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October 5, 2012

HISTORY and

PERSPECTIVE of

INDUSTRIAL ENGINEERING

History of Engineering and Development of

Industrial Engineering

Industrial and Systems Engineering

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Science and Engineering

Engineering and science have developed in a parallel, complementary fashion, although not always at the same pace.

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Whereas science is concerned with the quest for basic knowledge,

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engineering is concerned with the application of scientific knowledge to the solution of problems and to the quest for a “better life”.

Obviously, knowledge cannot be applied until it is discovered, and once discovered, it will soon be put to use.

In its efforts to solve problems, engineering provides feedback to science in areas where new knowledge is needed.

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Thus, science and engineering

work hand in hand.

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Although “science” and “engineering” each have distinguishing characteristics and are regarded as different disciplines, in some cases a “scientist” and an “engineer” might be the same person.

This was especially true in earlier times when there were very few means of communicating basic knowledge. The person who discovered the knowledge also put it to use.

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Is Engineering a Job, or an Occupation, or a

Profession?

What is the

difference

between a job,

occupation and

a profession?

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Job- definition

regardless of skill level and responsibility,

any work for you are paid for.

“a piece of work; especially : a small

miscellaneous piece of work undertaken

on order at a stated rate” (Merriam-

Webster Dictionary)

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Occupation- definition

Being employed and making a living.

An activity that serves as one's regular source of livelihood; a vocation.

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Profession?

We now know the

difference

between a job

and an

occupation so

what makes up a

profession?

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Attributes of a Profession

The profession

requires extensive

formal education

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Attributes of a Profession

Special

organizations set

and enforce

various standards

for members of the

profession

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Attributes of a Profession

A significant

service is provided

to the public

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Attributes of a Profession

The work requires

significant skill,

Judgment, and

Discretion

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Professional or Not?

Are professional athletes actually

“professional”?

What about carpenters?

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Professional or Not?

So what can we conclude?

Athletes and carpenters DO NOT meet the

standards required to be considered

professions

Medicine,Law, and Engineering ARE

professions

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ENGINEERING

“ the profession in which a knowledge of the

mathematical and natural sciences gained by

study, experience, and practice is applied with

judgement to develop ways to utilise,

economically, the materials and forces of nature

for the benefit of mankind ”

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The Modern Era

We choose 1750 as the beginning of modern engineering for two reasons:

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1. Engineering schools

appeared in France in the

eighteenth century.

2. The term civil engineer was

first used in 1750.

Principles of early engineering were first taught in military academies and were concerned primarily with road and bridge construction and with fortifications.

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This portion of academic training was referred to as military engineering. When some of the same principles were applied to nonmilitary endeavors, it was only natural to refer to these as civilian engineering, or simply civil engineering.

An important advancement was the development of a practical steam engine that could perform useful work.

Once such an engine was available (approximately 1700), many mechanical devices were developed that could be driven by the engine.

These efforts culminated in the emergence of mechanical engineering as a distinct branch in the early nineteenth century.

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The first significant application of electrical science was the development of the telegraph by Samuel Morse (approximately 1840). Thomas Edison’s invention of the carbon-filament lamp (approximately 1880) led to widespread use of electricity for lighting purposes.

This, in turn, spurred very rapid developments in the generation, transmission, and utilization of electrical energy for a variety of laborsaving purposes. Engineers who choose to specialize in this activity were naturally labeled electrical engineers.

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Along with the developments in mechanical and electrical technology were accompanying developments in the understanding of substances and their properties.

The science of chemistry is concerned with understanding the nature of matter and in learning how to produce desirable changes in materials. The field of engineering endeavor naturally became known as chemical engineering.

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As industrial organizations merged to capitalize on the rapidly developing array of technological innovations, the size and complexity of manufacturing units increased dramatically. Mass production was made possible through two important concepts:

1. Interchangeability of parts.

2. Specialization of labor.

Through mass production the unit cost of consumer products was reduced dramatically.

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During the early part of this movement it

was recognized that business and

management practices that had worked

well for small shops and farms simply

were inadequate for large, complex

manufacturing organizations.

The need for better management systems

led to the development of what is now

called “industrial engineering”.

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This five major engineering disciplines (civil, chemical, electrical, industrial, and mechanical) were the branches of engineering that emerged prior to the time of World War I.

These developments were part of the industrial revolution that was occurring worldwide, and the beginning of the technological revolution that is still occurring.

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The Engineering Process

Engineers solve problems, but so do mathematicians.

Engineers analyze, but so do statisticians and economists.

Engineers design systems. Do others?

We can say that the distinguishing characteristic of engineering is that it is concerned with the design of systems.

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What is design? Certainly, design involves a considerable amount of creativity.

Is design then simply an art that one learns through experience? Or are there design principles that can be learned and applied?

Synthesis is a term whose meaning is almost the same as design. Perhaps we can develop an understanding of design by discussing the two terms synthesis and analysis.

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Analysis is concerned with resolving

something into its basic elements;

synthesis is concerned with combining

elements into a whole.

Typically, analysis is concerned with

existing systems. Synthesis is usually

concerned with a new or improved

system.

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Problem symptom

or expression

of need

Problem definition,

including statement

of desired outcome

Analysis

Synthesis of

alternative

solutions

Decision

(selection of one

alternative)

Solution, system,

or method

Fig. 1.1.

Basic engineering

process

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Industrial Engineering emerged as a profession as a result of the industrial revolution and the accompanying need for technically trained people who could plan, organize, and direct the operations of large complex systems.

The need to increase efficiency and effectiveness of operations was also an original stimulus for the emergence of industrial engineering.

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Evolution of Operations Management

Craft production

process of handcrafting products or services for individual customers

Division of labor

dividing a job into a series of small tasks each performed by a different worker

Interchangeable parts

standardization of parts initially as replacement parts; enabled mass production

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Evolution of Operations

Management (cont.)

Scientific management

systematic analysis of work methods

Mass production

high-volume production of a standardized product for

a mass market

Lean production

adaptation of mass production that prizes quality and

flexibility

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Historical Events in Operations Management

Era Events/Concepts Dates Originator

Industrial

Revolution

Steam engine 1769 James Watt

Division of labor 1776 Adam Smith

Interchangeable parts 1790 Eli Whitney

Scientific

Management

Principles of scientific

management 1911 Frederick W. Taylor

Time and motion studies 1911 Frank and Lillian

Gilbreth

Activity scheduling chart 1912 Henry Gantt

Moving assembly line 1913 Henry Ford

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Historical Events in Operations

Management (cont.)

Era Events/Concepts Dates Originator

Human

Relations

Hawthorne studies 1930 Elton Mayo

Motivation theories

1940s Abraham Maslow

1950s Frederick Herzberg

1960s Douglas McGregor

Operations

Research

Linear programming 1947 George Dantzig

Digital computer 1951 Remington Rand

Simulation, waiting

line theory, decision

theory, PERT/CPM

1950s Operations research

groups

MRP, CIM 1960s,

1970s

Joseph Orlicky, IBM

and others

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Historical Events in Operations

Management (cont.)

Era Events/Concepts Dates Originator

Quality

Revolution

JIT (just-in-time) 1970s Taiichi Ohno (Toyota)

TQM (total quality

management) 1980s

W. Edwards Deming,

Joseph Juran

Strategy and

operations 1990s

Wickham Skinner,

Robert Hayes

Business process

reengineering 1990s

Michael Hammer,

James Champy

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Historical Events in Operations

Management (cont.)

Era Events/Concepts Dates Originator

Globalization European Union, and other

trade agreements

1990s

2000s

Numerous countries

and companies

Internet

Revolution

Internet, WWW, ERP,

supply chain management

1990s ARPANET, Tim

Berners-Lee SAP,

i2 Technologies,

ORACLE,

PeopleSoft

E-commerce 2000s Amazon, Yahoo,

eBay, and others

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Eli Whitney

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Born 1765; died 1825

In 1798, received government

contract to make 10,000

muskets

Showed that machine tools

could make standardized parts

to exact specifications

Musket parts could be used

in any musket © 1995 Corel Corp.

Frederick W. Taylor

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Born 1856; died 1915

Known as ‘father of scientific

management’

In 1881, as chief engineer for

Midvale Steel, studied how tasks

were done

Began first motion & time studies

Created efficiency principles

Taylor: Management Should Take More Responsibility for

Matching employees to right job

Providing the proper training

Providing proper work methods and tools

Establishing legitimate incentives for

work to be accomplished

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Frederick W. Taylor is credited with

recognizing the potential improvements to

be gained from analyzing the work content

of a job and designing the job for

maximum efficiency.

Taylor’s methods brought about significant

and rapid increases in productivity.

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Frank & Lillian Gilbreth

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Frank (1868-1924); Lillian

(1878-1972)

Husband-and-wife

engineering team

Further developed work

measurement methods

Applied efficiency methods

to their home & 12 children!

(Book & Movie: “Cheaper by

the Dozen,” book: “Bells on

Their Toes”)

© 1995 Corel Corp.

Frank B. Gilbreth extended Taylor’s work considerably.

Gilbreth’s primary contribution was the identification, analysis, and measurement of fundamental motions involved in performing work.

By classifying motions as “reach”, “grasp”, “transport”, and so on, and by using motion pictures of workers performing their tasks, Gilbreth was able to measure the average time to perform each basic motion under varying conditions. (THERBLIG)

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Henry Ford

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Born 1863; died 1947

In 1903, created Ford

Motor Company

In 1913, first used

moving assembly line

to make Model T

Unfinished product

moved by conveyor

past work station

Paid workers very well for 1911 ($5/day!)

© 1995 Corel

Corp.

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W. Edwards Deming

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Born 1900; died 1993

Engineer & physicist

Credited with teaching Japan

quality control methods in

post-WW2

Used statistics to analyze

process

His methods involve workers

in decisions

Another early pioneer in industrial engineering was Henry L. Gantt, who devised the so-called Gantt chart.

The Gantt chart was a significant contribution in that it provided a systematic graphical procedure for preplanning and scheduling work activities, reviewing progress, and updating the schedule.

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W.A. Shewhart developed

the fundamental principles of

statistical quality control in

1924. This was another

important development in

providing a scientific base to

industrial engineering

practice.

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Many other industrial engineering pioneers contributed to the early development of the profession. During the 1920’s and 1930’s much fundamental work was done on economic aspects of managerial decisions, inventory problems, incentive plans, factory layout problems, material handling problems, and principles of organization.

Although these pioneers are too numerous to mention in this brief chronology, more complete historical accounts are available elsewhere.

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ENM102, INTRODUCTION TO INDUSTRIAL

ENGINEERING, 2006 52

Definition of Industrial Engineering

The following formal definition of industrial

engineering has been adopted by the IIE:

Industrial 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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Industrial Engineering Education

Topics that later evolved into industrial

engineering subjects were initially taught

as special courses in mechanical

engineering departments.

The first separate departments of

industrial engineering were established

at Pennsylvania State University and at

Syracuse University in 1908.

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Industrial Engineering Education

An IE option in mechanical engineering was

established at Purdue University in 1911.

The practice of having an IE option within a

mechanical engineering department was the

predominant pattern until the end of World War II.

Following the World War II, separate IE

departments were established in colleges and

universities throughout the country.

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The American Institute of Industrial Engineers was founded in 1948. The AIIE provided, for the first time, a professional organization devoted exclusively to the interests and developments of the industrial engineering profession.

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Impact of Related Developments

The evolution of the industrial and systems engineering profession has been affected significantly by a number of related developments.

Operations Research

Digital Computers

Emergence of service industries

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Impact of Operations Research (OR)

This approach originated in England and the United States during World War II and was aimed at solving difficult war-related problems through the use of science, mathematics, behavioral science, probability theory, and statistics.

Following World War II the concepts of OR were extended to problems in industry and commerce.

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Impact of Digital Computers

Another development that has had a

significant impact on the IE profession is

the digital computer.

Digital computers permit the rapid and

accurate handling of vast quantities of

data, thereby permitting the IE to design

systems for effectively managing and

controlling large, complex operations.

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Computer simulation is emerging as the most widely used IE technique.

A recent development that is having a profound (although still uncertain) impact on industrial engineering is computer-aided design (CAD) and computer-aided manufacturing (CAM).

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Emergence of Service Industries

In the early days of the industrial

engineering profession, IE practice was

applied almost exclusively in

manufacturing organizations.

After World War II there was a growing

awareness that the principles and

techniques of IE were also applicable in

nonmanufacturing environments.

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Relationship to Other Engineering Disciplines

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Military Engineering

Civilian Engineering

Mechanical Engineering

Industrial Engineering

Industrial and Systems

Engineering

Mathematics

and Physics

Electrical

Engineering

Computer

Science

Social Sciences

Chemical

Engineering

Chemistry

Psychology

Early Management Philosophy

Statistics

Operations

Research

Challenges of the Future

The world has a finite amount of nonrenewable resources. One of the major challenges for future engineers is to learn to accomplish the engineer’s mission in recognition of these constraints.

Another major challenge facing the engineering profession is to design systems and processes that are compatible with our natural environment.

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A major challenge that future engineers will

encounter is that of designing products that are safe

and reliable.

There is also an icreasing emphasis on improved

quality.

Perhaps the greatest challenge facing the

engineering profession is to become involved in

political issues and to provide assistance to

lawmakers in the design of social systems.

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