INDUSTRIAL ENGINEERING AND MANAGEMENT With an Appendix introducing ‘ISO 9000 Quality Systems’ Dr. O.P. Khanna B.Sc. Engg., M.E. (Hons.), Ph.D. Professor & Head (Retd.), Mechanical Engineering Department YMCA Institute of Engineering Faridabad, Haryana A. SARUP M. Com. REVISED & ENLARGED EDITION @ DHANPAT RAI PUBLICATIONS (P) LTD. FIRST FLOOR, 67/4 MADRAS HOUSE, DARYAGANJ, NEW DELHI - 110 002 PHONES : 327 4073, 325 8319PREFACE ————————$ In a society, which is producing more technically qualified persons, newer materials, complex products and more information than ever before, Systematic and Organised Approach in every discipline, is indispensable to meet the challenge of coimplexity. A large industry or business organization cannot rely on ‘Rules of Thumb’ or “Trial and Error’ methods of judgement. The optimum operation of any Industrial organisation demands its staff to share the Administrative and Technical responsibilities efficiently and effectively. Keeping the above facts in view, the book covers various topics of Industrial Engineering and Management with special emphasis on comparatively latest techniques, ie. Systems Concept, Value Analysis, Operations Research, Network Analysis, Work Study, Computers, Business and Environment, Professional and Business Ethics, Management Information Systems, Group Technology, etc. This revised edition of the book with its 39 chapters covers almost the complete syllabus of subjects such as industrial Engineering, Production Management, Management Science etc., being taught in various Universities and Engineering Institutes. As such, this book will be of considerable value to both Practising Engineers and the Engineering Students. New Year Dr. OP. Khanna Jan 1, 1999 Faridabad PUBLISHER’S NOTE If this book does not cover any portion of your syllabus, please write to the Publisher/ Author. ;Other useful books by Dr. Khanna PRODUCTION TECHNOLOGY — Vol. I Contents: (1) Introduction (2) Engineering Metals and Alloys (3) Heat Treatment Processes (4) Testing of Materials (5) Surface Cleaning (6) Finishes and Coatings (7) Painting (8) Plastics (9) Wood Working Machines (10) Foundry (11) Welding (12) Fasteners (13) Adhesive Bonding (14) Powder Metallurgy (15) Mechanical Working of Metals (16) Smithy and Forging (17) Metai Spinning (18) Fundamentals of Metal Forming (19) Metal Forming Processes (20) Press Work (21) Rolling (22) Extrusion (23) Drawing of Rods, Wires and Tubes (24) High Velocity Forming of Metals (25) Pipe and Tube Manufacture (26) Typical Examination Problems. PRODUCTION TECHNOLOGY — Vol. II Contents: (1) Introduction to Machine Tools (2) Kinematics of Machine ‘Tools (3) Metal Sawing (4) Lathe (5) Turret, Capstan and Automatic Lathes (6) Shaping Machine (7) Slotting Machine (8) Planning Machine (9) Drilling and Reaming (10) Boring (11) Milling Machine (12) Gear Manufacturing (13) Broaching (14) Grinding Machine (15) Surface Finishing Processes (16) Metrology (17) Jigs and Fixtures (18) Newer Machining Processes (19) Automation and Transfer Machines (20) Numerical Control of Machine Tools (21) CAD/CAM, FMS and CIMS (22) Robotics (23) Testing of Machine Tools (24) Installation of Machine Tools (25) Machine Tool Vibrations (26) Machining of Plastics and Ceramics (27) Thread Manufacturing (28) Tool Making and Die-Sinking Machines (29) Automatics (30) Theory of Metal Cutting (31) Tool Wear and Machinability (32) Press Too! Design (33) Cutting Tool Design (34) Machine Tool Design (35) Machine Tool Maintenance (36) Repair of Machine Tools (37) Advanced Manufacturing Systems (38) Economics of Machining. ENGINEERING MATERIALS & MATERIAL SCIENCE Contents: (1) General (2) Structure of Metals and their deformation (3) Ferrous Materials (4) Non-ferrous Materials (5) Metallurgical Considerations (6) Identification of Metals and Alloys (7) Testing of Metals and Alloys (8) Selection, Specification, Forms and Availability of Materials. (9) Fundamentals of Heat Treatment (10) Plastic Materials (11) Insulating Materials (12) Ceramic Materials (13) Miscellaneous Materials. ‘WORK STUDY Contents: (1) Introduction (2) Method Study (3) Work Measurement (4) Production and Work Study (5) Engonomics (6) Health and Occupational Safety (7) Job Evaluation and Merit Rating (8) Wage Payment Plans for Direct and Indirect Workers (9) Plant Layout (10) Material Handling (11) Organisation and Training of Work Study Department and its Place in the Organisation of an Enterprise (12) Work Content of a Job and Management Techniques to Reduce Work Content and Inefficient Time. (13) The Human Content of Work Study (14) Statistical Aids to Work Study (15) Measurement of Indirect Work (16) Value Analysis and Value Engineering (17) © & M (18) Question Bank.CONTENTS AT A GLANCE CHAPTERS Page Nos. 1. INDUSTRIAL ENGINEERING AND MANAGEMENT hae 1.1-L13 2. PRODUCTION AND PRODUCTIVITY ...... wee 24-211 3. ORGANISATION. ............00- 7 3.1-3.57 4 PLANT LOCATION, LAYOUT AND LINE BALANCING 41-435 5. PRODUCT DESIGN, PLANNING AND DEVELOPMENT . . . 5.1-5.25 6. PROCESS PLANNING AND GROUP TECHNOLOGY ... . . - 6.1-6.24 7. PRODUCTION, PLANNING AND CONTROL 71-752 8. INSPECTION AND QUALITY CONTROL 8.1-8.48 9 WORKSTUDY .... 6 tous ew. 9.1-9.51 10. NETWORK ANALYSIS . Hee, - + 10,1-10.22, 11, OPERATIONS RESEARCH anes fee, 7 11.1-11.39 12. SYSTEMS CONCEPT & VALUE ANALYSIS... ........ 12,1-12.6 13, PLANTMAINTENANCE ....-.... he eo 131-1316 14. REPLACEMENT ANALYSIS . . . . . es 141-1416 15. MANAGEMENT CONCEPT . foe “ + 15,1-15.38 16 INDUSTRIAL OWNERSHIP . on 7 ss 161-1610 17, SUPERVISORY AND LEADERSHIP se ee ee 171-176 18. DECISIONMAKING ......... ee es 18,1-18,33, 19, INDUSTRIAL PSYCHOLOGY we ~ 2 19.1-19.14 20. PERSONNEL MANAGEMENT wh. . - 20.1-20.44 21, UNION AND INDUSTRIAL (LABOUR) RELATIONS ... - .. . 21.1-21.14 22, INDUSTRIAL (LABOUR) LEGISLATION .... . sees 22,1-22.22 23, MATERIALS, PURCHASE AND STORES MANAGEMENT . 23.1+23.22 24, INVENTORY CONTROL AND MANAGEMENT - - - 24,1-24.1621. 28. 29. 31. 32. 33. 34. 35. 36. 37. 38. 39. CONTENTS MATERIAL HANDLING 6c ee 25.4625.14 FINANCIAL MANAGEMENT ©. 002 ee ey 26.1-26.49 COST ACCOUNTING ANDCONTROL .--- 1.5 5--. 21.1-27.35 BUDGET AND BUDGETARY CONTROL -.-..-. 5... + 281-2814 JOB EVALUATION AND MERIT RATING ........- ss 29,1-29.8 WAGE PAYMENT PLANS .. 0... 07 02s vee 301-3012 SALES AND MARKETING MANAGEMENT . - . se. 3113136 SMALL SCALE INDUSTRIES AND ENTREPRENEURSHIP»... . 32.1-32.15 ENVIRONMENTAL POLLUTION ©... 2.5 = 33.1-33.13 MANAGEMENT BY OBJECTIVES 34,1-34.3 ENGINEERING ECONOMICS .. . 21S GAR Sow. 850-8550 COMPUTERS... .......5 05-55 5 Sean ee 36,1-36.69 BUSINESS AND ENVIRONMENT... 0-2-2, 0-0-0 37.1-37.23 PROFESSIONAL AND BUSINESS ETHICS... 0... 5s 38.1-38.11 MANAGEMENT INFORMATION SYSTEMS ©». 0) sss 39,1-39.13 QUESTION BANK 25. + .QB-1-QB-20 APPENDIK os 3 hose ew a, + Add to 429CONTENTS 1. INDUSTRIAL ENGINEERING AND MANAGEMENT SCIENCE 11-113 1.1 Concept of Industrial Engineering .. 0.0.02. 06 Sere Caencl 1.2 History and Development of Industrial Ene = 1 1.3. Roles of Industrial Engineer ....... 13 1.4 Applications of Industrial Engineering . 14 1.5 Production Management 14 1.6 Production Management Versus Industrial Eagiesing 16 1,7 Operations Management ......... X 16 118 Management Science — Its Historical Development 16 19 The Tools of Management Science... .......- 1-8 1.10 Managerial Economics rs 1-10 1.11 Managerial Accounting 12 2,_ PRODUCTION AND PRODUCTIVITY 21-211 (2.1 Production... .« 21 2.2 Production Function 21 2.3 Production System . é 22 2.4 — Input Output Model . 24 25 25 — Micro-Economics, Applied to Plants and Industral Undenaking 2.6 Productivity... . 27 28 29 Productivity Measures 3. ORGANISATION 3.1 Concept of Organisation ......-.. 4. 3.2 Importance of Organisation... . 3.3 Characteristics of Organisation... . 3.4 Elements of Organisation . . 3.5 The Process of Organisation 3.6 Organisation Theory . we 3.6.1 Classical Organisation Theory . . 3.6.2 Neo-Classical Organisation Theory - 3.6.3 Modem Organisation Theory - - : . -