IE 231 2013 Syllabus

IE

231: ANALYSIS SYSTEMS

OF

PRODUCTION

Department of Industrial Engineering & Operations Research College of Engineering, University of the Philippines- Diliman First Semester, 2013-2014, Saturday, 7-10 Noon Human Factors Engineering Laboratory (HFEL), 4th Floor, Melchor Hall Building Prof. Nestor O. Raneses- Instructor; Consultation hours; Sat 10-1 pm; 4-6 pm Tel. 9818500 ext 3128, Associate Professor, UP College of Engineering Dept of Industrial Engineering & Operations Research Tel 9206923, Director, UP Institute for Small Scale Industries (UP ISSI) Tel 9256721, UP Assistant Vice President for Administration
Email: nestorraneses@yahoo.com ; nestor.raneses@up.edu.ph 1.0 LEARNING OUTCOMES: Upon completion of this course, the students should be able to: State and explain the theories and principles underlying the structure and behavior of operations and production & supply chain systems (OPSCS). Define, characterize, and model the critical problems and decisions in designing, operating, controlling, and improving OPSCS. Analyze, design, & evaluate total system or sub-system performance of operations and production systems with structured problem solving methods and models. Install, and improve the operational effectiveness, and sustainability of operations/production systems. Conduct continuous improvement action research in the whole supply chain. 2.0 COURSE REQUIREMENTS Group Term Project (20 %) Group Problem Solving Exercises and Case Presentations (20 %) Two Long Examinations (40%) Individualized homework and integration work (20 %)

3.0. REFERENCE- TEXTS Hopp, W. J. And Spearman, M. L (2008), Factory Physics, 3rd Edition, McGraw-Hill International Edition, New York, New York, USA. Hopp, W. J., (2008) Supply Chain Science . Waveland Press, inc, Ill. USA Johnson and Montgomery, Operations Research in Production Planning, Scheduling and Control, John Wiley and Sons, Inc.

IE231 Raneses 2012

IE 231 2013 Syllabus

Elsayed & Boucher , Analysis and Control of Production Systems, 2nd Edition, Prentice-Hall Series in Industrial and Systems Engineering Womack, J.P, Jones, D.T. And Roos, D, (2007), The Machine That Changed the World The Story of Lean Production Toyotas Secret Weapon in the Global Car Wars that is Revolutionizing World Industry , Free Press, New York, New York, USA.

IE231 Raneses 2012

IE 231 2013 Syllabus

4.0 GRADING SYSTEM 94-100- 1.0 90-93 - 1.25 87-89 - 1.5 84-86 - 1.75 80- 83 - 2.0 76-79 - 2.25 71-75 - 2.5 65-70 -2.75 60-64 - 3.0 50-59 - 4.0 Below 50 -5.0 Unless fully justified and tenable, no INC grade will be given.

5.0 COURSE OUTLINE Meeting #

Coverage

#1 (6/08/12) Class Organization and Leveling of Expectations

(What Do We Want to Learn?)

#2 (6/15/13) Introduction to Operations and Production Systems (OPS) Historical Evolution & Evolving Factory Physics & Supply Chain Systems ( SCS) Survey of the State of the Art and Practice Circa 21st Century Improvement and Competitiveness Paradigms ( 6C +12Ps= 4Rs ) Role of IEs in OPS ( Design, Develop, Install and Improve) Class Organization Work Group Organization, Topics and Report Formats

Survey and Review of Structured Problem Solving Approaches in OPSCS

Product/Service Realization Process Modeling Critical Problems and Decisions in OPS Integrated Structured Problem Solving in OPS o 8D Approach o Methods Engineering ( FASES) o Statistical Problem Solving ( DMAIC) o Operations Research (OR) o Value Engineering & Analysis (VEA) o Lean Pathway ( VVSFPP) o Theory of Constraints ( TOC) o Quality Function Deployment ( QFD)

IE231 Raneses 2012

IE 231 2013 Syllabus

Group Homework #1 : Problem Diagnostic : Pro-Coat Hal, Inc o Methods Engg Approach Presentation o OR Approach Presentation

IE231 Raneses 2012

IE 231 2013 Syllabus

#3 (6/22/13) Understanding the Toyota Production System (TPS)

and Lean System

Just- in Time & Cycle Time Reduction Quality Autonomation Muda, Muri, Mura Implementing JIT Group Homework # 2 : Pro-Coat Hal, Inc o Lean Pathway Approach Presentation o Statistical Problem Solving /Six Sigma Approach Presentation Individual Homework #1 o Reflections on the Evolution of the Lean System from the IE Perspective: Due 14 July 2012 o Schonberger( 1982)Japanese Manufacturing Techniques: Nine Hidden Lessons in Simplicity o Schonberger(1986) World Class Manufacturing : The Lessons of Simplicity Applied o Schonberger( 1996)World Class Manufacturing: The Next Decade Building Power, Strength, and Value o Womack, Jones & Roos, ( 1990, 2007) The Machine That Changed the World: The Story of Lean Production : How Japan s Secret weapon in the Global Auto Wars Will Revolutionize the Western Industry o Womack & Jones ( 1996), Lean Thinking : Banish Waste and Create Wealth in Your Corporation o Hopp & Spearman( 2008) Factory Physics Chapter 4 From the JIT Revolution to Lean Manufacturing

#4 (6/29/13)

Understanding the Lean Systems Part 2

Visual Factory Cellular Layout Set-Up Reduction Kanban Systems Total Productive Maintenance ( TPM) Poka- Yoke Methods Group Homework #3 Pro-Coat Hal, Inc o Value Engineering Approach Presentation

IE231 Raneses 2012

IE 231 2013 Syllabus

o Theory of Constraints ( TOC) Presentation Approach

IE231 Raneses 2012

IE 231 2013 Syllabus

# 5 (7/06/13)

Basic Factory Dynamics & Basics of Variability

Definitions & Parameters Littles Law- WIP, Throughput CT Relationships Best Case, Worst Case and Practical Worst Case Analysis Constrained Systems Process Time Variability Flow Variability Queueing- Variability Interactions Variability Pooling Group Homework #4 Pro-coat Hal , Inc o 8D Approach Presentation o QFD Approach Presentation Individual Homework : Pro-Coat Hal Case : Best Case, Worst Case & Practical Worst Case Analysis

#6 (7/13/13)

Corrupting Influence of Variability

Variability Laws Flow Laws Batching Laws Cycle Time Performance & Variability Diagnostics and Improvement Group Homework Intuition Building Exercise -#3 Hopp & Spearman Book, p350. Individual Homework: Hopp & Spearman, problem #8, p 351.

#7 (7/20/13)

#8 (7/27/13)

Pull Planning & Forecasting Systems

Pull Planning Framework Forecasting System Configuration Moving Average Models Exponential Smoothing Models Adaptive Control Models Box- Jenkins Models Individual Homework - Forecasting Exercises

Design for Total Quality

Design for Reliability Design for Quality Six Sigma Quality ( DMAIC/ DFSS) Group Homework

IE231 Raneses 2012

IE 231 2013 Syllabus

#9 & 10 (8/10/13) (8/17/13)

Supply Chain & Inventory Systems

Types and Reasons for Inventory Supply Chain Configurations Single Item Inventory Models Constrained Multi-item Inventory Models Periodic Review Inventory Models Continuous Review Inventory Models Materials Requirements Planning MRP Materials Resources Planning MRP II Individual Homework on Inventory Modeling

#11 & 12 (8/24/13) (8/31/13)

Planning for Pull Systems

Hierarchical Production Planning Product Mix Problems Blending Problems Process Choice Problems Single Activity Multiple Products Problems Single Facility Lot Sizing Problems Multi-Stage Planning Problems Individual Homework Solve completely. Write a brief formal report for each of them ( Montgomery , OR in Production Planning, Scheduling & Inventory Control ) o Exercise 3-2, 3-11, 3-12 &3-13. o Exercise 3-14 o Exercise 3-18 o Exercise 3-26 o Exercise 3-45 &3-46.

#13 & 14 (9/07/13) (9/14/13)

Production Planning Dynamic Models

Models with Linear Costs Dynamic Programming & Network Production Planning Models Production and Work Force Smoothing Models Integrated Adaptive Production Control Models Multi-Product Models Multi-Stage Multi Product Models Individual Homework. Solve completely. Write a brief formal report for each of them. ( Montgomery, OR in Production Planning, Scheduling & Inventory Control ) o Exercise 4.9 , 4.10& 4.11 o Exercise 4.33 & 4.34 o Exercise 4.41, 4.42 & 4.43

IE231 Raneses 2012

IE 231 2013 Syllabus

o o Exercise 4.4 Exercise 4.65 & 4.66

IE231 Raneses 2012

IE 231 2013 Syllabus

# 15 & 16 (9/21/13) (9/28/12)

Scheduling in a Pull Environment

Scheduling and Sequencing Job and Flow Shop Scheduling Assembly Line Balancing Line of Balance ( LOB) Project Scheduling Individual Homework Exercise OR in Production Planning, Control ) o Exercise 5.52 o Exercise 5.54

( Montgomery, Scheduling &

#17 (10/05/13)

Systems Design and

System Development Process System Operation Integration & Feedback FINAL EXAMINATION TERM PROJECT REPORTING

Implementation

Revised 2013: 08 June 2013

IE231 Raneses 2012