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K L University

Department of Mechanical Engineering


Course Handout for IV Year B.Tech. Program
A.Y.2016-17, First Semester
Course Name

: INDUSTRIAL ENGINEERING TECHNIQUES

Course Code

: 13-ME403

L-T-P structure

:302

Course Credits

:4

Course Coordinator

: Mr. M. Nageswara Rao

Course Instructors

: Mr. P. Ratna Prasad, Mr. M. Nageswara Rao, Mr. K. Someswara Rao

Course Teaching Associates

: Nil

Course Objective:
The objective of the course is to enable the learners to understand and apply the techniques of industrial engineering for
management of production and operation systems. It is targeted to introduce real world management systems and
systematically develops analysis techniques for such systems to learners..
Course Rationale:
The course starts with work study, method study, work measurement & productivity and its applications to the
calculations of time, cost and energy involved in various processes such as flow motion study and micro-motion study.
The application of quality control concept such as Statistical Quality Control (SQC) charts, Acceptance sampling and
concept of Operating Characteristic (O.C) curve to improve quality standards of products and process to meet customer
satisfaction is discussed. It describes different production systems, facility layout design procedure, scheduling of
continuous production, batch production & job-shop, forecasting techniques and their application to real world
situations. A brief introduction about PPC, JIT, lean manufacturing, six sigma and supply chain management is included.
Course Outcomes (CO):
CO No:

Course Outcome

1
2

Apply various work-study techniques to determine the standard time and efficiency.
Analyze various quality control techniques for bringing out the best quality output.
Apply various plant layout and production scheduling techniques to optimize
productivity.
Calculate future demand for the product in the market by applying appropriate
forecasting technique.
Analyze and develop a system, component, process to meet desired needs within
realistic constraints.

3
4
5

Student
Outcomes
K
K

Blooms
Taxonomy Level
2
2

COURSE OUTCOME INDICATORS (COI):


CO No.
1
2
3
4
5

COI 1

COI 2

Illustrate the application of various method study Calculate the standard time, efficiency of various methods
techniques to improve the working methods
using appropriate work measurements techniques.
Demonstrate the understanding and application of Analyze the concept of acceptance sampling plans by
various Statistical Quality Control Charts.
application of OC Curve.
Employ the concepts of plant layouts and assembly line Schedule the jobs so as to ensure the completion of jobs on
balancing, sequencing for balancing workloads on m/c.
time and monitor their performance.
Analyze future demand using Forecasting Techniques to
Prepare Aggregate Plans to establish general levels of
provide information to the managers for developing
output, inventories for future periods.
meaningful plans.
Analyze and develop a system, component, process to meet desired needs within realistic constraints.

SYLLABUS (As approved by BoS):


Work study: Techniques of work study, basic procedure of work study. Method study: Tools for recording techniques Flow
process chart, flow diagram, string diagram, multiple activity chart, Man-machine chart. Micro motion study: Therbligs, motion
economy principles, SIMO chart. Work measurement: Stopwatch time study procedure - breaking the job into elements, timing
methods, number of cycles to be timed, rating, allowances, setting standard time. Work sampling: Confidence levels, number of
observations, use of random number table. Inspection & Quality Control: Concept and Types of Inspection, Quality Control Charts
SQC, Charts for variables and charts for attributes, application and construction of charts and problems. Acceptance sampling,
Single and double sampling, OC curve, Production Management: Types of production systems, Mass production, Batch
production, Job order production. Productivity and factors influencing productivity, Facility layout definition, types product
layout, process layout, fixed position layout, cellular layout, introduction to computerized layout. Scheduling : Introduction,
concept of assembly line balancing, scheduling of batch production, scheduling of job order, loading, sequencing,- definition,
sequencing of n jobs through one machine, n jobs through 2 machines, ( Johnsons algorithm ), sequencing of n jobs through 3
machines, n jobs through m machines. Forecasting: Definition, approach, types, Methods Qualitative methods Judgmental
methods, Quantitative methods times series, regression, Introduction to aggregate planning, Production planning & control:
Introduction, definition, functions of PPC. Brief introduction to: JIT, Lean manufacturing, six sigma, Supply chain management
BoS Approved Text books:
rd
1. ILO, Introduction to Work-Study, Oxford & IBH Publishing Pvt. Ltd., 3 Edition, 1979.
th
2. Everette E. Adam, Ronald J. Ebert, Production and Operations Management, PHI Learning Pvt. Ltd., 5 Edition, 1992.
BoS Approved Reference Books:
1. S.N. Chari, Production and Operations Management
rd
2. R. Pannerselvam, Production and Operations Management, PHI Learning Pvt. Ltd., 3 Edition, 2012.
Other Books, References: (As recommended for reference by the course team, if any)
nd
1. Martand Telsang, Industrial Engineering and Production Management, S.Chand and Company Ltd., 2 Edition, 2008.
th
2. Steven Nahmias, Production and Operations Analysis, McGraw-Hill International, 5 Edition, 2005
COURSE DELIVERY PLAN:
Session
CO
COI
Topic(s)
No.
Introduction about the course, its objectives, concept of
1
1
1
productivity, factors influencing productivity.
Techniques and basic procedure of work study, method
2
1
1
study, outline, flow process charts.
Recording techniques two handed process chart, man3
1
1
machine chart, flow diagram and string diagram.
Micro motion Study, Motion Economy Principles and SIMO
4
1
1
Chart.
Work measurement and its procedure, stop watch time
5
1
2
study procedure.
Allowances and setting standard times, and sample
6
1
2
problems. (Active Learning)
Work sampling, confidence levels, use of random number
7
1
2
table.
Sample problems on work sampling and time study.
8
1
2
(Active Learning)
9

Introduction to statistical quality control.

10

Quality control charts for variables. (Active Learning)

11

Quality control charts for attributes. (Active Learning)

12

13

14

15

16

Concept and types on inspection, acceptance sampling


plan.
Acceptance sampling single, double and multiple
sampling plans and sample problems. (Active Learning)
Construction of OC curve and sample problems on OC
curve. (Active Learning)
Types of facility layouts product, process, cellular and
fixed position layouts.
Introduction to computerized layout CRAFT and ALDEP.

Teaching-Learning
Methods
Explanation
using
board, Listen & Observe
Explanation using ppt,
Listen and Observe
Explanation using ppt,
Listen and Observe
Explanation using ppt,
Listen and Observe
Explanation
using
board, Listen & Observe
Chalk and Talk, problem
solving and Practice
Chalk and Talk, Listen
and Practice
Chalk and Talk, problem
solving and Practice
Chalk and Talk, Listen
and Observe
Chalk and Talk, problem
solving and Practice
Chalk and Talk, problem
solving and Practice
Chalk and Talk, Listen
and Observe
Chalk and Talk, problem
solving and Practice
Chalk and Talk, problem
solving and Practice
Explanation using ppt,
Listen and Observe
Explanation using ppt,
Listen and Observe

Evaluation
Components
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
TestI & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test2 & SEE
Questionnaire,
Test3 & SEE
Questionnaire,
Test3 & SEE

Assembly line balancing and sequencing and sample


problems. (Active Learning)
Introduction to sequencing and scheduling (Active
Learning)

17

18

19

Scheduling of batch production(Active Learning)

20

Scheduling of job-order production(Active Learning)

21

22

23

24

Introduction to production planning and control (PPC).

25

Introduction to aggregate planning.

26

Problems on aggregate planning.

Introduction to forecasting and qualitative forecasting


techniques.
Quantitative forecasting techniques moving averages,
exponential smoothing, regression analysis. (Act. Learning)
Forecasting error estimation techniques and sample
problems. (Active Learning)

Chalk and Talk, problem


solving and Practice
Chalk and Talk, problem
solving and Practice
Chalk and Talk, problem
solving and Practice
Chalk and Talk, problem
solving and Practice
Chalk and Talk, Listen
and Observe
Chalk and Talk, problem
solving and Practice
Chalk and Talk, problem
solving and Practice
Explanation
using
board, Listen & Observe
Chalk and Talk, Listen
and Observe
Chalk and Talk, problem
solving and Practice

Questionnaire,
Test3 & SEE
Questionnaire,
Test3 & SEE
Questionnaire,
Test3 & SEE
Questionnaire,
Test3 & SEE
Questionnaire,
Sem End Exam
Questionnaire,
Sem End Exam
Questionnaire,
Sem End Exam
Questionnaire,
Sem End Exam
Questionnaire,
Sem End Exam
Questionnaire,
Sem End Exam

Session wise Teaching Learning Plan


Session Number: 1
Session Outcome: Understand the concept of productivity and compute various measures of productivity.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Introduction about the course and its objectives


Concept of productivity, factors affecting productivity
Interactive session and Questionnaire
Computation of various measures of productivity

1
1
2

Using Black Board


Questionnaire using Q & A
Using Black Board

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 2
Session Outcome: Understand techniques of work study and illustrate the basic procedures of work study and method study.
Time (in min)
Topic
BTL
Teaching Learning Method
10
Recap/Introduction
30
Techniques and basic procedure of work study, method study
1
Using PPT
10
Interactive session and Questionnaire
1
Questionnaire using Q & A
30
Analyze the new method of doing work using recording techniques
2
Using PPT
10

Interactive session and Questionnaire

05

Conclusion & Summary

Session Number: 3
Session Outcome: Analyze the new method of doing work using recording techniques.
Time (in min)
Topic
10
Recap/Introduction
30
Two handed process chart
10
Interactive session and Questionnaire
30
Man-machine chart, flow and string diagrams
10

Interactive session and Questionnaire

05

Conclusion & Summary

BTL

Questionnaire using Q & A

Teaching Learning Method

2
2
2

Using PPT
Questionnaire using Q & A
Using PPT

Questionnaire using Q & A

Session Number: 4
Session Outcome: Understand motion economy principles and employ these principles for construction of SIMO chart.
Time (in min)
Topic
BTL
Teaching Learning Method
10
Recap/Introduction
30
Micro motion study and motion economy principles
1
Using PPT
10
Interactive session and Questionnaire
1
Questionnaire using Q & A
30
SIMO chart
1
Using PPT
10

Interactive session and Questionnaire

05

Conclusion & Summary

Questionnaire using Q & A

Session Number: 5
Session Outcome: Illustrate the basic procedures of work measurement and stop watch time study procedure.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Work measurement procedure and stop watch time study procedure
Interactive session and Questionnaire
Time study equipment and selecting and timing of the job

1
1
1

Using Black Board


Questionnaire using Q & A
Using Black Board

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 6
Session Outcome: Understand various types of allowances and calculating of standard times.
Time (in min)
10
30
10
30

Topic
Recap/Introduction
Allocation of types of allowances and setting standard times
Interactive session and Questionnaire
Computation of standard times for the given problem
(Active Learning)

10

Interactive session and Questionnaire

05

Conclusion & Summary

BTL

Teaching Learning Method

1
1

Using Black Board


Questionnaire using Q & A

problem solving

Questionnaire using Q & A

Session Number: 7
Session Outcome: Compute the percentage of occurrence of a certain activity by random observations, statistical sampling.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Work sampling, confidence levels
Interactive session and Questionnaire
Use of random number table and computation of standard times

2
2
2

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 8
Session Outcome: Compute the standard time of activities using time study and work sampling procedures.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Standard time using time study procedure.
Interactive session and Questionnaire
Standard time using work sampling procedure(Active Learning)

2
2
2

Chalk and talk


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 9
Session Outcome: Understand the concept of statistical quality control.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Dimensions of quality, objectives of quality control
Interactive session and Questionnaire
Quality characteristics and concept of reliability

1
1
1

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 10
Session Outcome: Demonstrate the application of Quality control charts for variables.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Various types of control charts for variables
Interactive session and Questionnaire
Develop X-bar and R-Charts(Active Learning)

1
1
2

problem solving
Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 11
Session Outcome: Demonstrate the application of Quality control charts for attributes.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Various types of control charts for attributes
Interactive session and Questionnaire
Developing p and c charts(Active Learning)

1
1
2

problem solving
Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 12
Session Outcome: Understand the concept of Inspection and acceptance sampling plans.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Concept and types of inspection.
Interactive session and Questionnaire
Acceptance sampling plan

2
2
2

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 13
Session Outcome: Illustrate various acceptance sampling plans.
Time (in min)
10
30
10
30

Topic
Recap/Introduction
Single and double acceptance sampling plan
Interactive session and Questionnaire
Multiple acceptance sampling plan and sample problems
(Active Learning)

10

Interactive session and Questionnaire

05

Conclusion & Summary

BTL

Teaching Learning Method

1
1

Using Black Board


Questionnaire using Q & A

problem solving

Questionnaire using Q & A

Session Number: 14
Session Outcome: Demonstrate the usage and construction of Operation Characteristic curve.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Construction of OC curve
Interactive session and Questionnaire
Sample problems on OC Curve(Active Learning)

2
2
2

Using Black Board


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 15
Session Outcome: Classify and explain about various plant layouts.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Factors affecting layout design, Principles of plant layout
Interactive session and Questionnaire
Product layout, process layout, cellular Layout, fixed position layout

1
1
1

Using PPT
Questionnaire using Q & A
Using PPT

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 16
Session Outcome: Illustrate the application of computerized plant layouts.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Computerized relative allocation of facilities technique (CRAFT)
Interactive session and Questionnaire
Automated layout design program (ALDEP)

2
2
2

Using PPT
Questionnaire using Q & A
Using PPT

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 17
Session Outcome: Employ assembly line balancing techniques to allocate work elements to assembly stations to reduce idle time.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Concept of assembly line balancing
Interactive session and Questionnaire
Sample problems on assembly line balancing (Active Learning)

2
2
2

Using Black Board


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 18
Session Outcome: Explain about various sequencing rules and activities involved in scheduling.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Scheduling process
Interactive session and Questionnaire
Priority sequencing rules (Active Learning)

1
1
1

Chalk and talk


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 19
Session Outcome: Schedule jobs of batch production system so as to ensure completion of jobs on time.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Dynamic sequencing rules, objectives of scheduling batch production
Interactive session and Questionnaire
Sample problems on batch production scheduling(Active Learning)

2
2
2

Chalk and talk


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 20
Session Outcome: Schedule jobs of job order production system so as to ensure completion of jobs on time.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Objectives of job order scheduling, Johnsons Algorithm
Interactive session and Questionnaire
Sequencing of n jobs through 3 and m machines. (Active Learning)

2
2
2

Chalk and talk


Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 21
Session Outcome: Illustrate the need for forecasting and qualitative methods of forecasting.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Needs for forecasting and steps in forecasting process
Interactive session and Questionnaire
Qualitative forecasting techniques

2
2
2

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 22
Session Outcome: Demonstrate the application of various quantitative forecasting techniques.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Quantitative forecasting moving averages, exponential smoothing
Interactive session and Questionnaire
Quantitative forecasting linear regression analysis(Active Learning)

2
2
2

problem solving
Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 23
Session Outcome: Demonstrate various forecasting error estimation techniques.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Forecasting error estimation techniques
Interactive session and Questionnaire
Sample problems on forecasting error estimation(Active Learning)

2
2
2

problem solving
Questionnaire using Q & A
problem solving

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 24
Session Outcome: Describe and explain about production planning and production control aspects.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Production planning
Interactive session and Questionnaire
Production control

1
1
1

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 25
Session Outcome: Illustrate the aggregate planning procedure and examine the chase strategy.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Introduction to aggregate planning, aggregate planning procedure
Interactive session and Questionnaire
Chase strategy of aggregate planning

1
1
2

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

Session Number: 26
Session Outcome: Compare the level strategy and stable workforce strategies of aggregate planning.
Time (in min)

Topic

BTL

Teaching Learning Method

10
30
10
30

Recap/Introduction
Level strategy of aggregate planning
Interactive session and Questionnaire
Stable workforce strategy of aggregate planning

2
2
2

Chalk and talk


Questionnaire using Q & A
Chalk and talk

10

Interactive session and Questionnaire

Questionnaire using Q & A

05

Conclusion & Summary

EVALUATION PLAN:
Evaluation
Weightage / Marks
Component
COI Number
BTL
Weightage (7.5%)
Test 1
Max. Marks (30)
Weightage (7.5%)
Test 2
Max. Marks (30)
Weightage (7.5%)
Test 3
Max. Marks (30)
Weightage (5%)
Active Learning
Max. Marks (20)
Attendance
Weightage (5%)
Lab Continuous Weightage (2.5%)
Evaluation
Max. Marks (20)
Weightage (5%)
Lab Exam
Max. Marks (20)
Weightage (5%)
SE Lab Exam
Max. Marks (20)
Weightage (10%)
SE Project
Max. Marks (20)
Weightage (45%)
Semester End
Max. Marks (60)
Exam
Question Number

Date

Duration
(Hours)

1.5 Hrs
1.5 Hrs
1.5 Hrs
1.5 Hrs
1.5 Hrs
1.5 Hrs

CO 1

CO 2

3.75
15

3.75
15

.625
2.5

.625
2.5

CO 3

3.75
15

3.75
15

.625
2.5

.625
2.5

CO 4

CO 5

3.75
15
.625
2.5

3.75
15
.625
2.5

.625
2.5

.625
2.5
2.5
20
5
20
5
20
10
20

3 Hrs
3 Hrs
3 Hrs

4.5
6
1, 2

4.5
6
1, 2

4.5
6
3, 4

4.5
6
3, 4

4.5
6
5, 6

LABORATORY DELIVERY PLAN


Session
Experiment/Activity
Session 1 Introduction about lab and dividing the students in to batches and Assigning projects
Session 2 Exp.No.1. Pin Board Assembly-Two Handed Process Chart
Session 3 Exp.No. 2. Bulb and Plug Assembly- Two Handed Process Chart
Session 4
Review of Projects
Session 5 Exp.No. 3. Bolts and Washer Assembly- Two Handed Process Chart
Session 6 Exp.No. 4. Quality Control Charts for Variables ( X Bar & R)
Session 7 Exp.No 5. Quality Control Chart for Attributes (P-Chart)
Session 8 Review of Projects
Session 9 Exp.No. 6. Control Charts For Count Of Defects(C-Chart)
Session 10 Exp.No. 7. Ergonomic Cycle Heart Beat
Session 11 Exp.No. 8. Ergonomic Cycle Energy
Session 12 Exp.No. 9. Tread Mill - Energy
Session 13 Exp.No.. 10 Performance Rating - Assembly Of An Unit

4.5
6
5, 6

9
12
7, 8

9
12
7, 8
CO
1
1
1
2
2
2
3
3
4
4

Course Team members, Chamber Consultation Hours and Chamber Venue details:
Chamber Consultation
Chamber Consultation
S. No. Name of the Faculty
Day(s)
Timings for Each Day
Mon: 5:00 PM to 7:00 PM
1
M. Nageswara Rao
Monday, Saturday
Sat: 3:00 PM to 5:00 PM
Wed: 5:00 PM to 7:00 PM
2
P. Ratna Prasad
Friday, Saturday
Sat: 9:30 AM to 11:30 AM
Mon: 5:00 PM to 7:00 PM
3
K. Someswara Rao
Monday, Saturday
Sat: 3:00 PM to 5:00 PM

Chamber Consultation
Room No:
M 111
M 107
M 103

Signature of COURSE COORDINATOR:

Recommended by HEAD OF DEPARTMENT:

Approved By: DEAN-ACADEMICS


(Sign with Office Seal)

Signature of
Course Faculty

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