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Handbook of Industrial, Systems, and Quality Engineering

Copyright © January 7, 2021 by Robert Wayne Atkins, P.E.
All Rights Reserved.


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ISBN: 978-1-7327883-8-1
Type of Book: Paperback
Book Size: 6 inches by 9 inches
Number of Pages: 700
Normal Price: $19.95

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Book Description on Amazon.com

Why is there only one handbook for the three branches of engineering? The reason is because the same body of knowledge is used by industrial engineers, systems engineers, and quality engineers. Therefore each of these individuals needs to understand all the concepts in this handbook because the concepts are all interrelated. The primary difference between these three types of engineers is the area in which they specialize. But each of these engineers needs to understand how their decisions impact their entire organization.

Why do engineers need a reference handbook? The reason is because it is relatively easy for most engineers to remember the details of the engineering concepts we use on a regular basis. However, it is not always easy to remember the precise details of engineering concepts we only use occasionally. Although we usually remember the general details about a specific concept, we may not remember all the nuances and equations about the concept. That is why most engineers have a good engineering handbook in their office or somewhere near their desk. When they suspect that a specific concept may be relevant to the engineering decision they are currently confronted with, then being able to quickly and easily refresh their memories about the exact details of that concept helps them to determine if a specific concept is relevant to their decision. And if it is relevant then they can quickly and correctly apply the concept using the procedure as explained in the engineering handbook. In most cases the engineer is not learning the concept for the first time. Usually the engineer is simply refreshing his or her memory about a concept that the engineer mastered at some time in the past. But the engineer does not remember the concept and the equations with the precise clarity that is required at the current time. That is why many engineers purchase a good engineering handbook that concisely and clearly explains the engineering concepts they may only need to use occasionally if the need should arise.

Another reason that many engineers purchase a good engineering handbook is because it allows them to find the information they need quickly. This helps them to use their time productively and they do not waste time searching the internet for a good summary of the information they need that contains enough information but which is also not overwhelming. And it also allows them to avoid internet websites that are cluttered with annoying ads and other stuff that interferes with the proper absorption of the information they are looking for.

This handbook was written so it could be successfully used by engineers, managers, supervisors, and other individuals who desire to enhance the operations of their organization by improving quality, increasing productivity, and reducing total costs.

This handbook does contain technical terminology but all the concepts are explained in simple English and a college degree in engineering is not required to understand and apply the concepts in this handbook.

Finally, it should be mentioned that this handbook does not contain any color pictures. The reason is because color pictures increase the cost of a printed book by about 400% when compared to a book without color pictures. Since it is my desire that a printed copy of this handbook should be extremely affordable, there are no color pictures in this handbook.


Preface to
Handbook of Industrial, Systems, and Quality Engineering

Engineers need to be able to think abstractly. But they also need to be able to clearly understand the actual impact of their decisions. The early editions of Industrial Engineering Handbooks were heavily focused on the application of traditional Industrial Engineering concepts. However, as time passed more theory was included and some of the practical applications were omitted. In the twenty-first century these handbooks are heavily focused on theory and they only contain a trivial amount of practical applications of basic engineering concepts.

From 1984 to 2021 I taught engineering concepts at a major state university and I have seen how engineering courses have evolved during this time period. Most of the changes have enhanced the ability of a student to grasp fundamental engineering concepts. However, as technology has advanced some engineering courses are teaching students how to use software and technology to solve engineering problems. This is both good and bad. It is good because it enables an engineer to arrive at a mathematically correct solution very quickly based on the data that is entered. It is bad because it does not guarantee that the solution is correct for the application to which it is being applied.

As an engineer I personally use handheld calculators and Microsoft Excel. And I encourage engineering students to use calculators and Excel. But I also insist that an engineering student be able to explain every answer in simple English. And the student must also explain the technical and financial impact of the answer. In other words, I do not simply want to know that the answer is 847. I want to know exactly what that number means in the context of the engineering problem the student is solving.

In this handbook I explain basic engineering concepts in simple English. And I also explain how that knowledge should be applied to the actual engineering problem that it was designed to resolve.

But I do not explain how to use any of the software that is currently available, or how to use specific pieces of equipment. The reason is because software and hardware are both changing extremely rapidly and any book that explains how to use the software or hardware that is currently available will be obsolete in 2 or 3 years. But a book that explains engineering concepts in simple English will still be of value for many years because it will explain how an engineer needs to think in order to arrive at a good engineering solution. A modern engineer who knows how to think like a traditional engineer will be able to easily adjust to the new software and hardware as it becomes available because that engineer will understand what the software and the hardware is doing. For example, an engineer who knows the basic multiplication tables can easily master the use of a new handheld calculator, and that engineer will also have a basic understanding of what the software is doing inside the new calculator to process the mathematical equation the engineer enters. The reason is because the basic math concepts have not changed. Only the design of the calculator has changed.

This information in this handbook is timeless and it does not depend on software or hardware. The information in this handbook depends on an engineer's ability to think like an engineer and this type of thinking does not change with the passage of time. Therefore this handbook will not need to be updated every 2 or 3 years.

Respectfully,
Robert Wayne Atkins, P.E.
January 7, 2021


Table of Contents

Chapter Page
Section One: Introduction
1Academic Approach versus a Practical Approach 1
2Computer Hardware and Computer Software 5
3History of Industrial, Systems, and Quality Engineering 9
4Safety 15
Section Two: Charting Techniques
5Charting Symbols 19
6Operation Process Charts 23
7Flow Process Charts and Flow Diagrams 27
8Left Hand - Right Hand Charts 37
9Multiple Activity Charts 41
10Histograms, Frequency Distributions, Bar Charts 45
11Scatter Diagrams 49
12Affinity, Structure Tree, and Force Field Diagrams 53
Section Three: Probability and Statistics
13Basic Math, Algebra, Geometry, Trigonometry 57
14Probability Theory 65
15Basic Statistics: Averages, Variability, and Proportions 71
16Discrete Distributions: Hypergeometric, Binomial, Poisson 77
17Continuous Distributions: Normal, Exponential, Weibull 87
18Minimum Sample Size 103
19Simple Linear Regression 107
20Reliability 117
21Queuing Theory 131
Section Four: Quality Theory and Practice
22A Brief History of the Evolution of Quality Theories 139
23Quality Standards and Continuous Improvement 143
24Quality Acceptance Sampling Plans 147
25Quality Control Charts 167
26Lean Six Sigma, 7 QC Tools, SPC, Root Cause Analysis 197
Section Five: Metrology, Calibration, and Gage Studies
27Metrology: The Science of Measurements 207
28Standards and Procedures 213
29Basic Calibration Concepts 223
30Gage Studies: Repeatability and Reproducibility 239
Section Six: Job Analysis
31Job Analysis and Data Collection Techniques 255
32Learning Curves 263
Section Seven: Human Factors and Ergonomics
33Anthropology and Anthropometry 279
34Human Factors Engineering and Ergonomics 281
35Motion Study and Therbligs 285
36Motion Economy Principles 289
Section Eight: Work Measurement
37The History and the Future of Work Measurement 299
38Element Analysis 301
39Personal, Fatigue, and Delay Allowances 305
40Work Measurement and Engineered Standards 319
41Performance Rating, Pace/Speed Rating Systems 329
42The Best Pace/Speed Rating System & 100% Performance 343
43Time Study 357
44Work Sampling 381
45Predetermined Motion Time Systems (PMTS) 387
46Walter G. Holmes' Predetermined Motion Time System 399
47Methods-Time Measurement (MTM) 419
48Maynard Operation Sequence Technique (MOST) 443
49Basic Engineered Standard Times for a Few Activities 447
50Quotas and Engineered Standard Times for New Jobs 453
Section Nine: Project Management
51Introduction to Project Management 461
52Project Control Tools: PERT, CPM, and Gantt Charts 467
53Implementation Timetables 475
Section Ten: Inventory Management
54Forecasting Future Sales 477
55Inventory Management 481
56Production Planning and Control 493
Section Eleven: Facilities Design and Plant Layout
57The Facilities Planning Process and a Feasibility Study 499
58Warehouse Management 507
59Manufacturing Decisions 525
60Workstation Layouts for Manufacturing Operations 537
61Labor Estimates 541
62Scrap Loss Estimates 543
63Employee Service Areas and Offices 545
64Activity Relationships and Block Diagrams 555
65Plant Layout 561
66Facility Location and Site Selection Criteria 567
67Plot Plan or Site Plan 579
Section Twelve: Financial Analysis
68Depreciation Methods 587
69Product Costing and Process Costing 597
70Financial Statements 603
71Cost of Goods Sold and Overhead Allocation Methods 609
72Engineering Economic Analysis, Engineering Economy 613
Section Thirteen: Process Improvements
73Team Dynamics 623
74Productivity: How to Measure It and How to Improve It 639
75How to Implement Changes 643
Section Fourteen: Effective Communication Skills
76Formal Reports 645
77Professional Presentations 647
78Your Professional Image and Appearance 655
Appendix: Reference Tables 663
Index 687
About the Author 692

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Grandpappy's e-mail address is: RobertWayneAtkins@hotmail.com

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