Time
Time study with stopwatch
Performance Rating Systems
Learning curve
Qualification by Speed and Number of Cycles to observe
Obtaining normal time
Work Sampling
Establishment of Standards
Standard data
Time Formulas
System of Default Times
Methods timing
Work factor
MTM
MOST
- Distribution plant
- Material handling
- Hygiene and industrial security
- Pollution and Environmental Management
- Strategic Planning
INDUSTRIAL ENGINEERING AND ADMINISTRATIVE SCIENCES
Personnel Administration: At present, no country can be considered independent in scientific, technological or economic matters; But there are different levels of dependency that in developing countries become serious. Engineers are limited to carrying out activities that only require routine technique that restrict "the use of the creative capacity of the human being." That is why; One of the main missions of the Industrial Engineer is to create and innovate to:
Apply methods and techniques to staff optimization
Find cutting-edge technology
Develop technology appropriate to our needs
For one task or another, people with firm knowledge and critical aptitude are required, who are capable of acting with a broad, sensitive vision in the administration and coordination of human resources. As a main administrative activity, the engineer faces many problems with it; staff placement, leadership style, organizational fairness, performance appraisal, compensation and reward, collective bargaining, and organization development. These intensified challenges are those that the Industrial Engineer must be prepared for for the personal benefit, the community and the Country.
For the industrial engineering student, whatever his specialty, this subject will allow him to have a broad vision of human behavior, because although he will deal with equipment and machines, these will be managed or programmed by human personnel. The treatment aspect and knowledge of various obligations and rights will allow you to properly manage the staff for a common benefit, obtaining the best performance based on the capacity of the staff, including themselves as a person.
Personnel Management Concept
Personnel Administration Planning
Training and Learning Principles
Labor Relations
Remuneration Administration
Factors involved in determining wages and salaries
Performance evaluation
Services and Benefits
Marketing and Market Research
Cost Accounting (Standard costs)
Presentation of the Statement of Income and Financial Position
Determination of Cost by Orders or Processes
State of Production and Sales Costs
Valuation Methods: UPES, FIFO and Inventory Average
Labor and indirect charges
Determine the total and unit standard cost and analyze the differences between this and the actual cost
PREDETERMINED COST SYSTEM
The Cost Accounting systems previously studied can be called: Actual, Historical or Incurred Costs
They are called Real, Historical, or incurred, because they record the incurred or actual value of the operations, and they constitute the history of what happened in the industry in which they are operating.
All the systems studied, fulfill their mission as elements of record and information; However, they suffer from a common defect: as a control element, they are incomplete systems, since they record the cost incurred, but do not compare it with the expected cost, which prevents knowing variations or deviations and, therefore, adopting corrective measures conductive.
In order to correct this deficiency, the Predetermined Cost systems have been devised, which do not eliminate the real ones, but rather complement them, especially the System of Costs for Production Orders and the Processes System, since, to operate a system By default, it is necessary for any of the real ones noted to work simultaneously, in order to be able to establish comparisons between the cost incurred and the predetermined cost, thereby achieving its control.
Within the classification of the Default Cost Systems we find two essential types:
Dear
Standard
Both the Estimated Costs system and the Standard, requires the formulation of Budgets of the costs that will be incurred.
In order to make this concept clearer, it is necessary, before studying the Default Costs, to specify, even roughly, what is understood by Budget.
The budget is the anticipated computation of operations to be carried out, with the purpose of setting goals, serving as a guide and, later, exercising control by comparing the actual figures with those budgeted.
STANDARD COST SYSTEMS
The Standard Costs system is based on the same principles as the Estimates system, that is: it calculates the cost of the item before it is produced, using budgets.
However, the budgets that are made for the purpose of establishing a Standard Costs, are not formulated simply by estimates of the Accounting Department no matter how careful they are, but require a series of specialized studies that are entrusted to professionals and that They result in budgets so reliable for the person who must apply them, that any variation between the actual cost and the budgeted one can be assured that it is the result of an error, or of an unjustified deviation in the production process.
This certainty that must exist in the default calculation of standard costs is what establishes one of the differences that exist between the Standard and the Estimate: in the Estimate, the Estimate is adjusted to the Real, and instead, in the Standard, The Real must always conform to the Standard.
A system of Standard Costs is very difficult to apply in countries like ours, in which the unstable conditions of the production of many raw materials and the imbalance between production and consumption, force a constant oscillation of prices in the market; Therefore, although in many cases it is said that the Standard Costs system is working in a certain company, we can assure that in reality, it is only an Estimate, which is continually being modified in order to adjust it to the prevailing market conditions.
Advantages of standard costs
They can be an important instrument for management evaluation. When standards are realistic, achievable, and properly administered, they can stimulate individuals to work more effectively.
Variations in standards lead management to implement cost reduction programs by focusing attention on areas that are out of control.
They are useful to management for the development of their plans. The very process of setting standards requires careful planning in areas such as organizational structure, assignment of responsibilities, and policies related to performance appraisal.
They are useful in decision making, particularly if product cost norms are segregated according to fixed and variable cost elements and if material prices and labor rates are based on expected trends in costs for the following year.
They can result in a reduction in office work.
DESIGN OF MANUFACTURING PROCESSES IN INDUSTRIAL ENGINEERING
Most of the processes not only of manufacturing, but also of services, evolve over time in a natural and disorderly way. The idea of process design in the manufacture of products is to plan them, so that they evolve in an efficient and controlled manner.
| Accumulated production | Processing time |
| one | 100 |
| two | 95 |
| 4 | 90.25 |
| 8 | 85.74 |
The processing time of the nth unit is given by:
T n = T 1 * n ln k / ln 2 … Equation 1
Where, k is the learning rate, Tn is the processing time for the nth unit (n) and T 1 is the processing time for the first unit. In Equation 1, we see that once T 1 is established, we can only estimate the learning rate k in order to know the processing time of the nth unit. Of course, the learning rate will depend on factors such as the type of product, the degree of complexity of the process, the percentage of human intervention in the process, etc. Thus, it is likely that in automated processes, the "learning curve" has learning rates very close to 100%.
In the case of processes where human hands intervene to a great extent, the cycle time behavior pattern will be that of an exponential curve similar to that defined by Equation 1.
One way to model the Learning Curve is shown in figure 2.
The idea of such combined modeling is to anticipate decisions that we will probably have to make in the future and its use in training should be very useful. Knowing what to do in situations such as "what if…" gives us greater security and confidence when making decisions. However, we must assess the effort / benefit ratio before proceeding to develop such models.
THE PROFILE OF THE INDUSTRIAL ENGINEER IN THE 21ST CENTURY
By Domingo González Zúñiga
Currently, the national industry needs to face the global competition in which the parameters are set by the common denominator of waste elimination, a more competitive and agile organization, better service and higher value to customers.
Applying the above concept to companies, the strategies observed worldwide are based on eliminating:
- Inventories, controlling manufacturing flows with the support of techniques such as Just in Time (JIT);
- Defects, controlling quality with the total quality approach (TQC);
- Obsolescence in the knowledge of the personnel, applying permanent improvement programs (PIP);
- Failures in facilities and equipment, with the support of total preventive maintenance (TPM).
- Incompetence, lack of agility and customer withdrawal, applying Business Process Reengineering (BPR).
All this with the support of an administration of excellence, so the industrial engineer who will occupy any of these positions requires a strong training in the aforementioned techniques, and in:
- Strategic Planning;
- Adaptive Organization;
- Participatory management;
- Prospective Control;
- Strategic Information Systems;
which are the essence of such administration and which are based on:
System approaches.- From an overall vision, identify ideals, mission, objectives, strategies, policies, plans and specific activities that will take the company to the level of world-class manufacturing.
Resource optimization.- Based on an adaptive and waste elimination approach, establish optimal efficiency as the basis for allocating and using resources continuously seeking customer satisfaction in an intelligent way.
Teamwork.- Starting from the fact that the only approach that has proven to be effective is the one in which everyone participates with their best effort, skill and knowledge, so that everyone succeeds, not only within the company, but must be included clients and suppliers.
Desirable future.- Work with a positive and enveloping mentality that leads those involved (all) to establish the future that is desired and not to wait for a probable future that is glimpsed if one acts poorly and in an individualistic way.
Success criteria.- Define with the support of a strategic information system the indicators that will lead the company to leadership in a world-class environment.
Since improvement in the industry starts from the basic operations existing in the system, then improvement becomes a process of continuous application that includes the product, the process, the management and the workers.
The continuous improvement applied to the product gave way to the philosophy of total quality, which is based on the approach of zero defects, and which started from the fundamental means proposed by the ILO of: product, market and customer research, study applied product, improvement of management methods, study of methods and value analysis.
When analyzing the process, the Just in Time approach was developed, which seeks a continuous and efficient flow of the process and zero inventories and which was based on: research and planning of the process, experimental installation, study of methods, training of workers and analysis Of value.
At this point, the analysis of the operation is a procedure used by the Methods engineer to analyze all the productive and non-productive elements of an operation with a view to its improvement. Methods Engineering aims to devise methods to increase production per unit time and reduce unit costs. The essential procedure of operations analysis is as effective in planning new workplaces as it is in continuous improvement of existing ones.
Operations analysis has become increasingly important as competition with overseas intensifies, while labor and material costs rise at the same time.
Experience has shown that practically all operations can be improved if they are studied sufficiently. Since the systematic analysis procedure is equally effective in large and small industries, in mass production, it can be safely concluded that the operation analysis is applicable to all activities of manufacturing, business administration and government services. If used correctly it is expected to lead to a better method of doing the job by simplifying operational procedures and material handling and making equipment use more effective.
When continuous improvement is applied to management and workers in addition to considering traditional means, which are based on the techniques that guided the world-class approach to manufacturing, it is necessary to take into account the process of change.
Managers who want to introduce change must recognize that change occurs slowly, and that they go through a series of stages. Someone in the organization has to first recognize a need to relate to the problem, where they want to be and how they will get there.
Due to the fact that in our days, the successes of science and technology allow us to achieve a degree of material well-being, which can also lead to a gradual loss of sensitivity of man for everything that is essentially human and to fall into a situation where you work for the machines and not the other way around, it is very important that the engineer training includes:
- administration elements
- human relations
- personal growth
- leadership and motivation
- supervisor responsibilities
- performance evaluation
- Work groups
- working conditions
- hygiene and safety
- productivity, quality and work methods with a social focus.
Every executive called to assume responsibilities at the senior management level must know the concepts, techniques and tools of the strategic management of the company. Those that can be synthesized in:
- Tomorrow's business scene and state of readiness;
- Use of available technology;
- The strategic needs of the client;
- The new strategic process;
- The impact on top management;
- The development of senior management;
- Planning and control of strategic development.
And that they should be supported by prospective techniques, among others: brainstorming, structural analysis, actors' play, cross impact matrices and scenario.
They should be able to handle the need to change organizational and work structures, seeking practical and common sense methods for their participatory development.
They will also have to face the challenge posed by the survival of companies in the face of advances in production methods, technology, information, internationalization, and an increasingly complex and different consumer profile. All this with creativity, with an attitude of innovation and integration with the increasingly close world community.
The challenge of increasing productivity raises the support of new technologies, which is why the industrial engineer requires training in various areas, which can be identified:
To improve quality, it also requires knowledge of techniques such as:
Saving labor also requires the application of some of the following techniques:
To reduce accidents, in addition to some of the techniques already mentioned, it is necessary to apply:
- Design of safety at work Improvement of working conditions Human factor engineering
An important aspect to consider in automation is the social aspect since a real threat to unemployment is generated, so the industrial engineer must prepare to face this challenge. However, according to a survey carried out in the United States of America by the Robotics International of the Society of Mechanical Engineers in 1982, it was estimated that 25,000 workers would be displaced during the next 15 years, but 50,000 employees would be needed in the robot industry mainly in the design, programming and maintenance of machines. The challenge here is to retain the workforce to fill the new positions mentioned above for the development, operation and maintenance of highly technical equipment.A second challenge is to consciously direct the efforts of human beings away from tasks that can be done by robots and other machines, and channel them towards other functions in which time can be invested and rewarded in activities that serve humanity..
In the case of national companies, in the field of Work Method Engineering, a series of diagnoses of productivity of facilities, materials and labor were carried out from July 1994 to July 1997 to a sample of medium-sized companies in which The following results were obtained:
Therefore, the industrial engineer must be trained to: analyze and improve product and service designs, use of materials, applying concurrent engineering approaches, reengineering, outsourcing, total quality, logistics, plant distribution, materials handling, planning. and control of production, maintenance, study of work, with the support of market study techniques for customers and products.
Must be able to establish production, efficiency and productivity measures that guide organizations to increase total sales of goods and services, to minimize inventories and operating costs as proposed by Eliyau Goldratt, in his book La Meta.
You must identify principles to understand how manufacturing works and how to bring order to the chaos that so often exists in companies, by seeking answers to three simple questions: What to change? What to change to? And how to cause change? To apply them to improve our world "so that life is more fruitful and makes sense" as Goldratt mentions in his work, to find the answers, throughout history, techniques have been proposed that They range from the fundamental questions: what? how? when? where? who? and why ?, which are in general use, up to a range of diverse techniques and methodologies, such as method engineering whose motto is "there is always a better method", or the Kaisen strategy, which literally means continuous improvement, which involves everyone alike, managers and workers,and it is the basic philosophical underpinning for the best of the Japanese administration, which has generated:
- a way of thinking that sustains that our way of life, be it work, social or family, deserves to be constantly improved and oriented towards results;
- and an administrative system that supports and recognizes the efforts of process-oriented people for improvement, which consumer-oriented assumes that all activities should ultimately lead to greater customer satisfaction. Kaisen's strategy has produced a systems approach and troubleshooting tools that can be applied to achieve that goal.
And also be updated in recent techniques such as reengineering that together with other well-known tools, such as total quality, just in time, total productive maintenance, reengineering introduces the need to radically rethink business processes, this modality can be applied when the company goes badly or even when it is going well and wants to strengthen its leadership position.
To apply it, it is necessary to start with the clients, it must be analyzed if the product is competitive, if it really is what the client wants and needs, the complete structure of the company is questioned, it is possible to start with natural work groups while reaffirming the figure of the boss, moving to continuous improvement groups, then to the so-called self-directed and, finally, to the high-performance ones. Reengineering allows cycle reduction, service development, customer service, quality improvement, cost reduction and as a result, a better position in the market. Its purpose is competitiveness and the means are:
- horizontally redesign the fundamental processes of an organization, from the customer to the last consumer;
- flatten the organizational structure;
- dignify the relationships between bosses and subordinates;
- and, above all, redistribute power and information management throughout the structure.
In short, a solid understanding of the bases of human, technical and economic factors to apply optimization methodologies that generate:
- optimization of human work; minimization of work cycles; maximization of product quality per monetary unit of cost; maximization of the welfare of workers and employees including:
pay, job security, health and comfort;
- maximization of benefits for all (customers, company, workers and suppliers) in a "win-win" approach.
An essential aspect that the industrial engineer will strengthen is to overcome the natural reluctance of all people to change, so that:
- you will never accept anything as correct just because it is now or has been done for years; you will need to ask, explore, investigate, and finally, having considered all the essentials, decide for that moment; you will be aware that there is always a better method; Establish an atmosphere of participation, understanding, and cordiality; Recognize everyone's knowledge of their own work, and request their help to make improvements; Keep everyone involved in the changes informed; Inspire confidence rather than suspicion and suspicion; Above all, he will maintain an enthusiastic attitude toward improvement.
THERBLIG AND INDUSTRIAL ENGINEERING - IN TECHNOLOGY AND THE HUMAN FACTOR
In 1911 Gilbreth, an engineer and his wife, Lillian, a psychologist, published the book, The "Study of Motion" which emphasized the patterns of motion that were made by factory workers at their jobs. From his observation a classification system consisting of 17 basic activities of the hand and arm was developed. Typical movements, such as "reach" and "hold" were described and coded in units that could be described and measured in exact time. These units became known as "therbligs" (Gilbreth spelled backwards with "th" unreversed) and evolved to a universally accepted basis for human analysis of movement in the workplace. The concept led to the continuing refinement of the movement's descriptions.Synchronizing precision with film photography provided micromotion descriptions with millisecond precision and even microseconds in special cases. The information was used for job site design, safety analysis and for setting labor rate standards during union negotiations. With the time factor and the movement factor considered together, workplace tasks could be redesigned to provide increased output, worker comfort and improved safety and, of course, a payoff at the bottom line of profit. Mass, micromotion analysis and task redesign led to higher efficiencies in the manufacturing environment. However, as time and motion standards for specific tasks were set,It became apparent that all workers did not have the same talents and abilities. Attention in the 1930s was thus directed to placing more emphasis on worker selection and training.
The therblig notation evolved from the observation of human movement. It was observed that manual skill could be analyzed in a series of about 16 actions. These actions were called "therbligs" that used the roughly reverse spelling of their developer's name, Gilbreth. The idea was first reported in about 1919 and with a few minor adjustments and modifications it has stood up as a usable model to the present time. The names of the movement units were search, find, select, seize, position, mount, use, dismount, inspect, transport loaded, transport unloaded, preposition for next operation, launch load, wait (inevitable delay), sait (avoidable delay) and rest (to overcome fatigue).Each of these units was observed and timed as they occurred by trained "motion and time specialists" who were highly trained, used stopwatches, films and various specialized timing devices. The timing was generally in milliseconds but under certain specialized conditions it could be in microseconds. The various manuals, tables, etc. they have been generated for typical industrial tasks. The social impacts have been enormous, including labor and rest legislation, union-management negotiations, workplace safety, etc., etc… Detailed time tables for standard employee tasks. workplace are available in bookstores and technical librariesDetailed time tables for standard workplace tasks are available from bookstores and technical libraries
THERBLIGS: THE KEYS TO SIMPLIFY YOUR WORK
The term may sound like a new computer term or some obscure part of the human anatomy, but Therbligs are really the keys, which unlock the mystery of the way, we work. In today's world of business, which requires longer and longer working days from its employees, Therbligs might just be the method, which can shave hours from one working day.
Therbligs comprises a system to analyze the movements involved in the execution of a task. The identification of individual movements, as well as moments of delay in the process, was designed to find unnecessary or ineffective movements and to use or eliminate even split-seconds of lost time. Frank and Lillian Gilbreth invented and refined this system, roughly between 1908 and 1924.
It is truly ironic that Gilbreth's most often requested material, was for a subject that was never covered in any of his books. While the Therblig concept was born around 1908, it was constantly refined and tested, as a tool; a very powerful tool.
In their writings from about 1915 to 1920, the Gilbreths begin to speak of 15 to 16 "stroke cycles", but rarely named them all and did not refer to any comprehensive system. In fact, it was not until the late summer of 1924, shortly after Frank's death that the entire Therblig system was presented in two articles on Management and Administration {August, 1924 pp 151-154; September, 1924 pp 295-297}. I have found some material in the Gilbreth collection at Purdue and some helpful refinements in books by Alan Mogensen: Common Sense Applied to the Study of Motion and Time and by Dr. Ralph Barnes: Study of Motion and Time. These sources have been used in this article to provide a description of the topic.
Before proceeding, it must be made clear that Therbligs had no relation to the study of time. No matter what the tailor or his merry band of followers may have been intimated, nor did the latest attempts in motion study binding to time study, as Frank Gilbreth put it: «…. Taylor never did any study of the motion of the class what. » The very name, "Therblig", was created to demonstrate Gilbreth's ownership of the term (the word that is, Gilbreth spelled backwards except for the "th").
With various methods of motion study (study of micro-Motion (film film) and the Chronocyclegraph) the Gilbreths were able to examine the smallest of movements. However, to make the process uniform, among the doctors, they needed a method of categorizing the types of movements. The method would also have to be a system that could easily be applied to all types of activities but still allow the identification of what the Gilbreths saw as unnecessary or fatigue producing movements. The resulting method included anywhere from 15 to as many as 18 Therbligs (which were added by the Gilbreths and later authors).
The Therbligs would then be plotted on a Simo chart (simultaneous move chart) along with the time each move took. The sequences of movements of each hand were traced, as was a foot, if used for the pedal controls. Then, by examining the charts, one could determine which Therbligs were lasting too long or which could be eliminated by changing the job. They could also identify periods of delay caused be whatever the tool / part setup.
INDUSTRIAL ENGINEERING AND OPERATIONS INVESTIGATION
Operations research
Planification and control of the production
Economic engineering
Industrial Logistics
Project Evaluation
"Operations Research (IO) is the application, by interdisciplinary groups, of the scientific method to problems related to the control of organizations or systems in order to produce solutions that better serve the objectives of any organization."
"What is operations research? One way to try to answer this question is to give a definition. For example, operations research can be described as a scientific approach to decision making that requires the operation of organizational systems. However, this description, like previous attempts at definition, is so general that it can be applied to many other fields. Therefore, perhaps the best way to understand the unique nature of operations research is to examine its salient features.
As the name implies, operations research means "doing research on operations." This says something about both the focus and the area of application. So, Operations Research is applied to problems that refer to the conduct and coordination of operations or activities within an organization. The nature of the organization is essentially immaterial and, in fact, operations research has been applied in business, industry, military, government, hospitals, etc. Thus, the range of applications is extremely wide. The approach to operations research is the same as the scientific method. In particular,the process begins with careful observation and formulation of the problem and continues with the construction of a scientific (usually mathematical) model that attempts to abstract the essence of the real problem. At this point, the hypothesis is proposed that the model is a sufficiently precise representation of the essential characteristics of the situation so that the conclusions (solutions) obtained are also valid for the real problem. This hypothesis is verified and modified by appropriate tests. So, in a way, operations research includes creative scientific investigation of the fundamental properties of operations. However, there is more than this. In particular, operations research is also concerned with the practical management of the organization. So, to be successful,It should also provide clear, positive conclusions that the decision maker can use when needed. One more characteristic of operations research is its broad point of view. As implied in the previous section, operations research takes an organizational point of view. It can be said that it tries to resolve conflicts of interest between the components of the organization so that the result is the best for the entire organization. This does not mean that the study of each problem must explicitly consider all aspects of the organization, but rather that the objectives sought must be consistent with those of the entire organization. An additional feature, which was mentioned incidentally, is that operations research tries to find the best solution,or the optimal solution, to the problem under consideration. Rather than being content with just improving the state of affairs, the goal is to identify the best possible course of action. Although it must be interpreted with great care, this "search for optimality" is a very important aspect of operations research. All these characteristics lead in one almost natural way to another. Clearly, no single individual can be expected to be an expert in all multiple aspects of operations research work or the problems being studied; it requires a group of individuals with diverse backgrounds and abilities. So when a full operations research study of a new problem is to be conducted, it is usually necessary to organize a team.This should include individuals with a strong background in mathematics, statistics, and probability theory, as well as economics, business administration, electronic computing, engineering, physical and behavioral sciences, and, of course, the special techniques of operations research. The team also needs to have the experience and skills necessary to allow proper consideration of all ramifications of the problem throughout the organization and to efficiently execute all phases of the study.The team also needs to have the experience and skills necessary to allow proper consideration of all ramifications of the problem throughout the organization and to efficiently execute all phases of the study.The team also needs to have the experience and skills necessary to allow proper consideration of all ramifications of the problem throughout the organization and to efficiently execute all phases of the study.
In short, operations research is concerned with optimal decision making and modeling of deterministic and probabilistic systems that originate in real life. These applications, which occur in government, business, industry, engineering, economics, and the natural and social sciences, are largely characterized by the need to allocate scarce resources. In these situations, a deep understanding of the problem can be obtained from the scientific analysis provided by operations research. The contribution of the operations research approach comes primarily from:
1.- The structuring of a real life situation as a mathematical model, with which an abstraction of the essential elements is achieved so that a solution can be found that agrees with the objectives of the decision maker. This means looking at the problem within the context of the whole system.
2.- The analysis of the structure of such solutions and the development of systematic procedures to obtain them.
3.-The development of a solution, including mathematical theory, if necessary, that leads to the optimal value of the measure of what is expected of the system (or perhaps that compares alternative courses of action evaluating this measure for each one). »
The OR approach incorporates the systematic approach by recognizing that internal variables in decision problems are interdependent and interrelated. Operational research is "the application of scientific methods, techniques and instruments to problems involving the operations of a system, in such a way as to provide those who control the system with optimal solutions to the observed problem." This "generally deals with operations of an existing system…", that is, "existing materials, energies, people and machines". "The goal of operational research is to train management to solve problems and make decisions."
The main fields of application of IoT are:
- Relating to people:
1.- Organization and management.
2.- Absenteeism and work relationships.
3.- Economy.
4.- Individual decisions.
5.- Market research.
- Relating to people and machines:
1.- Efficiency and productivity.
2.- Organization of flows in factories.
3.- Methods of quality control, inspection and sampling.
4.- Accident prevention.
5.- Organization of technological changes.
- Relative to movements:
1.- Transportation.
2.- Storage, distribution and handling.
3.- Communications.
OPERATIONS INVESTIGATION IN PRACTICE
This section presents a brief overview of Operations Research techniques. Then some research results are presented showing which techniques have been used most frequently in practice and what needs to be done to enable the reader to use Operations Research successfully throughout their career.
Linear programming: it is a problem solving method that has been developed for situations that involve the maximization or minimization of a linear function subject to linear restrictions that limit the extent to which it can tend towards the objective function.
Linear programming with integers: It is a method used for problems that can be posed as linear programs, with the additional requirement that some or all of the recommended decisions must assume integer values.
Network models: It is a graphic representation of a problem that consists of small circles, called nodes, interconnected by lines called arcs. There are specialized solution procedures for these types of problems that allow many management problems to be quickly resolved in areas such as transportation system design, information systems design, and project scheduling.
PERT / CPM project management: In many cases, managers take responsibility for planning, scheduling, and controlling projects that consist of numerous tasks or jobs that are carried out by various departments, people, etc. PERT and CPM are techniques that help managers fulfill their responsibilities in managing projects.
Inventory models: These models are used to assist managers who face the dual problems of maintaining sufficient inventories to satisfy the demand for goods and, at the same time, incurring the lowest possible costs for maintaining those inventories.
Waiting Line Models (Queue Theory): Waiting line models (queues or queues) have been developed to help administrators understand and make better decisions regarding the operation of systems that involve waiting lines.
Computer simulation: This is a technique used to test models of the operation of a system over time. Such a technique uses a computer program to model the operation and perform calculations on the simulation.
Decision analysis: Decision analysis can be used to determine optimal strategies in situations where there are several decision alternatives and an uncertain or risky pattern of events.
Goal programming: This is a technique used to solve multi-criteria decision problems, usually within a linear programming framework. Analytical ranking process. It is a multi-criteria decision-making technique that allows for the inclusion of subjective factors to arrive at the recommended decision.
Forecasts: Forecasting methods can be used to predict future aspects of a business operation.
Markov process models: Markov process models are useful for studying the evolution of certain systems after several repetitions. For example, Markov processes have been used to describe the probability that a machine that is running in one period will continue to run or break down in another period.
Dynamic programming: This programming is a technique that allows you to decompose a large problem so that, once the smaller problems obtained in the decomposition have been solved, you have an optimal solution for the complete problem.
Most frequently used methods
A study by Forgionne of business executives indicates the frequency with which various techniques from the science of Operations Research are used. As shown in the Table below, the most frequently used methods are statistical methods, computer simulation, PERT / CPM, linear programming, and queuing theory.
Frequency of use in% of responses
Never Moderate Frequent
Statistics 1.6 38.7 59.7
Computer simulation 12.9 53.2 33.9
PERT / CPM 25.8 53.2 21.0
Linear programming 25.8 59.7 14.5
Queuing theory 40.3 50.0 9.7
Nonlinear programming 53.2 38.7 8.1
Dynamic programming 61.3 33.9 4.8
Game theory 69.4 27.4 3.2
Ledbetter and Cox study supports these conclusions by ranking, in order of use, regression (statistical analysis), linear programming, simulation, network models (PERT / CPM), rows or queues, dynamic programming and game theory. Research by Thomas and DaCostaS showed that 88% of all large companies use forecasting and that more than 50% make use of quantitative methods for production scheduling, inventory control, capital budgeting, and transportation. A study conducted by Gaitheró on the applications of management science in manufacturing companies also supports the high frequency of use of statistical analysis, simulation and linear programming.
The PERT method, which belongs in principle to the area of programs within planning, is closely related to all administrative functions, since in addition to being a program within planning, it serves as a basis for the organization as a model to carry out a objective and clear development of its stages (follow a logical sequence in the division of labor through a list of activities, as well as in the description of the functions, avoiding duplication).
It is applicable to the management, insofar as it provides valuable information, knowing which are the critical routes, for decision-making, referring to saving time, money, other resources, as well as in relation to communication, motivation and supervision of the activities and responsible personnel.
The PERT is an excellent element within the control function, especially in the stage of measurement of results against pre-established standards, it helps in the correction and / or speeding up to reach said standards and external valuable information in the feedback stage as they are compatible with the factors that comprise the control (Quantity, time, cost).
Given the unquestionable dynamic and changing life that we are witnessing, with clear tendencies towards acceleration, as a result of the speed in communications and globalization at a world level, the companies that intend to survive and finally succeed; They must resort to "planning" and solving three major areas:
- a) technological resources; b) financial resources; c) human resources.
The PERT method provides the administrator with the tool that allows him to plan in an objective, simple and practical way, but at the same time effective, each and every one of the activities to be carried out to achieve success in the objectives that the company intends to achieve.
QUALITY CONTROL AND INDUSTRIAL ENGINEERING
A total quality system is the functional structure of work agreed throughout the company and throughout the plant, documented with effective integrated technical and administrative procedures, to guide the coordinated actions of the workforce, the machines and the information of the company and plant of the best and most practical ways to ensure customer satisfaction with quality and quality economic costs.
The system approach to quality starts with the basic process of total quality control that customer satisfaction cannot be achieved by concentrating on a single area of the company and plant-engineering design, reliability analysis, equipment quality inspection, analysis of materials for rejection, education for the operator or maintenance studies because of the importance that each phase has in its own right. Their achievement depends, in turn, both on how well and how thoroughly these quality actions in the different areas of the business work individually, and on how well and how thoroughly they work together.
SYSTEMS APPLICATION
The quality control process takes place within the framework of the systems application. The objective of the quality control system is generally the achievement of particular levels of quality, as indicated in the specifications and tolerances. Important characteristics of these specifications include exact product description, clearly defined limits of various characteristics, standards for direct measurements (such as dimensions) or indirect measurements (such as moisture content, deduced from readings of electrical resistance), and the differentiation between major or critical quality characteristics and minor or less important defects. The way to achieve the objective of the quality control system passes through the production team, the staff,and processing, operations and similar services. Specifications should be viewed as the vehicle through which consumer needs and requirements are communicated to design, engineering, production, quality control testing and inspection, and other operations. Feedback from the consumer provides the main impetus to improve the performance of the quality control system. In this way, not only the product specifications, but also those of the quality and process evaluation are geared to the needs of the market.quality control testing and inspection and other operations. Feedback from the consumer provides the main impetus to improve the performance of the quality control system. In this way, not only the product specifications, but also those of the quality and process evaluation are geared to the needs of the market.quality control testing and inspection and other operations. Feedback from the consumer provides the main impetus to improve the performance of the quality control system. In this way, not only the product specifications, but also those of the quality and process evaluation are geared to the needs of the market.
INTERACTIONS BETWEEN QUALITY, COST AND PRODUCTIVITY
The installation and operation of a quality control system within an organization with leads to an improvement in cost and productivity factors along with better quality. These results are supported by world experience, and can be explained simply: by having materials, processes and operations under control, there will be a greater flow of products manufactured within specifications and tolerances. In turn, this greater uniformity in the product means that there will be less waste, reprocessing, recovery and repairs, so that costs will be reduced and materials and energy will be saved. Higher quality products, and therefore more valuable to the user, will be easier to put on the market and sell,with the result of a certain decrease in the sales efforts required per unit sold.
Finally, by avoiding improper machine settings and faulty operating conditions, not only quality but also productivity will be increased. In addition to these advantages, there are still more subtle and far-reaching benefits to quality controlled operations. Raise quality, and at the same time lower costs and boost productivity. Indeed, the effort in control necessary to obtain good quality redounds to manufacturing and other areas of operations, with parallel beneficial results.
SYSTEMS IMPLICATIONS
Emphasis has been placed on the engineering aspects of quality control systems as failure to pay attention to all elements of the approach will result in an ineffective overall program. Within this context, the following considerations are particularly important:
- A complete quality control system must include all the functions of the factory, including those of management, production and engineering, as well as those of quality control. Whether it is large or small, the organization must guarantee an environment in the all of the above functions are performed by people working together as a team. Quality control is not just inspection. Neither does the application of sampling procedures, as they have been incorporated into some published sampling plans. Again the class is in the system as a whole. Inspection at 100% or according to a pre-established sampling plan, makes quality measurements the link in the engineering system that leads to controlled quality.Most of the efforts required to achieve a successful quality control program stem from functions concerning general management, engineering, and production, all of which are not generally part of organization, inspection, and control. quality. A large part of the efforts include the analysis of various alternative courses of action that lead to an improvement of the quality of the product and the behavior of the process where it is necessary, which leads to the detection and isolation of those places where they are necessary. the corrective efforts on the part of the general management, engineering and production is the care and the efficiency of the functions of quality control and inspection.As a result of activities 4 and 5 here we mention must stand out among certain types of changes: (1) Changes in product and process design, (2) recognition that operators need additional or better information, (3) seek specialized technical assistance on certain persistent types of quality problems and (4) be alert to the need for program and systems reviews anywhere.
Quality is measured in terms of the ability of the product to meet reasonable and relevant specifications.
BOOK REFERENCES
- ELWOOD, S. Buffa, " Administration and technical direction of Production ", Fourth Edition, Editorial: Limusa, México, DF, 1982, Pp 672 Emery J., Information Systems for Management, Critical Strategic Resource, Ed. Díaz de Santos, Madrid, 1990. GONZÁLEZ, Ruiz Lucinda, ESPRIU, Torres José, " Theoretical-Practical Instructive of Systematic Analysis of Production II " Mexico DF, January 2001, Pp 60KRICK, Edward V. " Methods Engineering " Editorial: Limusa, México DF 1961MAYNARD, Harold B. " Manual of Engineering and Industrial Organization "Third Edition, Editorial: Reverté, SA, Spain, 1987 Monks J., Operations Administration, Ed. Mc GrawHill, Mexico, 1989.NIEBEL Benjamín, FREIVALDS Andris, " Industrial Engineering: Methods, Standards and Work Design " Tenth edition, Editorial: Alfa omega Grupo Editor, SA de CV, Mexico DF, 2001. INTERNATIONAL LABOR OFFICE, “ Introduction to the Study of Work ”, Fourth Edition, Editorial: Limusa, Mexico DF 2001R. M. Curie, “ Analysis and measurement of work ”, Editorial: Diana, México DF 1972, P: 152 - 154, 163 - 164.
