Dr. Mohammed Al-dujaili
Department of Non-Metallic Materials Engineering
Faculty of Materials Engineering
University of Babylon
2013-2014
Lecture 1
Stage: forth
Subject: Industrial Engineering
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
INDUSTRIAL ENGINEERING LECTURES (1)
Overview
While the term originally applied to manufacturing, the use of
"industrial" in "industrial engineering" can be somewhat misleading,
since it has grown to encompass any methodical or quantitative
approach to optimizing how a process, system, or organization operates.
Some engineering universities and educational agencies around the
world have changed the term "industrial" to broader terms such as
"production" or "systems", leading to the typical extensions noted
above. In fact, the primary U.S. professional organization for Industrial
Engineers, the Institute of Industrial Engineers (IIE) has been
considering changing its name to something broader (such as the
Institute of Industrial & Systems Engineers), although the latest vote
among membership deemed this unnecessary for the time being.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
Concept of Industrial Engineering
Industrial engineering is a branch of engineering dealing with the
optimization of complex processes or systems. It is concerned with the
development, improvement, implementation and evaluation of
integrated systems of people, money, knowledge, information,
equipment, energy, materials, analysis and synthesis, as well as the
mathematical, physical and social sciences together with the principles
and methods of engineering design to specify, predict, and evaluate the
results to be obtained from such systems or processes. Its underlying
concepts overlap considerably with certain business-oriented disciplines
such as operations management, but the engineering side tends to
emphasize extensive mathematical proficiency and usage of quantitative
methods.
Or.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
Depending on the subspecialties involved, industrial engineering may
also be known as, or overlap with, operations management, management
science, operations research, systems engineering, manufacturing
engineering, ergonomics or human factors engineering, safety
engineering, or others, depending on the viewpoint or motives of the
user. For example, in health care, the engineers known as health
management engineers or health systems engineers are, in essence,
industrial engineers by another name.
Importance of Industrial Engineering
Industrial engineering is a type of engineering. It is one of the fastest
growing areas of engineering. It looks at what makes organizations work
best. An industrial engineer tries to find the right combination of human
and natural resources, technology, equipment, information and finance
to do the work best. Industrial engineering is important to finding the
answers to many important problems in manufacturing, distribution of
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
goods and services, health care, utilities, transportation, entertainment,
and the environment. Industrial engineers design and change how things
are done to increase quality, safety and productivity. Accordingly, the
industrial engineering are very important to the companies according to
the following reasons;
1. Industrial engineering has provided a systematic approach to
streamline and improve productivity and efficiency in the business
world.
2. The most distinctive aspect of industrial engineering is the flexibility
that it offers. Whether it’s shortening a rollercoaster line, streamlining
an operating room, distributing products worldwide, or manufacturing
superior automobiles, all share the common goal of saving money and
increasing efficiencies.
3. Industrial engineers are the only engineering professionals trained as
productivity and quality improvement specialists.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
4. Industrial engineers figure out ways to do things better. They engineer
processes and systems that improve quality and productivity. They work
to eliminate waste of time, money, materials, energy, and other
commodities. Most important of all, IE’s save companies money. This is
why more and more companies are hiring industrial engineers and then
promoting them into management positions.
5. The industrial does not mean just manufacturing. It encompasses
service industries as well. It has long been known that industrial
engineers have the technical training to make improvements in a
manufacturing setting. Now it is becoming increasingly recognized that
these same techniques can be used to evaluate and improve productivity
and quality in service industries.
IEs Work in Many Types of Industries
 Aerospace & Airplanes
 Aluminum & Steel
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
 Banking
 Ceramics
 Construction
 Consulting
 Electronics Assembly
 Energy
 Entertainment
 Forestry & Logging
 Insurance
 Materials Testing
 Medical Services
 Military
 Mining
 Oil & Gas
 Plastics & Forming
 Retail
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
 Shipbuilding
 State & Federal Government
 Transportation
Some Techniques Utilized by IEs
 Benchmarking
 Design of Experiments
 Employee Involvement
 Equipment Utilization
 Flow Diagramming
 Information & Data Flow
 Diagramming
 Interviewing for Information
 Lean Manufacturing
 Modeling & Testing
 Operations Auditing
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
 Organizational Analysis
 Pilot Programs
 Plant & Equipment Layout
 Project Management
 Simulation
 Six Sigma projects
 Statistical Analysis
 Strategic Planning
 Theory of Constraints
 Time Studies
 Work Sampling
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
Ceramic Coating of Automotive Components
Ceramic coatings are increasingly used to provide protection between
different engine parts, helping to increase wear resistance, reduce
friction, and improve heat shielding. These factors have a significant
influence on horsepower ratings, and augmenting them through ceramic
coating can often enhance an automobile’s performance. In addition,
these coatings enable metal components to interact in a more uniform
and compatible fashion.
Applying a Ceramic Coating
Before a ceramic coating is applied to an
automotive component, the component’s
surface is typically treated with a smoothing
agent or sandblasting in order to remove the
uneven outer surface and any contaminants
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
that may have accumulated. After the clean bottom layer is revealed, the
part is often heated in an oven to reduce its molecular porosity. Without
this treatment, any contaminants remaining after the initial stage may be
brought to the surface, forcing the coating layer to detach from the
substrate.
Common automotive ceramic coatings, such as titanium and tungsten,
are usually applied with a gravity-fed spray gun. The gun’s nozzle tends
to be narrow to provide precise application control. Solvent coatings are
typically sprayed at lower pressure, while liquid-based coatings are
sprayed at higher pressure, but in both cases the process occurs inside a
spraying booth. During spraying, it is important to keep careful control
over the ceramic layer’s thickness, as the coating must be very thin and
evenly distributed in order to keep it from running.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
Automotive Applications
Two of the most common applications for automotive ceramic coatings
involve exhaust manifolds and headers. A ceramic coating applied to a
manifold or header will provide increased resistance to corrosion, such
as rust, and lower the rate of heat loss, resulting in greater power output.
When applied to internal headers, these coatings increase the speed of
the exhaust gas and reduce overall turbulence by providing a smoother
surface. Some other automotive components commonly coated with
ceramics include:
• Cylinder Heads: Applying a ceramic coating to a combustion
chamber’s cylinder head and exhaust ports helps circulate exhaust gas at
a faster pace while providing a more intense burn in the chamber. This
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
coating can also improve thermal transfer between the gas and the
cylinder head, and an additional heat dispersal coating can help cool the
head.
• Pistons: A piston can be made more efficient with a ceramic coating,
which improves the device’s heat reflection and transfers part of the
detonation energy into the fuel burning phase. This can result in higher
fuel burning efficiency and reduced carbon accumulation, which in turn
makes detonation more effective.
• Piston Skirts: Coated piston skirts provide a dry sliding surface for
engine startup, and feature increased resistance to abrasion and
scratching while moving within the engine block. A ceramic coating can
also be layered on the piston ring to reduce friction and enhance wear
resistance between the ring and the cylinder’s inner surface.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon
• Intake Manifolds: An intake manifold with an interior ceramic
coating exhibits a lower level of heat penetration and a cooler mixture of
air and fuel. Applying an oil dispersing coating to the bottom of the
manifold can also lower heat transfer between the oil and the intake.
Ceramic coatings are often available in specific formulations designed
to focus on thermal resistance, friction reduction, corrosion resistance,
or oil shedding. These specialized coatings can be used to deliver a
particular material characteristic without compromising the rest of the
component’s properties.
Dr. Mohammed Al-dujaili- Department of Non-Metallic Materials Engineering/ Faculty of Materials Engineering/ University of Babylon