Monday, July 12, 2021

Engineering Management - The Definition, Scope and Content

Contents


What is Engineering Management? Definition,
Engineering Management Journal,
American Society for Engineering Management (ASEM) Handbook
Books, Articles and Papers

Definition of Engineering Management


by Narayana Rao K.V.S.S.


Engineering management is management applied to functions, departments, and organizations where engineering is the primary technical skill. (Narayana Rao)  31st January 2010

Management - Definition

Management of an organization is the process of establishing objectives and goals of the organization periodically, designing the work system and the organization structure, and maintaining an environment in which individuals, working together in groups, accomplish their aims and objectives and goals of the organization effectively and efficiently (Narayana Rao). (3rd December 2008) ( Management - Definition and Process )
The above definition was a modification of the definition given by Koontz and O'Donnell.

The definition implies the following.

(i) Management is a process.
(ii) Management applies to every kind of organization, government, profit making, or nonprofit making.
(iii) It applies to managers at all levels in the organization.
(iv) Management is concerned with effectiveness and efficiency.  Effectiveness is producing the product or service the customer wants in business context with the required functional benefits and product attributes at the price he is willing to pay. Efficiency is minimization of resources to produce the saleable output.

The following functions or departments are natural choices for engineering management

Research and Development
Design department
Process Planning department
Tool Design department
Production departments
Maintenance departments
Utilities departments
Vendor development department
Industrial Engineering department
Information systems departments
Safety Engineering department
Environmental Engineering department
After Sales Service Department in case of manufactured products
Project Construction
Operation of Power Plants
Operation of Telecommunications Facilities

At organizational levels the following are natural choices for Engineering Management

Engineering companies
Manufacturing companies
Power Plants
Civil Construction Organizations
Telecommunications services
Software companies
Transport companies


 Other Explanations and Definitions of Engineering Management

__________________________________________________________________________



“Engineering Management is the discipline that addresses making and implementing decisions for strategic and operational leadership in current and emerging technologies and their impact on interrelated systems.”

IEEE, “Editorial: Research and Education Characteristics of the Engineering Management Discipline,” IEEE Transactions on Engineering Management, vol. 37, no. 2, 1990, p. 1.


Based on the above definition, and other literature Hongyi Sun et al. concluded that Engineering Management can be expected to cover the following topics:

• Management of engineering projects
• Management of the design process
• Personnel and communication skills for engineers
• Management of scientific methods for engineering
• Human resources for engineering
• Variation, quality, and reliability

( http://www.jee.org/1999/april/726.pdf  )

The ABET  Engineering Criteria 2000 requires that: “the Engineering Management curriculum must emphasize the application of the management function in the technological setting while recognizing the basic and applied sciences in engineering systems. Emphasis shall be placed on the engineering relationships between management tasks of organizing, staffing and the human element in production, research and service organizations.”

(“Engineering Criteria 2000: Criteria for Accrediting Programs in Engineering in the USA”, Accreditation Board for Engineering and Technology, USA, 1997.)

___________________________________________________________________________

Engineering Management is a specialized form of management that is required to successfully lead engineering or technical personnel and projects.
•Management of technical functions
•Direct supervision of engineers and/or the engineering function
•Engineering managers typically require training and experience in both general management and the specific engineering disciplines that will be used by the engineering team to be managed

Included in a presentation by Muhammad Asif Akhtar, imasif@uet.edu.pk
http://www.engineering-resource.com/Files/LECTURE%202.pdf
__________________________________________________________________________

As an MSEMT student, you will learn how to lead technology projects as well as manage teams, engineering functions, and companies.  (University of Souther California) http://mapp.usc.edu/mastersprograms/degreeprograms/ISE/documents/MSEMT.pdf

Engineering management professionals deal with the planning, organization, scheduling, monitoring and control of engineering projects. (Univerisity of the Pacific) http://www.pacific.edu/x10461.xml

_________

Kansas University College of Engineering

What is Engineering Management?


A graduate program designed specifically for engineers and scientists who want to add management skills and knowledge to their technical undergraduate base. It’s not as technical as a master’s in engineering nor as general as an MBA—it’s the intersection of technology and management.

The Engineering Management Mission


The mission of the Master of Science in Engineering Management (EMGT) program is to prepare technical managers from fields of engineering, science, math and computer science to manage more effectively within technologically-based organizations and to promote entrepreneurial activities in the formation of new business enterprises.

The EMGT program integrates management with technology by focusing on three dimensions.

TECHNICAL: an understanding of and proficiency in engineering and science.

HUMAN: the ability to build a collaborative effort within a group.

CONCEPTUAL: the ability to apply analytical thought to the management process and to enterprise as a total system.

Why a Graduate Program in Engineering Management?

The scope and complexity of engineering management responsibilities has changed dramatically during the past 10 years.

Stiff competition in the marketplace and the need to eliminate the trade and service deficit have put an emphasis on technology. It is the source of new products and improved productivity in manufacturing and service delivery. Today's engineer-manager simply must incorporate technological innovation.

Today's engineer-manager also must satisfy design and safety requirements, manage human resources to boost productivity, use natural resources efficiently, stay on top of other environmental concerns and emphasize total quality in operations.

To meet these challenges, engineers require better education and training in technology management. Precisely these needs led in 1982 to the development of the Master of Science program in Engineering Management at the KU School of Engineering.

Source
Accessed on 31.1.2010
__________

Engineering Management Journal

EMJ is the quarterly journal of the American Society for Engineering Management. EMJ is designed to provide practical, pertinent knowledge on the management of technology, technical professionals, and technical organizations.

EMJ strives to provide value to the practice of engineering management and engineering managers.  EMJ's goals are to:

1.     Improve the practice of technology organizations and engineering management.
2.     Improve the reflective practitioner skills of the practicing engineering manager.
3.     Improve the research skills of faculty to produce useful and relevant knowledge for engineering management.
4.     Improve student's understanding of the engineering management field.

Engineering management focus areas.

To support the practice of engineering management, EMJ publishes papers within key engineering management focus areas. 

Strategic: the processes and tools by which the organization positions itself externally and aligns itself internally. Focus areas include:

Strategic & operations management
Management of design & consulting engineering organizations.

Core: the processes and tools by which the organization produces it products and services for its customers. Focus areas include:

Systems engineering/systems engineering management
Program & project management
Technology management: Research & development, technology transfer, commercialization
Technology management: technology forecasting, emerging technologies
Innovation & new product development.

Enabling: the processes and tools by which the strategic and core processes are supported with the necessary facilities, equipment, personnel, and supporting business functions. Focus areas include:

Organization and work system design
Economics of engineering
Quantitative methods & models
Knowledge & information management
Quality management
Developing engineering management professionals.

Perspectives of the Profession: articles to provide an evolving historical perspective to the profession. Focus areas include:
Engineering management: Past, present, & future

Accessed on 31.1.2010
_______________________

American Society for Engineering Management (ASEM)

Vision
To speak for the Engineering Management profession

Mission
Provide Engineering Management Solutions to leadership and management challenges to create and lead technical organizations

Promote the development and practice of the engineering management profession

Goals

Be the custodian of the engineering management body of knowledge
Grow and share the engineering management body of knowledge
Guide and enhance engineering management educational programs
Advance the careers of engineering management professionals

Connect engineering management professionals

Foster and recognize engineering management best practices
______________________________________

ASEM Engineering Management Handbook


Purpose Statement
The Engineering Management Handbook provides engineering management practitioners, researchers, policy makers, and analysts with a singular, easy-to-navigate web site through which continuously updated, peer reviewed information and tools can be readily accessed and easily utilized. The EM Handbook will further provide a medium through which users, subject matter contributors, and subject matter experts can communicate on items of mutual interest.

History
At the 1995 American Society for Engineering Management (ASEM) Annual Conference held during September in Washington, D.C., Dr. Greg Sedrick, ASEM Member and then professor (now Acting Dean) in the College of Engineering Computer Science at the University of Tennessee at Chattanooga, presented an idea for using the Internet as a information resource and distribution medium for what he referred to as a "virtual engineering management (EM) handbook." This virtual EM handbook, once developed, was envisioned to place a variety of EM "resources" at the ready disposal of practicing engineering managers, engineering management researchers, policy makers, and analysts.


______________________________________

Articles and Papers

Engineering Management: Past, Present, and Future
By Farr, John V
Publication: Engineering Management Journal 
Date: Tuesday, March 1 2005 

Read the article in



INDUSTRIAL ENGINEERING AND ENGINEERING MANAGEMENT IN AUSTRALIA
by Professor John W H Price PhD, FIEAust
Mechanical Engineering Department,
Monash University, Australia.



Book Site
Sarah Drasner

Articles on Engineering Management
_____________________________________

Books


The practice of engineering management: a new approach By Patrick D. T. O'Connor, 1994


_____________________________________

Related Knols

Industrial Engineering Definitions - 1911 to 2009
"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety and income of persons involved."(Narayana Rao, 2009)
___________________________________________________________________________________________
Articles and Books by B.S. Dhillon

Engineering Product Usability: A Review and Analysis Techniques
www.wseas.us/e-library/conferences/2005argentina/papers/503-115.doc

Design Reliability by Dhillon - ebook available on net (Search)

Robot Safety Analysis
http://nacomm03.ammindia.org/Articles/Rob002.pdf

BECOMING LEAN ENTERPRISE: THEORY AND CASE STUDIES - Management Development Programme at NITIE, Mumbai, India by Narayana Rao K.V.S.S.


Updated on  13 July 2021,  2 March 2014
Published on this blog on 17 March 2012
Original knol - http://knol.google.com/k/narayana-rao/engineering-management-the-definition/ 2utb2lsm2k7a/ 2224

Engineering Management - Bulletin - Information Board -


13 July 2021


https://www.apollotechnical.com/engineering-management-skills/

https://www.aresprism.com/products/engineering-project-management-software/

https://waset.org/engineering-management-conferences

https://www.ieee-tems.org/category/conferences/

https://leaddev.com/professional-development/eight-flavors-engineering-management


https://www.nasa.gov/consortium/SystemsEngineeringManagementPlanTechnicalContent

https://medium.com/@rvprabhu/moving-to-the-dark-side-transitioning-into-engineering-management-266061921049

Jobs




2 June 2012

Craig Downing, was appointed as head of engineering management department of Rose Hulman Institute of Technology, Terre Haute, Indiana.

Down is co-editor of Industrial Engineering Handbook, which is being revised.
http://www.insideindianabusiness.com/newsitem.asp?ID=53975 







Updated 13 July 2021
Pub 2 June 2012

Saturday, August 31, 2019

Introduction - Product Design and Development


Chapter 1 Ulrich and Eppinger - Product Design and Development


Characteristics of Successful New Products


A successful product is one that is being sold profitably. But profitability of a new product cannot be assessed quickly  in the early years. Hence measures which ultimately relate to profits are used.
The success of the product development project is determined by five dimensions.

Product quality
Product cost
Development time
Development cost
Development capability

Who in an organization are involved in new product development?

Main departments or functions involved are:

Marketing, Design, and Manufacturing

The Challenges of Product Development


The product development process is risky. It is difficult to create highly successful products more than half time in case of companies which are considered as good product development companies.

Trade-offs: Design decisions have tradeoffs. Light weight versus cost in case of air planes.
Dynamics: Evolution of technologies, customer preferences, competitor's new products and change in environment.

Details,
Time pressure,
Economics: A large investment has to be made in developing the product, process and acquiring resources to set up the production plant. It must have return on investment.

Approach of The Book by  Karl Ulrich and Steven Eppinger


Structured methods

Step-by-approach is provided for each major activity of product design and development.

The step by step approach makes the process explicit. It provides checklist for practice. Also, the process when implemented provides documentation which can be analyzed later and used as reference.

Industrial examples

Each chapter in the book is developed around an industrial example.

Organizational realities

The negative activities highlighted by the authors in the product development process and teams are:

1. Lack of empowerment of the team.
2. Functional allegiances transcending project goals.
3. Inadequate resources given to the team.
4. Lack of cross-functional representation on the project team.


Updated on 1 September 2019, 2 August 2016

Friday, August 23, 2019

Product - Part Concept Generation, Selection and Testing - Product Architecture




Concept Generation


1. Clarify the Problem
2. Search Externally
3. Search Internally
4. Explore Systematically
5. Reflect on the Solutions and the Process




http://sites.tufts.edu/eeseniordesignhandbook/2013/product-concept-generation/


External Search


Whenever an engineering problem is to be solved, engineers have to consult existing literature, handbooks, catalogues supplied by vendors and also visit places and observe new products. This stage of the process is termed as external search.

– Lead Users
– Experts
– Patents
– Literature
– Benchmarking



• Internal Search

– Individual Methods
– Group Methods


During internal search

Suspend judgment
Generate lot of ideas
Welcome ideas that may seem infeasible
Use graphical and physical media also to generate ideas that can't be described in words.



• Systematic Exploration

– Classification Tree
– Combination Table

Concept Selection



It is based on method developed by Stuart Pugh. Called Pugh Concept Selection.

1. Prepare the Selection Matrix.
2. Rate the Concepts
3. Rank the Concepts
4. Combine and Improve the Concepts
5. Select One or More Concepts


Details

1. Prepare the Selection Matrix.
The concepts are portrayed by written description as well as graphical or pictorial representation.
A reference concept is chosen which is an industry standard or a well known concept to the participants so that it can be used to rate the generated concepts as better or worse.

2. Rate the Concepts
A relative score of "better than" (+) or "same as" (0) or "worse than" (-) is placed in each cell matrix formed by selection criteria and the specific concept.
3. Rank the Concepts
The +, 0 and -  are totalled against each concept to rank the concepts.
4. Combine and Improve the Concepts
The team can now see possibilities of combing the good features of various concepts into new concepts.
5. Select One or More Concepts
Selection of one or more concepts is now done for further refinement.


Concept Testing



1. Define the Purpose of the Concept Test
2. Choose a Survey Population
3.Choose a Survey Format
4. Communicate the Concept
5. Measure the Customer Response
6. Interpret the Results



Details

1. Define the Purpose of the Concept Test
2. Choose a Survey Population and Sample Size
The sample size of the survey should be large enough that the team's confidence in the results is high enough to guide decision making

3.Choose a Survey Format

Survey formats include face to face interaction, telephone, postal mail, electronic mail, internet etc.

4. Communicate the Concept

The concept can be communicated to the survey participant as verbal description, sketch, photo, story board, video, physical model or working prototype. Based on the communication form used, the survye format also will change.

5. Measure the Customer Response

The customer response can be taken in the form

Definitely would buy.
Probably would buy.
Might or might not buy.
Probably would not buy.
Definitely would not buy.

6. Interpret the Results

A product is developed based on functional elements. The product as developed has physical elements, parts and subassemblies.

The architecture of a product is the scheme by which the functional elements of the product are arranged into physical chunks (items of the product) and by which the chunks interact.

The most modular architecture is one in which each functional element of the product is implemented through  one distinct chunk.


Product Architecture


1. Create a Schematic of the Product
2. Cluster the Elements of the Schematic
3. Create a Rough Geometric Layout
4. Identify the Fundamental and Incidental Interactions


Delayed Differentiation of the Product


Platform Planning

A company may offer two or more products that are highly differentiated yet share a substantial fraction of their components. The fraction that is shared is called the platform,

In platform based products, there is a commonality or common parts plan and differentiation plan.

Thursday, August 22, 2019

Product Design and Development - Bibliography



2017

Automotive Product Development: A Systems Engineering Implementation
Vivek D. Bhise
CRC Press, 08-May-2017 - Technology & Engineering - 550 pages

This book is about how to develop future automotive products by applying the latest methodologies based on a systems engineering approach and by taking into account many issues facing the auto industry such as meeting government safety, emissions and fuel economy regulations, incorporating advances in new technology applications in structural materials, power trains, vehicle lighting systems, displays and telematics, and satisfying the very demanding customer.

It is financially disastrous for any automotive company to create a vehicle that very few people want. To design an automotive product that will be successful in the marketplace requires carefully orchestrated teamwork of experts from many disciplines, substantial amount of resources, and application of proven techniques at the right time during the product development process.

Automotive Product Development: A Systems Engineering Implementation is intended for company management personnel and graduate students in engineering, business management and other disciplines associated with the development of automotive and other complex products.
https://books.google.co.in/books?id=wbrODgAAQBAJ


Japan and the Global Automotive Industry

Koichi Shimokawa
Cambridge University Press, 03-Jun-2010 - Business & Economics

The Japanese automotive industry enjoyed spectacular success in the 1980s. This was largely due to the so-called 'Lean Production System' - the combination of an efficient production system, an effective supplier system, and a product development system. In the 1990s the industry fell on hard times because of the Japanese asset price bubble and extreme currency appreciation. In this book, eminent industry specialist Koichi Shimokawa draws on his thirty years of research and fieldwork with Japanese and American firms, to show how the Japanese automotive industry has managed to recover from this difficult period. He shows how firms like Toyota were able to transfer Japanese systems to overseas plants and how they have changed in order to compete in increasingly globalized markets. In addition, the book also addresses the two major challenges to the current industry model: the rise of China and the environmental and energy supply situation.

https://books.google.co.in/books?id=D90-Q6AEEIoC


Earlier posting

Features of Engineering Product Design and Development


Value engineering and cost reduction in a chip
http://www.techeta.com/powercolor-pcs-ax5870-video-card-refines-the-5870-design/

Rethinking Home Designs - 10 Value engineering trends


Updated on 24 August 2019, 18 December 2011

Product Design and Development - Ulrich and Eppinger - Summary Chapters


Summary of 16 chapters

Karl T. Ulrich – Steven D. Eppinger

Introduction to Product Design and Development - Summary Article - All Chapters

1. Introduction - Product Design and Development

2. Product Development Process

3. Product Planning

4. Identifying Customer Needs for Product Development

Industrial Design Process

Prototyping - Planning for Prototyping

Robust Design

Patents and Intellectual Property - Patent Application Process

Product Development  - Economic Analysis

Managing Projects




http://wesp.snt.utwente.nl/~newton//UserFiles/File/Summary%20Product%20Design%20and%20Development.pdf

Summary of 16 chapters

Karl T. Ulrich – Steven D. Eppinger


Updated  24 August 2019,  3 August 2016, 17 Mar 2016, 27 Aug 2012

Product Development Process

Chapter 2 Ulrich and Eppinger - Product Design and Development


A Generic Development Process


0. Planning
1. Concept Development
2. System Level Design
3. Detail Design
4. Testing and Refinement
5. Production Ramp-up



Details of the Steps

0. Planning
1. Concept Development

In this phage needs of the market and the target market are identified first. Based on the needs, product concepts are generated. They are evaluated marketers as well as product development team and one or more concepts are selected for further development and testing. A concept is a description of the form, function, and features of product. Thus specifications of the product based on the concept are developed. For evaluation of each concept, an analysis of competitive products, and the revenues expected from the concept and the fixed cost and variable cost of the concept are also provided.

2. System Level Design

Based on the concept design or designs approved for further development, the product architecture is now created. Architecture defines the subsystems and components and provides a description of function of each component and subassembly and how as a whole they satisfy all the requirements of the customers. Thus the final assembly scheme for the product is specified.  As output of this phase of development, a geometric layout of the product, functional specifications of each subsystem, component are provided. A preliminary process flow chart for the final assembly process is also created. The article on "Product Architecture" will contain the steps followed to complete the system level design.


3. Detail Design
4. Testing and Refinement
5. Production Ramp-up


Updated on 24 August 2019, 2 August 2016

Tuesday, November 20, 2018

Invention - Development - Patent - Prototype - Design - Differences




Patents and Designs are different. Patents and the related prototypes are proof of technology invented. Designs have to take care of customer requirements.  In practice, this often means mapping a customer journey (pain points and potential sources of delight). 

https://www.mckinsey.com/business-functions/mckinsey-design/our-insights/the-business-value-of-design

Sunday, June 17, 2018

Technology Ventures, From Idea to Enterprise - Book Information




Technology Ventures, From Idea to Enterprise 5e

   
 Technology Ventures, From Idea to Enterprise 4e

   
 Technology Ventures, From Idea to Enterprise 3e

http://www.mhhe.com/byersdorf/




 This website is free and open to students and instructors alike. It is associated with the Stanford Technology Ventures Program's Entrepreneurship Corner, which is a digital archive of entrepreneurship education materials including lecture podcasts.


http://web.stanford.edu/group/techventures/cgi-bin/joomla/


This website augments the official McGraw-Hill one to provide additional resources for learning about this important subject. The bulk of the information on this website is a collection of video clips from Stanford eCorner.


http://web.stanford.edu/group/techventures/cgi-bin/tv5/

Sunday, October 2, 2016

New Technology Adoption - Management Guidelines



Godoe, P. & Johansen, T.S., (2012). Understanding adoption of new technologies: Technology readiness and technology acceptance as an integrated concept. Journal of European Psychology Students. 3(1), pp.38–52.

http://jeps.efpsa.org/articles/10.5334/jeps.aq/




Organisations adopt new technologies to improve the efficiency and effectiveness of various work processes. Unfortunately, many technology-based products and services never reach their full potential, and some are simply rejected (Burton-Jones & Hubona, 2006). Failed investments in technology may not only cause financial losses, but also lead to dissatisfaction among employees (Venkatesh, 2000).

The technology acceptance model (TAM) has come to be one of the most widely used models. The two primary predictors in TAM that affect technology usage are perceived usefulness and perceived ease of use.

The other paradigm focuses on latent personality dimensions to explain the use and acceptance of new technologies (Porter & Donthu, 2006). In other words, an individual's personality influences the potential acceptance of technology in general. The technology readiness index (TRI) (Parasuraman, 2000) follows this approach. Technology readiness can be viewed as a gestalt resulting from four personality dimensions: optimism, innovativeness, discomfort, and insecurity. According to Parasuraman (2000) these personality dimensions affect people's tendency to embrace and use new technologies. In this respect, optimism and innovativeness function as mental enablers, while discomfort and insecurity function as mental inhibitors to accepting new technologies.
In the last decade, research has emerged combining the two paradigms by integrating the TRI and TAM into one model. Lin, Shih, Sher, and Wang (2005) and Lin, Shih, and Sher (2007) included technology readiness as an antecedent of perceived usefulness and perceived ease of use in TAM. Walczuch, Lemmink, and Streukens (2007) took a somewhat different approach by investigating how each dimension of technological readiness affects the predictors in TAM.


Beating Murphy's Law in New Technology Adoption


MIT Sloan Management Review, Spring 1991
W. Bruce Chew, Dorothy Leonard-Barton and Roger E. Bohn
http://sloanreview.mit.edu/article/beating-murphys-law/

Beating Murphy’s Law - Steps




Rule #1. Think of Implementation as R&D

 Acquisition of new technolgy  should  be considered an ongoing process of data gathering and learning that evolves over time. Initially, an organization must focus on technical data regarding equipment options and costs and a study of existing applications. Eventually, the technology goes through startup and data is generated in-house. But in every phase the goal is to learn all that can possibly be learned at that point in time. In effect, the introduction of technology should be considered less as an investment issue or technical issue and more as a question of research design.

The experiments should address both technical and organizational questions. Managers who understand that they are managing organizational change, not just technical change, are better positioned to direct the learning process. The work of technology managers should include: working very closely with users, whose role should be as codevelopers rather than receivers of the technology; constantly redefining the necessary support structure in the user organization, identifying and targeting potentially weak links; enlarging the definition of the technology to include the delivery system or other linkages on which the technology is critically dependent; and experimenting as consciously and productively with organizational forms as with technical ones, capitalizing wherever possible on experiments occurring naturally in the company.

Rule #2. Ask “What made it hard?” Not “How well did it work?”



The firm must look for answers to questions  of technology implementation like “How did you make this technology work? What had to be changed? What was hardest?”



Our studies suggest that technical knowledge, about the hardware itself, transfers more easily than organizational knowledge,




Rule #3. Learn in Many Ways at Once


Broadly speaking, there are four methods of learning that a firm can use:

vicarious learning—learning from the experience of others;
simulation—constructing artificial models of the new technology and experimenting with it;
prototyping—actually building and operating the new technology on a small scale in a controlled environment; and
on-line learning—examining the actual, full-scale technology implementation while it is operating as part of the normal production process. A clear hierarchy exists among these four methods: costs get higher moving down the list, but so does fidelity.


Managers in our studies consistently underinvest in preimplementation learning, choosing in effect to do most of their learning later, when it is most expensive.



Many managers appear unwilling to invest in learning by methods that offer less than perfect fidelity. They fail to recognize that learning need not be all or nothing. Another plant’s experience will not be completely relevant, but it is still possible to identify some issues that can be addressed vicariously. Similarly, simulation and prototyping can be effectively targeted at specific questions.

The consequence of these two competing hierarchies is important: use a mixed strategy for learning. Learn as much as possible using the low-cost, low-fidelity methods, but realize that some learning will probably be necessary from all four methods.

Furthermore, the ideal learning strategy includes parallel and simultaneous use of all methods, not just sequential use. For example, opportunities for improvements that are not uncovered until die prototype is running may become the target of simulation. Prototype pilot lines should be kept going in parallel with the main production line, as test beds for diagnostic experiments and trials of changes. Both technical and organizational learning must be documented and remembered. As noted earlier, one plant’s Murphy’s Law disaster is another plant’s opportunity for vicarious learning.

Rule #4. Simulate and Prototype Everything

 A simulation of a new technology is a model of how it will work. Simulations can range from simple mathematical models such as spreadsheets, through elaborate Monte Carlo computer models, to physical models of the entire plant, before and after the new technology is introduced. For example, in the steel industry it is common to simulate changes using scaled-down models with water in place of molten steel.

Simulation technology has improved dramatically in recent years due to advances in computer hardware (engineering workstations and personal computers are more than adequate for simulations of most production processes) and especially in easy-to-use, special purpose simulation languages. It is often possible to do a crude but useful initial simulation in less than a week of effort. In fact, we recommend that any new technology involving more than a few person months of total effort should probably be simulated in some way. Complex or large technology should usually receive several simulations targeted at different levels of detail and different aspects of the total system.



A prototype is a small-scale construction or isolated version of the final system for learning purposes, using methods as close as possible to the final technological target. The purpose of prototyping is to learn about problems and opportunities that were not found during the simulation but that will cause delays or expense if they are left for on-line learning.

Rule #5. “Everything” Includes the Organization

Simulation is equally applicable to organizational changes, though it is rarely applied. To implement a new MRPII system, the implementation manager persuaded representatives from all the potentially affected functions (shipping, purchasing, inventory, etc.) to come together in one room for several days to go through a noncomputerized simulation of the information flows The simulation served to educate the various functions about the coming system. The supervisors got to know each other and talked about the process interdependencies that the new system was going to cause or exacerbate. Because they came to understand the needs of other functions, whose representatives they often had not even known before, the participants negotiated compromises and agreements that forestalled problems when the actual system was implemented.

Organizational prototyping, like technical prototyping, is the execution of a design on a small scale for the express purpose of evaluating that design from an organizational viewpoint.  With organizational prototypes managers can anticipate needed alterations, potential pitfalls, and opportunities for additional benefits by observing the technology-organization interaction in microcosm before launching the full-scale production change.

Pilot runs of a new technology offer the opportunity for organizational prototyping, but they are rarely used for that purpose. Usually test runs are conducted by technical staff to learn about potential problems in the physical system. Litde attention is paid to the possibility of learning about organizational effects and opportunities, such as changes in roles, conflicts with existing rewards and incentives, differing responses to and use of the new technology depending upon operator background and skill, the different meaning that the technology has for different groups of users, and the most effective organizational structure.


Rule #6. Follow Lewis and Clark

The problem is not with planning per se but with the substance of a plan.
When Lewis and Clark headed west from St. Louis they did not attempt to specify in advance their exact trail and how they would cope with each expected contingency. They realized that the wilderness ahead was too unknown and the contingencies too many. Rather, they set out with a general sense of their route (up the Missouri River and over the Rockies), a good store of resources, and a team that had familiarized itself with everything known about the wilderness ahead.

Too often managers forget that new technologies have more in common with Lewis and Clark’s wilderness than today’s travel. thing go awry. Planning must provide a guiding structure for discovering and solving problems. It should focus more on what to look for and think about than on what to do. It should plan for an expedition of discovery, not a drive to a relative’s house; it should be a research design, not a recipe.

Rule #7. Produce Two Outputs: Salable Products and Knowledge

Eventually, the new technology is up and running. The new process produces not only salable products, but also usable knowledge. Production time, management time, labor, and materials should be budgeted for making both types of output.

Budgeting Time for the Seven Rules

The core of our argument has been that to beat Murphy’s Law it is necessary to plan for and manage directed learning. Anything you don’t learn about early will hurt you later.

One simple solution is to budget for this learning time throughout the project schedule. In particular, keep a reserve of production time for on-line learning in the first several months of startup. This is over and above the planned lower output during startup. Ten percent of production time is a realistic amount if vicarious learning, simulation, and prototyping have been done thoroughly.

The Rules in Practice: Different Kinds of Knowledge

In summary, managers typically underinvest in learning both before and after startup. This is particularly true of the organizational changes relating to new technologies.

The seven rules reflect a different vision of what it means to implement technology.

In all the most successful sites, investment was made in the creation of local user-experts, whose job it became to anticipate, model, prototype, and teach the new behavior necessitated by the technology, especially during the critical period of change from the old to the new system.








Tuesday, August 2, 2016

Manufacturing Management - Introduction

Manufacturing Management - Introduction

Authors

Narayana Rao
Published

All Rights Reserved

Version 26

Last edited: 12 Sep 2011

Exported: 26 Nov 2011

Original URL: http://knol.google.com/k/-/-/2utb2lsm2k7a/3309






Planning, organizing and controlling manufacture of goods is manufacturing management. Chase et al. define operations management as the design, operation, and improvement of the systems that create and deliver the firm's primary products and services. Operations management is a discipline that includes production of goods and services.

Once the company decides to manufacture and sell a product, the specialized responsibility of the manufacturing management starts. But the decision to manufacture a product is based on feasibility analysis. During this analysis also manufacturing management issues are involved. Therefore, the persons doing strategic analysis or corporate planning analysis include persons from manufacturing management discipline with manufacturing management knowledge and bring into the analysis or decision making process the manufacturing view point.

Manufacturing is carried out through processes. A process is any actvity or group of activities that takes one or more inputs, transforms them, and provides one or more outputs. The output could be for an external customer for sale or for an internal customer to use for further processing. In some cases it can be for consumption in the same process or by the consumption by the producer hmself. Manufacturing processes convert materials into goods that have a physical form.  The transformation processes change the materials on one or more of the following dimensions:

1. Physical properties
2. Shape
3. Fixed dimension
4. Surface finish
5 Joining parts and materials.

The outputs from manufacturing processes can stored and transported in anticipation of future demand (Krajewski et al. 2007).


Important Developments in Manufacturing Management


Developments in manufacturing management include certain technical developments that made manufacturing systems more productive and flexible.

Shopfloor management guidelines provided by F.W. Taylor were landmarks in the field of manufacturing management. Taylor further development Scientific management philisophy. Taylor also brought out the importantance of scientific studies in manufacturing processes improvement or design. His studies on machining were considered a very important research contribution. Taylor also introduced time study based best practice identification and training all operators in the best practice. He advocated that manufacturing managers have the responsibility of developing manufacturing methods and training operators in best methods.

Frank Gilbreth developed study of motions of operators to develop efficient operator movements either to do manual work or to operate machines. He and Lilian Gilbreth also introduced the concept of fatigue and proposed ways to prevent the negative consequences of fatigue in operators as well as in manufactuirng systems.

Henry Ford introduced moving assembly lines that revolutionized the production systems. Henry Gantt developed charts that helped scheduling production activities.

Harry Emerson wrote a book on principles of efficiency and it became part of industrial engineering and scientific management literature. Focus on efficiency in systems in general and especially manufacturing systems sharpened.

F.W. Harris developed theory of batch quantities in production and purchase. Walter Schewart developed procedures for using statistical thinking in process control. He created methods for determining when to change machine setups based on the measurements of samples taken at randome intervals. Hawthorne studies became another landmark development in manufacturing management. They brought out the importance of psychological variables in improving or decreasing productivity of operators. Unfortunately, the proponents of this line of thought have not integrated their conclusions with the ideas of scientific management appropriately. They chose to attack themes of scientific management. Manufacturing management might have had a different state today, if scientific management movement that had engineering foundations and human relations school of thought that had psychology as its foundation were appropriately integrated by human relations school.

Hawthorne studies became another landmark development in manufacturing management. They brought out the importance of psychological variables in improving or decreasing productivity of operators. Unfortunately, the proponents of this line of thought have not integrated their conclusions with the ideas of scientific management appropriately. They chose to attack themes of scientific management. Manufacturing management might have had a different state today, if scientific management movement that had engineering foundations and human relations school of thought that had psychology as its foundation were appropriately integrated by human relations school.

Development of operations research (OR) helped manufacturing managers to understand and optimize their systems better. Study of operations research became a part of studies of manufacturing managers.  Use of computers was started in recording store related transactions and data and it was extended to shopfloor transaction data. The use was further extended to calculation of batch quantities and preparation of  loading sheets and schedules.

In 1970s, scholars in USA recognized that Japanese had used their manufacturing management philosophies, strategies and techniqes as a strategic capability to win market shares in global markets. A new era of manufacturing strategy thought developed in manufacturing management.  Automation increased in factories. With this multiskilling of operators came into picture as now operators have more time and can operate more machines. As group layout became more popular, an operator was required to operate different machines which were in series. Total quality management, total productive maintenance, total cost management became the strategies. JIT or lean systems became the best practice production systems. While improvement everywhere reached its zenith, the important idea that it is improvement in bottleneck that has the most value was highlighted by Goldratt in the name of 'Theory of Constraints.'

Many new technologies came into existence and were adopted into manucturing processes. The existing ideas regardng technology adoption did not emphasize the suboptimal use of technology. The full power of technology was not being put to use by many. Theory of BPR brought this into focus and helped systems become more productive by utilizing the power and potential of the new technologies more. Ability to look at bigger and bigger systems using OR models and system dynamics models and the ability to access data anywhere using internet based data communication systems made coordination across distributed national and global facilities. This led to the development of theory of supply chain wherein information can be made visible to anybody and optimization can be done from the point of origin or raw materials to its dumping point. Manufacturing facilities are now a part of supply chains wherein information is available to both suppliers and potential customers in real time and purchasing is done through electronic orders. In a century, manufacturing management theory and pratice developed immensely.


Chase, Richard, B., F. Robert Jacobs, Nicholas J. Aquilano , Operations Management, 11th Edition, McGraw-Hill, New York, 2006.
Krajewski, Lee et al., Operations Management: Processes and Value Chains, 8th Edition, Prentice Hall, Upper Saddle River, 2007.



___________________________________________________________________________________________

Early Books on Manufacturing Management


Factory Organization and Administration
Hugo Dimer, First Professor of Industrial Engineering, Pennsylavania State College
First edition: 1910
Third edition digital copy
http://www.archive.org/stream/factoryorganiza00diemgoog#page/n10/mode/2up

Profit Making in Shop and Factory Management
Charles U. Carpenter, 1908
http://www.archive.org/stream/cu31924002748576#page/n1/mode/2up

Shop Management
Frederick Winslow Taylor, 1911
http://www.archive.org/stream/shopmanagement00taylgoog#page/n10/mode/2up

Factory and Office Administration
Lee Galloway, 1918
http://www.archive.org/stream/factoryofficeadm00galliala#page/n3/mode/2up

Factory Management Wastes: And How to Prevent Them
James F. Whiteford, 1919
http://www.archive.org/stream/factorymanagemen00whit#page/n7/mode/2up

Plant Management
Dexter S. Kimball, 1919
http://www.archive.org/stream/cu31924031222627#page/n7/mode/2up

___________________________________________________________________________________________


Article part of chapter  Introduction  to Manufacturing Management

Chapter - Introduction to Manufacturing Management

Authors

Narayana Rao
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Last edited: 20 Nov 2010 (On Knol)

Exported: 26 Nov 2011

Original URL: http://knol.google.com/k/-/-/2utb2lsm2k7a/3311


Chapter of Manufacturing Management - Knol Book

Contents of Chapter

Principles of Management – Koontz and O’Donnell

Manufacturing Management - Introduction

Manufacturing Management - Introduction - Interesting Web Pages  

Preface to Manufacturing Management - Blog Book




Preface to Manufacturing Management - Knol Book

Authors

Narayana Rao
Published

All Rights Reserved

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Last edited: 18 Nov 2010

Exported: 26 Nov 2011

Original URL: http://knol.google.com/k/-/-/2utb2lsm2k7a/3310



Study each book and seminar,
Attend every one you can, sir!
You'll find a thousand experts
--each with PART of the answer.    (O.W. Wight in the book, Production and Inventory Control: Principles and Techniques)

Digital media or electronic media products have made it possible for more experts (even in a limited way) to write their thoughts and understanding of issues and share the knowledge with rest. People in general have followed Wight's advice and are reading digital media articles.

Knol, a wiki-based article writing platform is another digital media product launched by Google to promote writing units of knowledge, knols. Number of professionals and faculty members are writing on Knol. Knol books of collections are part of efforts to bring articles or knols related to a subject together and present them to readers. Such books make accessing thousands of experts more easy for readers. Society will be benefited, if more people become more knowledgeable and use that knowledge to produce more goods and services and more importantly happiness and also preserve environment for present as well as future generations.

Robust Design

Chapter  13 Ulrich and Eppinger - Product Design and Development


Robust Design


1. Identify Control Factors,  Noise Factors, and Performance Metrics
2. Formulate an Objective Function
3. Develop an Experimental Plan
4. Run the Experiment
5. Conduct the Analysis
6. Select and Confirm Factor Setpoints

Prototyping

Chapter  12 Ulrich and Eppinger - Product Design and Development

Prototyping - Planning for Prototyping


1. Define the Purpose of the Prototype
2. Establish the Level of Approximation of the Prototype
3. Outline an Experimental Plan
4. Create a Schedule for Procurement, Construction and Testing

Design for Manufacturing - A Step in Product Design and Development

Chapter  11 Ulrich and Eppinger - Product Design and Development


Manufacturing cost is a key determinant of the economic success of a product. Economic success depends on the profit earned on each item sold, and how many units of the product the firm can sell.  if the price is set lower more sales can be achieved. But to maintain profit margin or profit on each item sold, cost also have to low. Design for manufacturing activity helps in lowering the cost of manufacturing by modifying the design to suit manufacturing capabilities without decreasing the quality of the product.

Design for Manufacturing


1. Estimate the Manufacturing Costs
2. Reduce the Cost of Components
3. Reduce the Cost of Assembly
4. Reduce the Costs of Supporting Production
5. Consider the Impact of DFM Decisions on other Factors


Details

1. Estimate the Manufacturing Costs
2. Reduce the Cost of Components

Understand the Process Constraints and Cost Drivers
Redesign Components to Eliminate Processing Steps
Choose the Appropriate Economic Scale for the Part Process
Standardize Components and Processes
Adhere to "Black Box" Component Procurement. Allow the supplier to design the product based functional specification.

3. Reduce the Cost of Assembly

Integrate Parts
Maximize Ease of Assembly
Consider Customer Assembly


4. Reduce the Costs of Supporting Production

Minimize Systemic Complexity
Error Proofing (Pokayoke)

5. Consider the Impact of DFM Decisions on other Factors

Industrial Design of New Products


Chapter 10  Ulrich and Eppinger - Product Design and Development


Western European industrial designers emphasized the importance of geometry, precision, simplicity, and economy in the design of products apart from functional requirements.

In America, the industrial designers were at the service of sales and advertising. They emphasized the exterior of the product as a way to attract buyers. Industrial designers created nonfunctional aerodynamic shapes to create product appeal.

It is now accepted that all products that are seen by people depend critically on ID for commercial success.

Industrial design now has two important categories: ergonomic and aesthetic design.

Industrial Design Process


1. Investigation of customer needs
2. Conceptualization
3. Preliminary Refinement
4. Further Refinement and final Concept Selection
5. Control Drawings or Models
6. Coordinating with Engineering, Manufacturing and External Vendors

Product Architecture in Product Development


Chapter 9 Ulrich and Eppinger - Product Design and Development


A product is developed based on functional elements. The product as developed has physical elements, parts and subassemblies.

The architecture of a product is the scheme by which the functional elements of the product are arranged into physical chunks (items of the product) and by which the chunks interact.

The most modular architecture is one in which each functional element of the product is implemented through  one distinct chunk.


Product Architecture


1. Create a Schematic of the Product
2. Cluster the Elements of the Schematic
3. Create a Rough Geometric Layout
4. Identify the Fundamental and Incidental Interactions


Delayed Differentiation of the Product


Platform Planning

A company may offer two or more products that are highly differentiated yet share a substantial fraction of their components. The fraction that is shared is called the platform,

In platform based products, there is a commonality or common parts plan and differentiation plan.

Concept Testing in Product Development


Chapter 8 Ulrich and Eppinger - Product Design and Development


Concept Testing


1. Define the Purpose of the Concept Test
2. Choose a Survey Population
3.Choose a Survey Format
4. Communicate the Concept
5. Measure the Customer Response
6. Interpret the Results



Details

1. Define the Purpose of the Concept Test
2. Choose a Survey Population and Sample Size
The sample size of the survey should be large enough that the team's confidence in the results is high enough to guide decision making

3.Choose a Survey Format

Survey formats include face to face interaction, telephone, postal mail, electronic mail, internet etc.

4. Communicate the Concept

The concept can be communicated to the survey participant as verbal description, sketch, photo, story board, video, physical model or working prototype. Based on the communication form used, the survye format also will change.

5. Measure the Customer Response

The customer response can be taken in the form

Definitely would buy.
Probably would buy.
Might or might not buy.
Probably would not buy.
Definitely would not buy.

6. Interpret the Results


Concept Selection in Product Development



Chapter 7 Ulrich and Eppinger - Product Design and Development


Concept Selection


It is based on method developed by Stuart Pugh. Called Pugh Concept Selection.

1. Prepare the Selection Matrix.
2. Rate the Concepts
3. Rank the Concepts
4. Combine and Improve the Concepts
5. Select One or More Concepts


Details

1. Prepare the Selection Matrix.
The concepts are portrayed by written description as well as graphical or pictorial representation.
A reference concept is chosen which is an industry standard or a well known concept to the participants so that it can be used to rate the generated concepts as better or worse.

2. Rate the Concepts
A relative score of "better than" (+) or "same as" (0) or "worse than" (-) is placed in each cell matrix formed by selection criteria and the specific concept.
3. Rank the Concepts
The +, 0 and -  are totalled against each concept to rank the concepts.
4. Combine and Improve the Concepts
The team can now see possibilities of combing the good features of various concepts into new concepts.
5. Select One or More Concepts
Selection of one or more concepts is now done for further refinement.