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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: $23.95


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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.

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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

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Table of Contents

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