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Industrial and Production Engineering

Industrial and Production Engineering is a mesh between three various areas: Mechanical Engineering (where the production engineering comes from), Industrial Engineering, and Management Science. The main objective for people within this discipline is to improve efficiency, drive up effectiveness of manufacturing, quality control, and to reduce cost while making their products more attractive and marketable. In general industrial engineers main goal is increasing productivity while production engineers work on the manufacturing sector (casting, fabrication, forging, etc.). Industrial Engineering dates back all the way to the It is critical for people within these disciplines to have knowledge of mechanical properties of structural materials, machine design, thermodynamics, statics and many other specific topics. University curriculum tends to reflect that. Undergraduates normally start off by taking courses like physics, mathematics (calculus, linear analysis, differential equations), computer science, and chemistry. Towards the later years of the undergraduate careers, they will take more major specific courses like production and inventory scheduling, process management, CAD/CAM Manufacturing, ergonomics, and many more. Now although in some parts of the world universities will offer Bachelor's in Industrial and Production Engineering, most universities in the U.S. will offer them separately. Various profiles that may follow for industrial and production engineers are as follows: Plant Engineers, Manufacturing Engineers, Quality Engineers, Process Engineers and Industrial Managers, Project Management, Manufacturing, Production and Distribution Ergonomics and Human Factors, Root cause analysis and process improvement, Make/Buy Analysis and Cost Estimation.. From all the various career paths you can take as an Industrial and Production Engineer, most of them average a starting salary of at least $50,000.

History

The origin of industrial and production engineering dates back to the 1700's. The ideology started developing the pioneers of this field who laid the foundation were Sir Adam Smith, Henry Ford, Eli Whitney, Frank Gilbreth and Lilian Gilbreth, Henry Gantt, F.W. Taylor, etc. Industrial and production engineering were practiced as two separate entities. Much later the world thought of combining this two fields, hence came the branch of industrial and production engineering though different countries have named the branch differently but the content remains unaltered its almost same. In developed countries it's known as industrial engineering and in south Asian countries it is popularly known as industrial and production

Overview

Production Engineering

This field also deals with the integration of different facilities and systems for producing quality products (with optimal expenditure) by applying the principles of physics and the results of manufacturing systems studies, such as the following:

Craft or guild Putting-out system British factory system American system of manufacturing Soviet collectivism in manufacturing Mass production

Computer integrated manufacturing Computer-aided technologies in manufacturing Just in time manufacturing Lean manufacturing Flexible manufacturing Mass customization

Agile manufacturing Rapid manufacturing Prefabrication Ownership Fabrication Publication

A set of six-axis robots used for welding.

Manufacturing engineers develop and create physical artifacts, production processes, and technology. It is a very broad area which includes the design and development of products. The manufacturing engineering discipline has very strong overlaps with mechanical engineering, industrial engineering, production engineering, electrical engineering, electronic engineering, computer science, materials management, and operations management. Manufacturing engineers' success or failure directly impacts the advancement of technology and the spread of innovation. This field of manufacturing engineering emerged from tool and die discipline in the early 20th century. It expanded greatly from the 1960s when industrialized countries introduced factories with:

1. Numerical control machine tools and automated systems of production.

2. Advanced statistical methods of quality control: These factories were pioneered by the American electrical engineer William Edwards Deming, who was initially ignored by his home country. The same methods of quality control later turned Japanese factories into world leaders in cost-effectiveness and production quality.

3. Industrial robots on the factory floor, introduced in the late 1970s: These computer-controlled welding arms and grippers could perform simple tasks such as attaching a car door quickly and flawlessly 24 hours a day. This cut costs and improved production speed.

History of Manufacturing Engineering

The history of manufacturing engineering can be traced to factories in the mid 19th century USA and 18th century UK. Although large home production sites and workshops were established in ancient China, ancient Rome and the Middle East, the Venice Arsenal provides one of the first examples of a factory in the modern sense of the word. Founded in 1104 in the Republic of Venice several hundred years before the Industrial Revolution, this factory mass-produced ships on assembly lines using manufactured parts. The Venice Arsenal apparently produced nearly one ship every day and, at its height, employed 16,000 people.

Many historians regard Matthew Boulton's Soho Manufactory (established in 1761 in Birmingham) as the first modern factory. Similar claims can be made for John Lombe's silk mill in Derby (1721), or Richard Arkwright's Cromford Mill (1771). The Cromford Mill was purpose-built to accommodate the equipment it held and to take the material through the various manufacturing processes.

One historian, Murno Gladst, contends that the first factory was in Potosí. The Potosi factory took advantage of the abundant silver that was mined nearby and processed silver ingot slugs into coins.

British colonies in the 19th century built factories simply as buildings where a large number of workers gathered to perform hand labor, usually in textile production. This proved more efficient for the administration and distribution of materials to individual workers than earlier methods of manufacturing, such as cottage industries or the putting-out system.

Cotton mills used inventions such as the steam engine and the power loom to pioneer the industrial factories of the 19th century, where precision machine tools and replaceable parts allowed greater efficiency and less waste. This experience formed the basis for the later studies of manufacturing engineering. Between 1820 and 1850, non-mechanized factories supplanted traditional artisan shops as the predominant form of manufacturing institution.

Henry Ford further revolutionized the factory concept and thus manufacturing engineering in the early 20th century with the innovation of mass production. Highly specialized workers situated alongside a series of rolling ramps would build up a product such as (in Ford's case) an automobile. This concept dramatically decreased production costs for virtually all manufactured goods and brought about the age of consumerism.

Modern Developments

Modern manufacturing engineering studies include all intermediate processes required for the production and integration of a product's components.

• Main article: Semiconductor manufacturing

Some industries, such as semiconductor and steel manufacturers use the term "fabrication" for these processes.

Main article: Automation

Automation is used in different processes of manufacturing such as machining and welding. Automated manufacturing refers to the application of automation to produce goods in a factory. The main advantages of automated manufacturing for the manufacturing process are realized with effective implementation of automation and include: higher consistency and quality, reduction of lead times, simplification of production, reduced handling, improved work flow, and improved worker morale.

Robotics is the application of mechatronics and automation to create robots, which are often used in manufacturing to perform tasks that are dangerous, unpleasant, or repetitive. These robots may be of any shape and size, but all are pre-programmed and interact physically with the world. To create a robot, an engineer typically employs kinematics (to determine the robot's range of motion) and mechanics (to determine the stresses within the robot). Robots are used extensively in manufacturing engineering.

Robots allow businesses to save money on labor, perform tasks that are either too dangerous or too precise for humans to perform economically, and to ensure better quality. Many companies employ assembly lines of robots, and some factories are so robotized that they can run by themselves. Outside the factory, robots have been employed in bomb disposal, space exploration, and many other fields. Robots are also sold for various residential applications.

Main article: Robotics

Modern Tools

Many manufacturing companies, especially those in industrialized nations, have begun to incorporate computer-aided engineering(CAE) programs into their existing design and analysis processes, including 2D and 3D solid modeling computer-aided design(CAD). This method has many benefits, including easier and more exhaustive visualization of products, the ability to create virtual assemblies of parts, and ease of use in designing mating interfaces and tolerances.

Other CAE programs commonly used by product manufacturers include product life cycle management (PLM) tools and analysis tools used to perform complex simulations. Analysis tools may be used to predict product response to expected loads, including fatigue life and manufacturability. These tools include finite element analysis (FEA), computational fluid dynamics (CFD), and computer-aided manufacturing (CAM).

Using CAE programs, a mechanical design team can quickly and cheaply iterate the design process to develop a product that better meets cost, performance, and other constraints. No physical prototype need be created until the design nears completion, allowing hundreds or thousands of designs to be evaluated, instead of relatively few. In addition, CAE analysis programs can model complicated physical phenomena which cannot be solved by hand, such as viscoelasticity, complex contact between mating parts, or non-Newtonian flows.

Just as manufacturing engineering is linked with other disciplines, such as mechatronics, multidisciplinary design optimization(MDO) is also being used with other CAE programs to automate and improve the iterative design process. MDO tools wrap around existing CAE processes, allowing product evaluation to continue even after the analyst goes home for the day. They also utilize sophisticated optimization algorithms to more intelligently explore possible designs, often finding better, innovative solutions to difficult multidisciplinary design problems.

Education

Manufacturing engineers (Production engineers) possess a bachelor's degree in engineering with a major in manufacturing engineering. The length of study for such a degree is usually four to five years followed by five more years of professional practice to qualify as a professional engineer. Working as a manufacturing engineering technologist involves a more applications-oriented qualification path.

Academic degrees for manufacturing engineers are usually the Bachelor of Engineering, [BE] or [BEng], and the Bachelor of Science, [BS] or [BSc]. For manufacturing technologists the required degrees are Bachelor of Technology [B.TECH] or Bachelor of Applied Science [BASc] in Manufacturing, depending upon the university. Master's degrees in engineering manufacturing include Master of Engineering [ME] or [MEng] in Manufacturing, Master of Science [M.Sc] in Manufacturing Management, Master of Science [M.Sc] in Industrial and Production Management, and Master of Science [M.Sc] as well as Master of Engineering [ME] in Design, which is a subdiscipline of manufacturing. Doctoral [PhD] or [DEng] level courses in manufacturing are also available depending on the university.

The undergraduate degree curriculum generally includes courses in physics, mathematics, computer science, project management, and specific topics in mechanical and manufacturing engineering. Initially such topics cover most, if not all, of the subdisciplines of manufacturing engineering. Students then choose to specialize in one or more subdisciplines towards the end of their degree work.

Specific to Industrial Engineers, you will see courses covering ergonomics, scheduling, inventory management, forecasting, product development, and in general courses that focus on optimization. Most colleges breakdown the large sections of industrial engineering into Healthcare, Ergonomics, Product Development, or Consulting sectors. This allows for the student to get a good grasp on each of the varying sub-sectors so they know what area they are most interested about pursuing a career in.

Curriculum

• Environment, health and safety
• Scheduling/Inventory/Forecasting Course

• Human factors engineering
• Living wage
• List of production topics
• Nutrient systems
• Overall equipment effectiveness
• Product design / industrial design
• Production engineering
• Reverse engineering
• Occupational safety and health
• Sales process engineering
• Statistical process control
• Operation Management
• Quality control and management
• Computer-integrated manufacturing
• CAD/CAM
• Supply chain management
• Statics and dynamics
• Strength of materials and solid mechanics
• Instrumentation and measurement
• Applied thermodynamics, heat transfer, energy conversion, and HVAC
• Fluid mechanics and fluid dynamics
• Mechanism design (including kinematics and dynamics)
• Manufacturing technology or processes
• Hydraulics and pneumatics
• Mathematics – in particular, calculus, differential equations, statistics, and linear algebra.
• Engineering design and graphics
• Circuit Analysis
• Lean manufacturing
• Mechatronics and control theory
• Automation and reverse engineering
• Quality assurance and control
• Material science
• Drafting, CAD (including solid modeling), and CAM, etc.

A bachelor's degree in these two areas will typically differ only by a few specialized classes, although the mechanical engineering degree requires more mathematics expertise.

Subdisciplines

Mechanics[edit]

Main article: Mechanics

Wikibooks has a book on the topic of: Solid Mechanics

Mohr's circle, a common tool to study stresses in a mechanical element

Mechanics, in the most general sense, is the study of forces and their effects on matter. Typically, engineering mechanics is used to analyze and predict the acceleration and deformation (both elastic and plastic) of objects under known forces (also called loads) or stresses. Subdisciplines of mechanics include:

• Statics, the study of non-moving bodies under known loads
• Dynamics (or kinetics), the study of how forces affect moving bodies
• Mechanics of materials, the study of how different materials deform under various types of stress
• Fluid mechanics, the study of how fluids react to forces
• Continuum mechanics, a method of applying mechanics that assumes that objects are continuous (rather than discrete)

If the engineering project were to design a vehicle, statics might be employed to design the frame of the vehicle in order to evaluate where the stresses will be most intense. Dynamics might be used when designing the car's engine to evaluate the forces in the pistons and cams as the engine cycles. Mechanics of materials might be used to choose appropriate materials for the manufacture of the frame and engine. Fluid mechanics might be used to design a ventilation system for the vehicle or to design the intake system for the engine.

Kinematics[edit]

Main article: Kinematics

Kinematics is the study of the motion of bodies (objects) and systems (groups of objects), while ignoring the forces that cause the motion. The movement of a crane and the oscillations of a piston in an engine are both simple kinematic systems. The crane is a type of open kinematic chain, while the piston is part of a closed four-bar linkage. Engineers typically use kinematics in the design and analysis of mechanisms. Kinematics can be used to find the possible range of motion for a given mechanism, or, working in reverse, can be used to design a mechanism that has a desired range of motion.

Drafting[edit]

Main articles: Technical drawing and CNC A CAD model of a mechanical double seal Drafting or technical drawing is the means by which manufacturers create instructions for manufacturing parts. A technical drawing can be a computer model or hand-drawn schematic showing all the dimensions necessary to manufacture a part, as well as assembly notes, a list of required materials, and other pertinent information. A U.S engineer or skilled worker who creates technical drawings may be referred to as a drafter or draftsman. Drafting has historically been a two-dimensional process, but computer-aided design (CAD) programs now allow the designer to create in three dimensions.

Instructions for manufacturing a part must be fed to the necessary machinery, either manually, through programmed instructions, or through the use of a computer-aided manufacturing (CAM) or combined CAD/CAM program. Optionally, an engineer may also manually manufacture a part using the technical drawings, but this is becoming an increasing rarity with the advent of computer numerically controlled (CNC) manufacturing. Engineers primarily manufacture parts manually in the areas of applied spray coatings, finishes, and other processes that cannot economically or practically be done by a machine.

Drafting is used in nearly every subdiscipline of mechanical and manufacturing engineering, and by many other branches of engineering and architecture. Three-dimensional models created using CAD software are also commonly used in finite element analysis (FEA) and computational fluid dynamics (CFD).

Mechatronics[edit]

Main articles: Mechatronics and Robotics Training FMS with learning robot SCORBOT-ER 4u, workbench CNC mill and CNC lathe

Mechatronics is an engineering discipline that deals with the convergence of electrical, mechanical and manufacturing systems. Such combined systems are known as electromechanical systems and are widespread. Examples include automated manufacturing systems, heating, ventilation and air-conditioning systems, and various aircraft and automobile subsystems.

The term mechatronics is typically used to refer to macroscopic systems, but futurists have predicted the emergence of very small electromechanical devices. Already such small devices, known as Microelectromechanical systems (MEMS), are used in automobiles to initiate the deployment of airbags, in digital projectors to create sharper images, and in inkjet printers to create nozzles for high-definition printing. In the future it is hoped that such devices will be used in tiny implantable medical devices and to improve optical communication.

Textile engineering[edit]

Textile engineering courses deal with the application of scientific and engineering principles to the design and control of all aspects of fiber, textile, and apparel processes, products, and machinery. These include natural and man-made materials, interaction of materials with machines, safety and health, energy conservation, and waste and pollution control. Additionally, students are given experience in plant design and layout, machine and wet process design and improvement, and designing and creating textile products. Throughout the textile engineering curriculum, students take classes from other engineering and disciplines including: mechanical, chemical, materials and industrial engineering.

Employment[edit]

Manufacturing engineering is just one facet of the engineering industry. Manufacturing engineers enjoy improving the production process from start to finish. They have the ability to keep the whole production process in mind as they focus on a particular portion of the process. Successful students in manufacturing engineering degree programs are inspired by the notion of starting with a natural resource, such as a block of wood, and ending with a usable, valuable product, such as a desk, produced efficiently and economically.

Manufacturing engineers are closely connected with engineering and industrial design efforts. Examples of major companies that employ manufacturing engineers in the United States include General Motors Corporation, Ford Motor Company, Chrysler, Boeing, Gates Corporation and Pfizer. Examples in Europe include Airbus, Daimler, BMW, Fiat, Navistar International, and Michelin Tyre.

Industries where manufacturing engineers are generally employed include:

• Aerospace industry
• Automotive industry
• Chemical industry
• Computer industry
• Electronics industry
• Food processing industry
• Garment industry
• Pharmaceutical industry
• Pulp and paper industry
• Toy industry

Career Options/Job Profiles

Salaries

References:

Wikipedia contributors. "Industrial and production engineering." Wikipedia, The Free Encyclopedia. Wikipedia, The Free Encyclopedia, 11 Feb. 2018. Web. 3 Apr. 2018.

Wikipedia contributors. "Industrial engineering." Wikipedia, The Free Encyclopedia. Wikipedia, The Free Encyclopedia, 31 Mar. 2018. Web. 3 Apr. 2018.

Wikipedia contributors. "Mechanical engineering." Wikipedia, The Free Encyclopedia. Wikipedia, The Free Encyclopedia, 1 Apr. 2018. Web. 3 Apr. 2018