Page: 1Updated: 11/08/2004 Owner:
Industrial Engineering Department
IE Training
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplanning
¨ Flow-Chart / PFMEA
¨ PFP / OBC
¨ WSD
¨ SMED
Page: 2Updated: 11/08/2004 Owner:
Industrial Engineering Department
What’s IE?
Include Everything
“IE, is...
&
Involve Everyone
“
IE is Industrial Engineering
Page: 3Updated: 11/08/2004 Owner:
Industrial Engineering Department
工业工程简介
• 什么是工业工程？
美国质量管理权威朱兰博士说：美国值 得向全世
界夸耀的东西就是IE，美国之 所以打胜第一次
世界大战，又有打胜第 二次世界的力量，就是
美国有IE。
Page: 4Updated: 11/08/2004 Owner:
Industrial Engineering Department
• IE----INDUSTRIAL ENGINEERING---工业
工程，简称IE，是世界上公认的能 杜绝各种
浪费，有效地提高生产率和经 济效益的把技
术与管理有机地结合起来 的一门边缘学科。
Page: 5Updated: 11/08/2004 Owner:
Industrial Engineering Department
Definition:
Goal:
Industrial Engineering
Page: 6Updated: 11/08/2004 Owner:
Industrial Engineering Department
工业工程的特点
– IE的核心是降低成本，提高质量和生产
率。
– IE是综合性的应用知识体系（技术和管理）
–注重人的因素是IE区别于其他工程学科特点 之
一。
– IE是系统优化技术。
– IE的面向--由微观向宏观管理。
Page: 7Updated: 11/08/2004 Owner:
Industrial Engineering Department
IE的意识：
• 成本和效率意识
• 问题和改革意识
• 工作简化和标准化意识
• 全局和整体化意识
• 以人为中心的意识。
Page: 8Updated: 11/08/2004 Owner:
Industrial Engineering Department
通常IE有哪些方法呢?
方法研究：寻求完成任何工作的最经济
合理的方法，达到减少人员、机器、无
效动作和消耗，并使方法标准化。
作业测定：制定用经济合理的方法完成
工作所需的时间标准，达到减少人员 、
机器设备的空闲时间.
Page: 9Updated: 11/08/2004 Owner:
Industrial Engineering Department
• 方法研究内容包括：
1。程序分析
2。操作分析
3。动作分析
4。路线分析
• 作业测定内容包括：
1。秒表时间研究
2。工作抽样
3。预定时间标准法
Page: 10Updated: 11/08/2004 Owner:
Industrial Engineering Department
IE分析过程的四大原则
(1)取消（Eliminate):
(2)合并(Combine)：
(3)重排(Rearrange):
(4)简化(Simplify):
Page: 11Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 12Updated: 11/08/2004 Owner:
Industrial Engineering Department
Engineering
Manager
Lee Cheng
Industrial
Engineering
manager
Terry Wang
Engineer
Supervisor
Euro
Tom Ding
FA Engineer
Supervisor
NA
Daniel Zong
FA Engineer
Supervisor
Nissan
Weiqing Li
James
zhang
IE engineer
Bob Zheng
IE engineer
Andrew
guan
IE engineer
Emily Qiu
IE engineer
VOLVO&WULING PSA&Sumida GMX&GMT Ford FN Ford EN
Ting Zeng
IE engineer
IE 的组织架构: 是按项目分类的
ME & PE
Yukun
Zhang
IE engineer
Loger Zhou
IE engineer
Chaolong
Yang
IE engineer
Nissan IP Nissan EN Nissan JA
Page: 13Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 14Updated: 11/08/2004 Owner:
Industrial Engineering Department
What is manufacturing system design (MSD)?
MSD
MSD is a Delphi-P globally common tool to develop
and document manufacturing system design
alternatives
Alt 1
Alt 2
Alt 3
Alt n
MSD Comparison Decision
Page: 15Updated: 11/08/2004 Owner:
Industrial Engineering Department
The Delphi Manufacturing Engineering Philosophy
is to design Manufacturing Systems that achieve
a balance between operators , equipment, and
material resulting in:
What is the purpose of MSD?
The best LIFE CYCLE manufacturing
system COST
MSD
Page: 16Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨For example:
Should I buy a car ($20,000)
Should I take a taxi ($10/trip) to work?
MSD use many form to calculate the life cycle cost
Page: 17Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 18Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨Bom Setup
IE ClerkReceive drawing from Product
Engineering Department
Analyze drawing IE Engineer/Technician
Create Excel BOM IE Engineer/Technician
Input EBOM IE Clerk
Create Item Master PE Engineer
Transmit into 4-Shift IT Server
Release Purchasing Engineer
Check BOM according to 4-S IE Engineer/Technician
Page: 19Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 20Updated: 11/08/2004 Owner:
Industrial Engineering Department
Preplanning (工艺策划) is a process to
standardize the process of preplanning traditional
final assembly harness for Delphi Packard
1. Maximum utilization of our operator’s skills
and attention.
Focused Plan(以人为本)
flow of material
parts presentation to the operator
schedule
design analysis
3. Labor estimates
DFM/BOM
Time study(theory)/control 17/19
Page: 21Updated: 11/08/2004 Owner:
Industrial Engineering Department
4. Pegboard review
5. Build sequence
6. Work content define
plan
breakdown
breakdown
breakdown
11. layout and flow
& flowchart
board release
14. Labor standard
release
16. Line start
Ergonomic/ECF
Note:
ECF:Ergonomic Correlation Factor
ECF=Actual ergonomic work summary/
Ideal ergonomic work summary
CTS/Total build sheet
Time study sheet(detail)
Final control 17/layout
WI(theory)
Final WI
Practise WI
Workshop
design,material rack
QA/WLL
Quota
QA
Ramp up plan
Page: 22Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 23Updated: 11/08/2004 Owner:
Industrial Engineering Department
Page: 24Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨PFMEA-Potential Failure Mode and Effects Analysis(Process FMEA)
· Identifies potential product related process failure modes
· Assesses the potential customer effects of the failures
· Identifies the potential manufacturing or assembly process
causes and identifies process variables on which to focus controls
for occurrence reduction or detection of the failure conditions.
· Develops a ranked list of potential failure modes, thus
establishing a priority system for corrective action considerations.
· Documents the results of the manufacturing or assembly process.
Page: 25Updated: 11/08/2004 Owner:
Industrial Engineering Department
Page: 26Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 27Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s WSD?
- Work Standard Data is a tool for calculating standard
work time of wiring harness
¨ What’s WSD used for?
- Quotation
- Labor estimate
- Line balance
¨ What types of WSD do we use?
- European WSD
- AP WSD
Page: 28Updated: 11/08/2004 Owner:
Industrial Engineering Department
Example: European WSD
Page: 29Updated: 11/08/2004 Owner:
Industrial Engineering Department
Example: AP WSD
Page: 30Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 31Updated: 11/08/2004 Owner:
Industrial Engineering Department
PFP - People Focused Practice
Page: 32Updated: 11/08/2004 Owner:
Industrial Engineering Department
OBC - Operator Balance Chart
Improvement
opportunities
Page: 33Updated: 11/08/2004 Owner:
Industrial Engineering Department
¨ What’s IE?
¨ IE organization chart
¨ MSD
¨ BOM setup
¨ Preplaning
¨ Flow-Chart / PFMEA
¨ WSD
¨ PFP / OBC
¨ SMED
Page: 34Updated: 11/08/2004 Owner:
Industrial Engineering Department
SMED - Single Minutes Change Die
Quick Setup
- Definition : The minimum amount of time needed to change over from
the last good part of one production run to the first good part of the next
production run.
- Objective : The objective of Quick Setup / Changeover is to minimize
the amount of time required to changeover from one activity to the next so
that changeover time is not an obstacle in achieving Flow Manufacturing.
Page: 35Updated: 11/08/2004 Owner:
Industrial Engineering Department
Implementation Guide:Quick Setup Install Steps
1. Set up best sequence to reduce complex changeover time.
2. Separate Internal and External Setup Elements.
- Internal Setup Element : is one that must be performed while the
machine or operation is stopped such as removing the die.
- External setup element : is one that can be performed while the
operation is running such as gathering material, tools and equipment.
3. Convert Internal Steps to External Steps.
4. Reduce Internal Setup Time (Changeover Time).
5. Reduce External Setup Time.
6. Standardize the Setup and Continuously Improve.
Page: 36Updated: 11/08/2004 Owner:
Industrial Engineering Department
Thank
You!
