İzmir University
Faculty of Engineering
Industrial Engineering Department
SUMMER PRACTICE GUIDE I
İZMİR, 2012
TABLE OF CONTENTS
Table of contents
Page
Preface
i
Manufacturing Practice Report (MPR) Format
ii
IEN 200 Manufacturing Practice Guide
iii
1. Introduction
1
2. Production Environment
2
3. Operations Planning and Control
4
4. Information Technologies/Systems
5
5. Engineering Cost Analysis
6
6. Human Factors and Work Study
7
7. Quality Aspects
8
8. Conclusions and Recommendations
9
9. Reference List
9
10. Appendices
9
10.1. Cover Page
10
10.2. Process Chart Symbols with Examples
11
10.3. Assembly Process Chart - Baking Soda Crackers
12
10.4. A Typical Flow Diagram for Make-to-Stock Manufacturing Firm
13
10.5. IEN 200 Manufacturing Practice Course Syllabus
14
10.6. Frequently Asked Questions
17
i
Preface
The aim of IEN200Manufacturing Practicein Department of Industrial Engineering is to
reinforce and improve the theoretical and practical knowledge on the concepts of industrial
engineering, manufacturing techniques, probability and statistics, and engineering cost
analysis acquired in the previously completed coursework. The minimum duration for
IEN200Manufacturing Practice is 5 weeks (25 working days). Students are expected to
practically work in a manufacturing company and observe the production system and various
aspects of the production process in detail. It is the benefit of students to solve real problems
in the production system within the context of their theoretical knowledge and the “IEN200
Manufacturing Practice”syllabus. Students are expected to prepare a “Manufacturing Practice
Report” which should include all the requirements stated in the “IEN200Manufacturing
Practice”Syllabus and should conform to the “Summer Practice Report Format” given in this
guide.
ii
Manufacturing Practice Report (MPR) Format
To start with, all submitted material should conform to the following:
Completely word-processed, spell-checked,
1.5 line-spaced,
In times new roman, font size 12,
With the margins: left: 3 cm, Right: 2.5 cm, Up: 3 cm, Down: 2.5 cm
Justified paragraph alignment
Additionally,it should include the following:
Cover Page: It should include name of the report, your name, date, university and
department, city, country (See Appendix I).
Exacutive Summary: It should briefly describe what the presented Manufacturing Practice
Report covers (a separate page).
Özet:Turkish Translation of the abstract (a separate page).
Table of contents (a separate page)
List of tables (if any, a separate page)
List of figures (if any, a separate page)
List of engineering drawings (if any, separate page)
Remaining part of the Manufacturing Practice Report should contain the followings:
1. A section introducing the aim and the scope of the summer practice should be
presented briefly in this section. The work done by the student during the summer
practice should also be explained in general.
2. Succeeding sectionsmay be composed of several subsections, which describe
everything that has been done during the summer practice in detail within the context
of the requirements given in “IEN200Manufacturing Practice Guide”. The necessary
data, tables and diagrams should be numbered and presented in the “Appendix”.
3. A final section presenting the discussion and assessment of results obtained, and the
recommendations made by the team.
4. Reference List: All the documents that are referenced within the report should be
provided as a list in the alphabetic order of surnames of authors.
The list of references should include
a.
Author’s name (publication date), title of book, publisher, and page numbers;
e.g., Taha, H. A. (1997).Operations Research: An Introduction, 6th edition.
Prentice Hall.
b.
Author’s name (publication date), title of article and journal with volume and
number;
iii
e.g., Harlow, H. F. (1983).Fundamentals for preparing psychology journal
articles.Journal of Comparative and Physiological Psychology, 55, 893-896.
c.
Title of article, web address, date accessed;
e.g., Fredrickson, B. L. (2000, March 7). Cultivating positive emotions to optimize
health and well-being,http://journals.apa.org/prevention/volume 3, retrieved on
May 20, 2011.
5. Appendix: All related data, tables, diagrams, charts, engineering drawings,
catalogues, etc., which are not immediately relevant to the main text should be given
in this section.
Milestones:
The Manufacturing Practice is a compulsory requirement following the secondyear courses.
The due dates relating to the Manufacturing Practice have been detailed as follows:
Task
Due Date
Staj Değerlendirme Formu ve Staj Raporu’nun, en geç, stajı takip eden akademik yarıyılın
kayıt dönemi içinde ilgili Staj komisyonuna teslim edilmiş olması gerekir.
Some Useful Hints to PrepareSuccessful Summer Practice Reports:

Write your report in accordance with the requirements of the Summer Practice Guide.

Write your report in English and get it printed in ink or typed.

Provide a glossary at the end of the text, giving detailed definitions of technical terms
used in the report.

Do not use first person pronouns (I, We) in your sentences in the text.

Number all of the pages. Place the page numbers at the bottom of the page.

All of the figures and tables in the text should be numbered. Figure and table captions
should be used whenever necessary.

Engineering drawings and other illustrations (charts, diagrams etc.) should be numbered in
a systematic manner and should be placed in the “Appendix”.

Each chapter should start on a new page. The titles and subtitles should be clearly
differentiated. Each chapter and its sections must also be numbered.

Give just sufficient information for an understanding of your summer practice. NO MORE
NO LESS.

Give the reference list at the end of the main text and refer to the references by their
corresponding reference number as [5], [12] etc.
iv
IEN200MANUFACTURING PRACTICE GUIDE
1. Introduction to the Company
 Give the full title and location of the company.
 Who are the main shareholders and what are the percentages of shares they own in
the company?
 Give a brief history of the company.
 Specify the sector and typical products.
 What are the market shares of the company in domestic markets and in foreign
markets (if any)?
 Is the company a joint venture, a franchise, a member of a holding company or part
of a multinational group?
 What is the number of blue-collar workers, administrative staff, white-collar workers
working in the company?
 Briefly explain the organization of the company and provide the organization chart.
 Are there any Industrial Engineering activities carried out in the company? If there
are any, explain the functions that Industrial Engineers perform and their duties and
responsibilities.
 Describe the major facilities of the firm (buildings, warehouses, shops, garages,
docks etc.).
While deciding on the location of the facility many factors should be considered. The
most important of these factors are:
1. Distribution requirements of the final product
2. Raw material procurement easiness
3. Availability and physical characteristics of raw material
4. Physical characteristics of the product
5. Labor availability and quality, wage levels
6. Community services and attitudes
7. Transportation facilities
8. Laws, taxation and government incentives
9. Cost of land and buildings
10. Environmental factors, issues related with municipality
11. Proximity to suppliers and customers
 What are the most important location factors in selecting the current location?
1
2. Production Environment
The production system mainly serves to convert inputs into outputs. Materials are
purchased from the supplier and, with the addition of overhead, direct materials and direct
labor; they are moved forward to completion by traversing routes on the production floor.
With the addition of these items mentioned above, when the production is completed, the
products are stored in the finished goods inventory or directly delivered to customer.
 What are the major inputs and outputs of the company’s production system and
explain how these inputs are supplied to the production system.
 State the frequency of deliveries, and the usage rates of the raw materials.
 Prepare a process chart of one of the products (See Appendices 2 and 3).
 Show the material flow of items for one of the main products manufactured by the
company by means of schematic drawing(s) (See appendix 4).
Modern manufacturing involves making products from raw materials by various
processes, machinery and operations, following a well-organized plan for each step. The
broad category of manufacturing processes is the following:
Casting: Molten metal is poured into a pre-produced mold and is solidified.
Forming and Shaping: Operations that induce shape changes on the work piece by
plastic deformation under forces applied by various tools and dies.
Machining: A broad term used to describe removal of material from a work piece. It
covers several processes divided into the following categories;
1. Cutting which involves single-point or multiple-point cutting tools each with a
clearly defined geometry,
2. Abrasive processes such as grinding,
3. Nontraditional manufacturing processes utilizing electrical, chemical and optical
sources of energy.
Joining: It is an all-inclusive term, covering processes (such as, welding, brazing,
soldering, adhesive bonding and mechanical fastening) in which different parts of a
product are joined.
Finishing: It is carried out to achieve closer tolerances, provide a protective coating
and/or improve the appearance of the part.
Production quantity is crucial in determining the type of machinery and equipment-and
the level of automation-required to produce parts economically. Small quantities per year
(50 or less) can be manufactured by job-shop manufacturing in which various standard
general-purpose machine tools (stand-alone machines) or machining centers are used.
Batch production usually involves lot sizes between 100 and 5000 and utilizes machinery
with computer controls, but with specially designed fixtures for higher production rates.
Mass production involves quantities of 100000 and over and requires special-purpose
machinery called dedicated machines and automated equipment for transferring materials
and parts.
 Explain the manufacturing processes used in the company under the classification
mentioned above and how they are applied to produce different parts.
 What type of production (job-shop, batch production or mass production) exists in
the company? Describe its characteristics.
2
 What is the level of computer integration in the manufacturing environment of the
company?
 How the company uses the following techniques and/or systems in their
design/manufacturing/production planning activities?
 CAD (Computer Aided Design)
 CAM (Computer Aided Manufacturing)
 CIM (Computer Integrated Manufacturing)
 CAPP (Computer Aided Process Planning)
 FMS (Flexible Manufacturing Systems)
 ASRS (Automatic Storage and Retrieval Systems)
 If the company is not using any of these techniques/systems, provide your suggestions
on how they can be used in the company’s design/manufacturing activities.
The layout of the facility is closely related with the type of the manufacturing processes.
In general they may be classified in 4 groups. Inprocess layout,all similar equipment and
operations are gathered in the same department. To cite an instance, all the welding
operations are carried out in the single department called welding department. However,
on the other side, in product layout, equipment is arranged so that a product always
follows the same path in the production floor. Home appliances and electronic industry
are typical examples of the product layout. The grouptechnology (cellular layout) is a
combination of the above two. The equipment is arranged into cells, each cell contains
equipment to process particular family of parts. On the other hand, a project shop uses
fixed-position layout. The huge parts stay in one place and the equipment and materials
are brought near it. Ship and airplane industry are examples of these.
 What type of layout have you observed in the manufacturing environment? Is there
any combination of different layouts? If exists, explain briefly.
The flow of materials and components within the plant is essential for successive
operations. In order to achieve this, generally a material handling system is installed
whenever necessary. The objectives of material handling may be summarized as follows:
1. to eliminate handling wherever possible,
2. to minimize travel distance,
3. to minimize work-in-process, and
4. to minimize losses from waste, breakage, spoilage and theft.
Generally the following equipment is used when handling materials:
Conveyors: They are used when the material is transferred between specific points over
a fixed path.
Cranes and hoists: Cranes are generally utilized in lifting heavy material and is
indispensable for fixed-position layout. The hoists are used for lifting and transferring
material within a small area.
Industrial trucks: They are used to transfer materials over long distances, between the
different facilities of the firm.
3
Automated Guided Vehicles(AGVs): AGVs are mobile robots that are used for only
indoor material handling.
Containers and supports: Containers and supports are essential class of the material
handling systems. An example may be the containers that are used for carrying liquid or
powdered material from one location to another within the facility.
 Identify the material handling equipment in the firm. Are automated systems installed
in the firm? Explain for what purposes are they used? By sketching, identify a path
followed by one of these equipment.
Productivity may be considered as the ratio of output to some or all of the resources used
to produce the output. Several productivity ratios may be considered for a firm, such as,
the material productivity (Output/Materials Input), the labor productivity (Units
Produced/Hours Worked), and capital productivity (Output/Capital Input). Labor
productivity may, also, be defined as “output per labor hour”.
 What type of productivity figures are used in the firm? If so, explain briefly, how they
are calculated.
 For what purposes and/or at what decision-stage, productivity figures are used?
 Graph the productivity figures for the last 2 years (if available) and comment on
them.
 What types of statistical analysis and for what purposes they are used in the
company?
3. Operations Planning and Control
The production planning and control activities within the firm mainly deal with:
1. Efficiently managing the flow of materials
2. Effectively utilizing people and equipment
3. Coordinating the internal activities with those of suppliers
4. Communicating with the customers to meet their requirements
The production planning activities are indispensable for the firm. They contribute to the
firm’s objectives by satisfying the production requirements with respect to cost, volume
and quality. This system may be further divided into subsystems such as:
1. Forecasting
2. Inventory System
3. Aggregate Production Planning and Master Scheduling
4. Material Requirements Planning
5. Resource Requirements Planning and Project Management
6. Operations Scheduling and Monitoring
7. Quality Control
8. Maintenance Planning
 Choose one of the alternatives below to answer the following questions :
4
 What are the main inputs for the chosen alternative?
 What are the resources? Specify the scarce ones and explain why they are scarce.
 What critical outputs are expected at the end for the chosen alternative?
 What type of performance measures are defined and followed up for the chosen
alternative?
Alternative 1: How production planning steps are realized (on a flow chart starting
from demand determination until the completion of actual production, be sure, all
responsible people/departments , their contribution are specified clearly, in your flow
chart and your explanation should cover the above stated questions)
Alternative 2: How a project, related with operations planning and control, such as,
scrap reducing, productivity improvement, etc., can be managed?
Alternative 3: How material acquisition process is managed through the supplier firms
until making ready to the workshop.
Inventories in a classical production system may be divided into three categories. Raw
materials inventory is the unprocessed parts waiting for further operations. Work-inprocess inventory (WIP) is the partially finished parts on the production floor at various
production stages. The finished goods inventory consists of finished goods waiting for
shipment. The inventory on the production floor may result from factors such as:
1. Stocks accumulated against seasonal fluctuations
2. Stocks caused by receiving in large quantities
3. Stocks due to processing rate differences between successive production stages
4. Stocks due to transport delays during the delivery
Inventories are sometimes unavoidable and they may be an effective tool for the future
uncertainties. However, high inventory means higher invested capital, which may, in turn,
decrease the profitability of the firm. Little or no stock, on the other hand, may involve the
risk of not satisfying the demand on time and may lead to back-ordering or even lost sales.
Both extremes are costly.
 State three different items that are kept in the firm as inventory.
 Draw a graph (inventory on hand versus time) for at least one of the items. Is there a
distinctive pattern on the graph? Is it cyclic? How can you explain the pattern if
there is one? Supply your sources of data within the plot.
4. Information Technologies/Systems
Every firm has an information system. Data for decision-making and other activities are
collected, classified, summarized and processed to produce information. Generally
decision-making is carried out at three different levels in the firm. These are:
1. Strategic level decisions: (Plant expansion, merging, product line formation,
expansion plans) Usually this kind of decisions span for 3-5 years.
2. Tactical Level Decisions: (Budget formulation, personnel problems, layout
decisions, funds flow analysis) These decisions are of medium-range and generally
span from 1 month to 1 year.
5
3. Operational level decisions: (Inventory control problems, quality control problems,
worker assignment for the jobs, procurement and shipping operations). These
decisions are usually classified as daily decisions.
 Identify who are the decision-makers and what are their positions in the firm?
 Focus on one of the decision making activity in the firm and identify factors that
affect the decision making process.
 Identify the computer system (PC, main frames, workstations) which is used in the
firm and comment on the capacities of the system components.
 For what purposes are the computers being used in the firm? Does the firm have
a web page on the Internet?
 What kind of software is used in the firm? Give some examples and comment on
their uses in the firm?
 Does the firm use any software packages for Material Requirements Planning
(MRP) and/or Enterprise Resource Planning (ERP) packages? For how long are
they being used?
5. Engineering Cost Analysis:
Summer Practice provides students the opportunity to become intelligent users and/or
interpreters of financial and cost accounting information. During your practice, you
should be able to
1. evaluate the company’s financial prospects using various financial statements,
2. identify how managers use cost information,
3. determine the cost of manufacturing an individual product or batch of products, and
4. explain, how unit costs are computed.
In your analysis, consider the following questions:
 Identify the type of the company (Sole proprietorship, partnership, limited, holding,
and the like).
 Explain basic manufacturing cost components and how the unit manufacturing cost
is computed.
 What type of costing system (process or job) is used? Give an example.
 How are the expenses allocated for different cost items? If the unit cost figures are
confidential, try to estimate the cost of a specific item by using the methods you have
learned in Engineering Cost Analysis course.
 Explain, on an example, what method of depreciation is used in the firm.
 Find the balance sheet and income statement (if available) of the company for the
last three years and comment on them.
 What type of computer packages are used for engineering cost analysis and financial
calculations?
6
6. Human Factors and Work Study
Human factors engineering (simply human factors) is based upon the concept of a humantechnological system that may be described quantitatively using the standard methods of
engineering analysis. Human performance characteristics fall into two broad categories;
physiological and psychological.
Physiological performance characteristics have to do with the physical aspects of human
activities (work activities) such as physical conditions of the work environment.
Psychological performance characteristics are those dealing with the mental aspects of
human activities, such as stress, boredom and motivation.
Environmental aspects are, also, important issues that the management should take care
of. The firms should take precautions to protect the environment. Some of the precautions
are obliged by low.
 Is there any human factors engineering activity within the company? If there is, what
kinds of specialists are involved in these activities?
 Criticize the working conditions of the employees in the company. If possible analyze
the job accident data for the past three years. What are the main factors that lead to
accidents? What are the possible precautions that may be taken to reduce the
number of accidents?
 What kind of waste materials are produced as a result of activities of the firm? Are
there any chemical pollutants such as CO2,NH3, SO2,etc…? What is the firm’s policy
for dealing with the waste materials? Where are they stored? Are they disposed
haphazardly to the environment or are there any special precautions for them? Is
there any recycling facility in the firm? Comment on them.
Work-study is composed of those techniques, particularly method study and work
measurement that are used to examine the human work in all its contexts. It is performed
by systematically investigating all the factors that affect the efficiency and economy of the
situation being considered, in order, to affect an improvement.
Method study(motion study)is the systematic recording and critical examination of the
existing and proposed ways of doing work as a means of developing and applying easier,
economic, and more effective methods of work.
Work measurement(time study) is the application of techniques designed to establish the
standard time, that is, the time for a qualified worker to carry out a specified job at a
defined level of performance. The time standards may be used for planning and scheduling
purposes, and for estimating and controlling the labor cost.
For example, in production, motion and time study can be used to:
1. increase labor productivity,
2. determine work contents of successive workers in a production line to equalize the
work contents, and
3. determine capacity usage ratios of workers and machines.
The normal time for an operation does not contain any allowances. It is merely the time
that a qualified operator would need to perform the job if he or she worked at a normal
7
tempo. It is calculated, from the observed (actual or measured) time by taking into account
of the rating factor. The standard time must include time for all elements in the operation,
and in addition, it must contain for all necessary allowance (i.e., personal allowances,
fatigue allowances, and delay allowances). In other words, standard time is equal to the
normal time plus the allowances. The following formula can be used to calculate the
standard time:
Standard Time = Normal Time x (100/ (100-Allowance in percent))
Example: Assume that in a particular operation of assembling an electric switch the
operator gave a consistent performance throughout the cycle and throughout the study, and
the total selected time was 0.80 minute. With a rating factor for the study of 110 percent,
Normal time = selected time x (rating in percent / 100)
Normal time = 0.80 x ( 110 / 100) = 0.88 minute
If an allowance of 5 % for personal time were made on the assembly operation,
Standard Time = Normal Time x (100/ (100-Allowance in percent)
Standard Time = 0.88 x (100/ (100- 5) = 0.88 x ( 100 / 95 ) = 0.926 minute
 Focus on a critical task where you carry out your manufacturing practice, and
calculate normal and standard times for those operations that compose the task.
Explain how they were calculated and for what purposes they were used.
7. Quality Aspects
Product quality is one of the most important aspects of production/service systems, as it
directly influences the marketability of a product/service and customer satisfaction. One
of the important definitions of quality is the following: Quality is the total composite
product and service characteristics of marketing, engineering, manufacture and
maintenance through which the product and service in use will meet the expectations of
the customer.
Among the emerging philosophies about quality assurance, Total Quality Control (TQC)
and Total Quality Management (TQM) play important roles. TQC is an effective system
for integrating the quality-development, quality-maintenance and quality-improvement
efforts of various groups in an organization so as to enable marketing, engineering,
production and service at the most economical levels which allow for full customer
satisfaction.
TQM is both a philosophy and a set of guiding principles that represent the foundation of
a continuously improving organization. TQM is the application of quantitative methods
and human resources to improve the materials and services supplied to an organization,
all the processes within an organization and the degree to which the needs of customers
are met, now and in the future.
 If exists what is the main function of the quality (control/management/ assurance)
department?
 Which of the following activities are realized by the quality department (receiving
inspection, in-process quality control and final inspection)
8
 If a quality policy exists in the firm what are the main messages given to the
customers and employees?
 What are the basic quality and total quality management tools used by the firm
(statistical process control, acceptance plan, etc...).
8. Conclusions and Reccommendations
Students are required to write down general conclusions about their summer practice
experience; to comment on the areas, if any, in which industrial engineers are employed
by the firm; and to discuss the top management’s impression and attitudes towards
industrial engineering functions and activities. They are required to evaluate the firm
from an industrial engineer’s point of view taking into account of the organization itself,
and the management information system used in the organization, production/operations
planning and control applications, human factors considerations, and quality control
measures employed within the firm. They are, also, expected to identify the problems
within the firms, where they carry out their summer practice, relating to some industrial
engineering applications and the reasons lying behind these problems; and develop and
suggest solution alternatives.
9. Reference List
1. Turner, W. C., Mize, J. H., Case K. E. and Nazemetz J. W. (1993), Introduction to
Industrial and Systems Engineering, Prentice Hall, USA.
2. Kolarik, W. J.(1995), Creating Qulity - Concepts, Systems, Strategies and
Tools,McGraw-Hill International Editions , Industrial Engineering Series , USA.
3. Phillips, C. A. (2000), Human Factors Engineering, John Wiley and Sons Inc.,
USA.
4. Barnes, R. M. (1980), Motion and Time Study Design and Measurement of Work,
John Wiley and Sons Inc., USA.
5. Hicks, P. E. (1994), Industrial Engineering and Management, A New Perspective,
McGraw-Hill International Editions, Industrial Engineering Series, USA.
6. Russell, R.S. and Taylor, B.W. (1999), Operations Management, 3rd Edition,
PrenticeHall, TS.155.RUS.
7. http://www.izmir.edu.tr/tr/images/stories/yonetmelik_yonerge/Izmir_Universitesi_S
taj_Yonergesi.pdf
8. İzmir Üniversitesi Mühendislik Fakültesi Staj Uygulama Esasları
9. Mühendislik Fakültesi Staj Formları
10. Appendices
Appendix 1 Cover Page.
Appendix 2 Process chart symbols.
Appendix 3 Assembly process chart – Baking soda crackers.
Appendix 4 A typical flow diagram for a make –to-stock manufacturing firm.
Appendix 5 IEN 200 Manufacturing Practice Course Syllabus.
Appendix 6Frequently Asked Questions
9
Appendix 1 Cover Page
İZMİR UNIVERSITY
FACULTY OF ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
MANUFACTURING PRACTICE REPORT
[Name of the Company]
Submitted to: [Name of Summer Practice Coordinator]
Submitted by:[Name and ID number of the student]
[Submission Date]
İZMİR / TURKEY
10
Appendix 2. Process Chart Symbols with Examples
11
Appendix 3: Assembly Process Chart - Baking Soda Crackers
12
Appendix 4: A Typical Flow Diagram for Make-to-Stock Manufacturing Firm
Sales Department
Picking List
Production Forecasts
Production Planning Department
Work Order Release
Purchasing Department
Stock Requirements
Inventory Records
Purchase Orders, Kanbans
Vendors
Stores
Raw Materials, Parts
Raw Materials, Parts
Move ticket, kanbans,
Move ticket, kanbans
Route sheet
Raw Materials, Parts
Manufacturing Department
Receiving Department
Sub-assemblies
Move ticket, assembly
Charts
Assembly Department
Finished Goods
Move ticket,
Kanbans
Bill of Lading
Receiving Report
Accounting Department
Shipping Report
Payment
Invoice
Warehouse
Finished Goods
Shipping Release
Dispatch List
Distributors
Sales Order, kanbans
Customer
Finished Goods
Flow of Materials
Flow of Information
13
Appendix 5 IEN 200 Manufacturing Practice Cource Syllabus
IEN 200 MANUFACTURING PRACTICE COURSE SYLLABUS
Course Name
Manufacturing Practice
Code
Semester
IEN 200
Spring
Theory
Application Laboratory Local
ECTS
(hour/week) (hour/week) (hour/week) Credits
Prerequisites
None
Course Language
English
Course Type
Required
Course Level
Undergraduate
Mode of Delivery
0
0
Yrd. Doç. Dr. Bayram Ali SU
Course Lecturer(s)
-
Course Assistants
Hazar ALTINBAŞ
Course Learning Outcomes
Course Content
0
3
Introductory Lectures
Power Point Slides
Internship
Written Sources
Internet Sources
Course Coordinator
Course Objectives
0
This course is designed to guide the student for observation, structured
information gathering and analysis of a manufacturing company via a
minimum of 5 weeks (25 working days) training in a manufacturing
facility.
The students who succeeded in this course will be able to
1. Observe and identify various departmental functionalities and
interactions of a real-life company.
2. Develop a broad perspective on industrial engineering systems and
roles/responsibilities of industrial engineers.
3. Develop formal report writing skills through written presentations.
25 work days hands-on-experience in a manufacturing company and
preparation of a written Summer Practice report according to Summer
Practice Guide prepared by the department.
WEEKLY SUBJECTS AND RELATED PREPARATION STUDIES
Week
Subjects
1
General overview of the company/ establishment
2
Management information systems and engineering
cost analysis
3
Study of production environment, operations
planning and control
4
Study of production environment, operations
planning and control
5
Analysis of human factors and quality applications
Related Preparation
14
SOURCES
Course Notes /
Textbooks
1.
References
2.
3.
Barnes, R. M.,Motion and Time Study Design and Measurement of Work, John
Wiley and Sons Inc., USA, 1980.
Hicks, P. E.,Industrial Engineering and Management, A New Perspective,
McGraw-Hill International Editions, Industrial Engineering Series, USA, 1994.
Russell, R.S. and Taylor, B.W.,Operations Management, 4th Edition, Prentice Hall,
2002.
EVALUATION SYSTEM
Semester Requirements
Number
Percentage of Grade
1
100
Total
1
100
PERCENTAGE OF
SEMESTER WORK
1
100
1
100
Attendance
Participation
Laboratory
Application
Field Work
Special Course Internship (Work
Placement)
Quizzes
Homework Assignments
Presentation
Project
Seminar
Midterm(s)
Final Report
PERCENTAGE OF FINAL
WORK
TOTAL
COURSE CATEGORY
Core Courses
Course Category
X
Major Area Courses
Elective Courses
15
THE RELATIONSHIP BETWEEN COURSE LEARNING OUTCOMES AND PROGRAM
QUALIFICATIONS
No
Level of Contribution
1
2
3
4
5
Program Qualifications / Learning Outcomes
1
Ability to apply the acquired knowledge in mathematics, science and
engineering
X
2
Ability to identify, formulate and solve complex engineering problems
X
3
Ability to accomplish the integration of systems
X
4
5
Ability to design, develop, implement and improve complex systems,
components, or processes
Ability to select/develop and use suitable modern engineering techniques and
tools
X
X
6
Ability to design/conduct experiments and collect/analyze/interpret data
X
7
Ability to function independently and in teams
X
8
Ability to make use of oral and written communication skills effectively
X
9
Ability to recognize the need for and engage in life-long learning
X
10
Ability to understand and exercise professional and ethical responsibility
X
11
Ability to understand the impact of engineering solutions
X
12
Ability to have knowledge of contemporary issues
X
*1 Lowest, 2 Low, 3 Average, 4 High, 5 Highest
ECTS / WORKLOAD TABLE
Activities
Number
Duration
(Hours)
Total Workload
4
20
80
Course Hours
Laboratory
Application
Special Course Internship (Work Placement)
Field Work
Study Hours Out of Class
Presentations / Seminar
Project
Homework Assignments
Quizzes
Midterms
Final
TOTALECTS
80 hours / 25 =
3 ECTS
16
Appendix 6 Frequently Asked Questions
1. What is the aim in making a summer practice?
Students, often, are not sure which career path to follow. A summer practice provides a way
for the student to find out about a particular profession before it is too late. After carrying out
a summer practice, students learn a lot about the business and they will get a chance to assess
their personalities, past experiences, hobbies, and preferences which will impact them,
positively, to make the right selection for their career.
Summer Practices are often a vital ingredient in the undergraduate experience. Most of the
prestigious companies recommend students to complete at least two internships during their
undergraduate education. A summer practice is usually the only job experience that a student
can have. Summer practices are highly critical items that attract attention to a recently
graduated student’s resume. Many students without internships are at a competitive
disadvantage because more and more employers are requiring internships [as a hiring
qualification].
Prestigious institutions are usually highly selective evaluating the summer practice applicants.
For such companies, summer practice is a testing period where the practitioners are assessed
for future or current job-openings. These companies in certain occasions directly offer jobs to
those students who complete a successful summer practice period. Hence a summer practice
may easily turn out to be a visa to one of such companies, if appropriately done.
2. How can you find an institution for your summer practice?
Finding a good institution for the summer practice can be a tedious process, but, still, there
are chances to find a good one if you are motivated well and make good use of your
resources.
a. The Department. The first step is to head over to us. Your instructor’s will help you with
a self-assessment process that will guide you toward the right field for your practice, and
your geographic options. Students can browse through practice opportunities in the
department with the help of instructors.
b. On-line. In addition to your department, there are hundreds of career-consulting sites that
you may reach on-line using a search engine like Yahoo or AltaVista by querying the
word “internship”. These sites also give coaching services on various issues like writing
successful resumes, interviewing, and self-assessment.
17
c. Books. Finding a book on summer practice/internship is pretty easy, but many students
don't want to pay much for a book from which they'll only need five pages. The other
problem with books is that it's hard to keep them up to date. Students may check local
book-stores or others like Amazon.com on the Internet.
d. The direct approach. One other way is to go right to the source. If you are interested in a
particular field and you have a particular company you would like to work for, contact
the company's human resources or personnel department. The staff should be able to
inform you of any internship opportunities. You may use the company’s web site for
obtaining a contact, ask the operator whether anyone can help you and be leaded to the
right person that may give you the good news.
3. Suggestions to tackle with the problems confronted while performing your summer
practice
a. Your supervisors are not giving you any responsibilities
Companies are liable in front of the law to accept certain amount of trainees in each year.
While some companies have serious practice and orientation programs for these trainees,
others see this type of practices as an overhead to their company. Unfortunately in certain
companies practitioner’s exact duties, hours, and dates of employment are not defined.
This leads summer practices to become entry-level appointments, clerical positions, or
mindless "go-for" work. If you are faced with a condition like this what you ought to do is
to request for a more substantive, challenging, and professional work from your
supervisors. Be active and search for opportunities.
b. You do not know the meanings of the terms used in the Summer Practice Guide, and
therefore, you can not answer them
The guideline is a tool for us, to ensure that you are really getting something form your
practice. Do not see the guideline as a burden. Instead, see it as a supplementary that
shows you the way for developing yourself. Ask it to your supervisors when you do not
know the meaning of a term used in the guideline. See the references or try to collect
information form the Internet.
18