Industrial Engineering and Production Design

IET is a full service industrial and manufacturing engineering firm. We serve as engineering and manufacturing consultants in addition to providing hands-on support. With a comprehensive range of capabilities in our toolkit from business process reengineering to plant layout analysis, we improve our clients’ competitiveness.

Our Production Design Chart is shown below. To learn more about our tools, click on a service from the list to the right or from the Service menu at the top.

Strategic Design

· Production relationships / philosophy

· General capacity / capital requirements

· Space allocation and planning

· Plant layout and vision

· Create current state process maps for each product family

· Conduct functional area relationship assessment

· Develop general capacity plan

· Develop general space analysis

· Prepare conceptual facility layout options

Detail Design

· Detail design for all flows

· Simplification

· Visual control

· Flexible use of all assets

· Appropriate plan for all working capital

· Effective performance design

· Identify product families and demand variation

· Perform detailed work sampling / measurement of production

· Develop current state summary / opportunity assessment

· Develop detailed equipment capacity analysis

· Perform detailed storage space requirements analysis (PFEP)

· Develop detailed plant layout

· Develop detailed work design

· Develop future state process map

Implementation Assistance

· Performance to design

· Continuous improvement

· Sustainability

· Launch success

· Shop floor design adjustments

· Production philosophy support

· Supervision & production support education

· Performance passion

Facility Layout / Design

If you can answer “No” to any of the following questions, IET can help you!

Is the production layout designed to meet our customer’s varied demand?
Do we have a place for everything (PFEP)?
Do we understand all of the flows for our new production design?
Have we separated pedestrian and vehicle traffic?
Our tools can assist you with your current or proposed facility layout in the following areas:

Existing Facility Layout Documentation on CADD
Manufacturing System Layout / Workplace Design
Manufacturing Consolidation or Relocation
Cellular Layout
Lean Manufacturing Design
Process and Material Flow Analysis
Space Utilization Analysis
Material Handling Design
Storage Analysis
Work Measurement

If you can answer “No” to any of the following questions, IET can help you!

Have we established realistic and flexible production standards?
Have we designed our indirect activities?
Can we explain the difference between current performance and 100% OEE?
Can we flex our labor requirements as volume and mix change?
IET can provide work measurement utilizing the appropriate tools for the client’s needs.

Time Studies to Determine Standards
Predetermined Time Standards
Methods Analysis
Line Balancing
Delay and Downtime Analysis
Overall Equipment Effectiveness (O.E.E.)
Work Sampling Studies
Direct and Indirect Labor Analysis
Labor Utilization
Standard Operating Procedures and Job Instructions
Ergonomic Evaluation
Production Variance Analysis
Capacity Analysis
Strategic Planning

If you can answer “No” to any of the following questions, IET can help you!

Do we know our strategic production flows?
Have we challenged the use of non-value added space?
Do we have a plan and measurement system for appropriate and timely performance improvement?
Our comprehensive toolkit includes a complete project management package. This may include preparing and presenting reports to your customer, monitoring the progress of your suppliers, preparing and following up on action plans and general coordination of any of the project’s activities.

Consolidation Evaluation
Make or Buy Analysis
Cost Analysis
Economic Modeling or Potential Costs, Savings and Justification
Project Management
CPM Diagrams and Action Plans
Value Stream Mapping
Production Planning

If you can answer “No” to any of the following questions, IET can help you!

Do we understand the implications of varied demand upon our constraints, space, and line balance?
Can we flex shifts and labor line-up to meet varied levels of production requirements?
Have we appropriately maximized asset utilization?
IET can assist with your production planning needs in a variety of ways:

Strategic plant flow
Production mix strategy
Shift schedule design
Value added work content design
Goal-setting and feedback design
Expansion planning

If your production system is difficult to model in a spreadsheet because of the many variations or you need to get your entire production team on the same page regarding your new design, simulation may be the tool to help you.

At IET, we use Witness simulation modeling software from Lanner to develop our models. Our simulation models evaluate equipment arrangements, material handling alternatives, labor balancing or assembly line sequencing. Areas of analysis include the following:

Proposed Manufacturing System Evaluation
Production Bottleneck Evaluation
Labor Efficiency and Manning
Product Mix, Scrap Rates, Set-ups, Downtime, etc.
MES: Manufacturing Execution System

If you can answer “Yes” to any of the following questions, IET can help you!

Is it time to automate the production monitoring and feedback systems?
Will immediate performance feedback support the challenges of production supervision?
Is production loss documentation and feedback (scrap and rework) a challenge for the production team?
IET partners with Nysus Solutions to provide the Manufacturing Execution System (MES). MES is a web application framed around quality assurance through providing automated work instructions. The MES system interfaces with PLCs and Databases in order to provide feedback to the operator even where feedback has not been readily available before.

System Features

Automated Work Instructions
Integration of PLC and Torque Tools
Bar Coding and Part Traceability
Operator Tracking
Machine Monitoring
Quality Alerts and OJT Verification
Production Scheduling and Sequencing
Production Dashboards
Pick to Light Display
Product Testing
Vision System Integration
Warehouse Management Systems (WMS)
Full System Integration
Supplier Portal Systems
Contract Engineering

If you can answer “Yes” to any of the following questions, IET can help you!

Do we need Industrial Engineering assistance that can immediately work independently?
Do we need quality engineering that can immediately integrate with our current team?
Do we need production launch support?
Do we have a significant data collection effort that requires technical expertise?

IET, Inc. can provide a wide variety of engineering staffing solutions to meet your needs. From quality engineering, mechanical engineering, project management, production and maintenance supervision, IET can provide solutions to your needs on a short or long-term basis. IET has the expertise to provide contract engineering support across all industries.

IET can provide contract support in the following areas:

Mechanical Engineering
Manufacturing Engineering
Quality Engineering
Project Management
Process Engineering
Production Supervision
Maintenance Supervision
Industrial Engineer Training

Would Industrial Engineering training provide consistency throughout your organization? IET offers the following group training in your facility

VIA, Productivity Improvement Through Time Study®
VIA, World Class Manufacturing®
Six Sigma Greenbelt
Quality Engineering and Management Services

In addition to IET’s Industrial Engineering solutions, we also offer Quality Engineering and Process Improvement services and provide a hands-on approach to assist in development of, and/or implementation of, your Quality Management or Continuous Improvement projects.

We provide Quality Engineering services including all facets of the APQP process from product inception through the entire PPAP process and on to successful production launches. Have an upcoming audit? We can help with gap analysis, authoring or updating policies or procedures and employee training. We have experience with TS-16949, the ISO 9000 standards and ISO/IEC 17020 as well as many OEM requirements.

IET can also provide assistance with process improvements and problem solving. We can help you solve problems, reduce waste and improve your processes using Six Sigma and Lean Manufacturing tools to identify root cause, choose the appropriate corrective action and, most importantly, put in place a sustainable preventive action to prevent recurrence.

So whether you need Industrial Engineering or Quality Engineering services to supplement existing efforts, IET has the resources, knowledge and experience to be your one-stop solution destination for your next project or to meet quickly approaching deadlines.