Industrial Engineering Training

Lesson 1 • IE Tools and Professional Standards

Surveys standard IE tools—flowcharts, cause-and-effect diagrams, and checklists. Connects tool selection to professional and ethical practice standards.

Lesson 2 • Systems Thinking and Process Perspective

Introduces systems thinking as the analytical lens for IE practice. Students model organisations as interconnected processes with inputs, outputs, and feedback.

Lesson 3 • Quantitative Reasoning for Engineers

Reviews essential maths and statistics used throughout IE coursework. Builds fluency in data interpretation, probability, and basic modelling.

Lesson 1 • Work Sampling and Activity Analysis

Uses statistical sampling to estimate activity proportions without continuous observation. Students design valid sampling studies and interpret results.

Lesson 2 • Methods Improvement and Documentation

Formalises improved methods through standard operating procedures and visual aids. Ensures changes are sustainable and transferable across shifts.

Lesson 3 • Method Study Fundamentals

Covers the six-step method study procedure from problem selection to implementation. Anchors all subsequent work analysis techniques in a disciplined framework.

Lesson 4 • Process and Flow Charting Techniques

Teaches ASME process chart symbols and flow diagram construction. Students document material and operator movement to expose non-value-adding steps.

Lesson 1 • Time Study Preparation and Equipment

Covers observer positioning, element breakdown, and timing equipment selection. Proper preparation ensures valid, repeatable time study data.

Lesson 2 • Performance Rating Techniques

Teaches Westinghouse, synthetic, and pace rating systems to normalise observed times. Accurate rating is the critical link between observed and normal time.

Lesson 3 • Predetermined Motion Time Systems

Introduces MTM and MOST as alternatives to stopwatch study for new or low-volume work. Students build time standards from motion-level data.

Lesson 4 • Allowances and Standard Time Calculation

Derives personal, fatigue, and delay allowances from data and policy. Students compute standard time and validate it against historical records.

Lesson 1 • Workstation and Tool Design

Translates anthropometric and biomechanical data into workstation and hand-tool specifications. Reduces awkward postures and excessive force requirements.

Lesson 2 • Ergonomics Programme Management

Structures a facility-wide ergonomics programme with hazard reporting, training, and metrics. Connects individual assessments to systemic injury prevention outcomes.

Lesson 3 • Musculoskeletal Risk Assessment

Applies RULA, REBA, and NIOSH lifting equation to quantify injury risk. Students prioritise interventions based on risk scores and exposure frequency.

Lesson 4 • Human Capabilities and Limitations

Covers anthropometric data, sensory limits, and cognitive load as design inputs. Establishes the human-centred foundation for all ergonomic interventions.

Lesson 1 • Material Handling System Design

Selects and integrates material handling equipment with the facility layout. Applies the ten principles of material handling to minimise cost and risk.

Lesson 2 • Space Requirements and Determination

Calculates space needs for equipment, operators, aisles, and storage using systematic methods. Ensures layouts accommodate material handling and safety clearances.

Lesson 3 • Layout Generation and Evaluation

Generates block layouts using systematic layout planning and computerised tools. Evaluates alternatives on cost, flow efficiency, flexibility, and safety.

Lesson 4 • Flow and Activity Relationship Analysis

Uses from-to charts and relationship diagrams to quantify and qualify department adjacency needs. Provides the data foundation for layout generation.

Lesson 1 • Just-in-Time and Pull Systems

Contrasts push MRP with pull-based kanban and JIT replenishment logic. Students size kanban loops and identify prerequisites for JIT implementation.

Lesson 2 • Demand Forecasting Methods

Covers qualitative and quantitative forecasting techniques including moving averages and exponential smoothing. Accurate forecasts drive all downstream planning decisions.

Lesson 3 • Inventory Management Models

Applies EOQ, reorder point, and safety stock models to minimise total inventory cost. Connects inventory policy to service level and demand variability.

Lesson 4 • Aggregate Production Planning

Develops medium-range plans balancing workforce, inventory, and subcontracting strategies. Students evaluate chase, level, and mixed strategies using cost models.

Lesson 1 • Acceptance Sampling Plans

Designs attribute and variable sampling plans using OC curves and risk parameters. Balances producer and consumer risk in incoming and outgoing inspection.

Lesson 2 • Process Capability Analysis

Calculates Cp, Cpk, and Ppk indices to assess whether processes meet specification limits. Students identify capability gaps and prioritise improvement actions.

Lesson 3 • Quality Management Principles

Establishes quality cost categories, customer-focused quality definitions, and management system frameworks. Provides strategic context for all technical quality tools.

Lesson 4 • Root Cause Analysis and Corrective Action

Applies 8D, 5-Why, and fault tree analysis to identify and eliminate defect root causes. Closes the quality loop with verified corrective and preventive actions.

Lesson 1 • Value Stream Mapping

Creates current-state and future-state value stream maps to visualise flow and target improvement. VSM is the primary strategic tool for lean transformation planning.

Lesson 2 • Kaizen Event Planning and Execution

Structures rapid improvement events from charter development through follow-up action tracking. Students facilitate team-based kaizen and sustain gains post-event.

Lesson 3 • 5S Workplace Organisation

Implements Sort, Set in Order, Shine, Standardise, and Sustain to create a stable work environment. 5S is the foundation for all other lean tools.

Lesson 4 • Lean Metrics and Sustaining Improvement

Tracks OEE, takt time, lead time, and first-pass yield to measure lean progress. Establishes visual management systems that sustain gains over time.