# Industrial Engineering - Processes Backlog

This document contains the Phase 2 backlog of processes for the Industrial Engineering specialization. These processes cover key activities across operations research, lean manufacturing, quality engineering, ergonomics, supply chain management, and production planning.

## Table of Contents

- [Operations Research and Optimization](#operations-research-and-optimization)
- [Lean Manufacturing and Continuous Improvement](#lean-manufacturing-and-continuous-improvement)
- [Quality Engineering](#quality-engineering)
- [Ergonomics and Human Factors](#ergonomics-and-human-factors)
- [Supply Chain and Logistics](#supply-chain-and-logistics)
- [Production Planning and Scheduling](#production-planning-and-scheduling)

---

## Operations Research and Optimization

### 1. Linear Programming Model Development

**Description:** Formulate and solve linear programming models for resource allocation, production planning, blending problems, and capacity optimization using mathematical optimization techniques.

**Key Activities:**
- Define decision variables, objective function, and constraints
- Model real-world problems in mathematical programming format
- Implement models using optimization solvers (CPLEX, Gurobi, OR-Tools)
- Validate model accuracy against known solutions
- Interpret results and perform sensitivity analysis
- Document assumptions and limitations

**Outputs:**
- Mathematical model formulation document
- Solver implementation code
- Sensitivity analysis report
- Decision recommendations with justification

---

### 2. Discrete Event Simulation Modeling

**Description:** Build discrete event simulation models to analyze system performance, test process changes, and support capacity planning decisions without disrupting actual operations.

**Key Activities:**
- Define simulation scope, objectives, and key performance indicators
- Collect input data and fit statistical distributions
- Develop simulation model logic and validate against real system
- Design and execute simulation experiments
- Analyze output statistics with confidence intervals
- Present scenario comparison results

**Outputs:**
- Simulation model (Arena, AnyLogic, SimPy, or FlexSim)
- Input data analysis and distribution fitting report
- Validation and verification documentation
- Experiment design and results analysis
- Recommendations report with visualizations

---

### 3. Queuing System Analysis

**Description:** Analyze queuing systems to optimize service capacity, reduce wait times, and improve customer satisfaction using queuing theory and simulation.

**Key Activities:**
- Characterize arrival and service patterns statistically
- Select appropriate queuing model (M/M/1, M/M/c, M/G/1, etc.)
- Calculate steady-state performance measures analytically
- Develop simulation for complex or non-standard systems
- Evaluate staffing scenarios and service level tradeoffs
- Recommend optimal capacity configuration

**Outputs:**
- Queuing system characterization document
- Performance metrics calculations
- Simulation validation results
- Staffing recommendations with service level analysis
- Implementation guidelines

---

### 4. Multi-Criteria Decision Analysis

**Description:** Apply structured decision analysis methods to evaluate alternatives against multiple conflicting criteria using techniques such as AHP, TOPSIS, or weighted scoring.

**Key Activities:**
- Define decision problem structure and stakeholders
- Identify evaluation criteria and alternatives
- Elicit criteria weights from decision makers
- Score alternatives against criteria
- Perform sensitivity analysis on weights
- Document decision rationale and recommendation

**Outputs:**
- Decision hierarchy or criteria tree
- Pairwise comparison matrices and consistency checks
- Alternative scoring matrices
- Sensitivity analysis results
- Decision recommendation report

---

## Lean Manufacturing and Continuous Improvement

### 5. Value Stream Mapping and Analysis

**Description:** Create current and future state value stream maps to identify waste, improve flow, and develop implementation plans for lean transformation.

**Key Activities:**
- Define product family and value stream boundaries
- Walk the process and collect current state data
- Create current state value stream map with metrics
- Identify waste and improvement opportunities
- Design future state map with lean flow concepts
- Develop implementation plan with kaizen bursts

**Outputs:**
- Current state value stream map
- Waste identification and quantification
- Future state value stream map
- Implementation roadmap with priorities
- Metrics dashboard for tracking progress

---

### 6. Kaizen Event Facilitation

**Description:** Plan, facilitate, and follow up on rapid improvement events that achieve measurable results within a focused timeframe (typically 3-5 days).

**Key Activities:**
- Define kaizen scope, objectives, and success metrics
- Select and prepare cross-functional team members
- Facilitate current state analysis and waste identification
- Guide team through solution development and testing
- Implement changes during the event week
- Establish sustainment plan and 30/60/90 day follow-up

**Outputs:**
- Kaizen event charter and preparation checklist
- Current state documentation and baseline metrics
- Implemented improvements with before/after comparison
- Standard work documentation
- Sustainment plan and audit schedule

---

### 7. 5S Workplace Organization Implementation

**Description:** Implement 5S methodology (Sort, Set in Order, Shine, Standardize, Sustain) to create organized, efficient, and safe work environments.

**Key Activities:**
- Assess current workplace organization maturity
- Conduct Sort phase with red tag process
- Design Set in Order layouts with visual management
- Establish Shine cleaning and inspection standards
- Create Standardize checklists and visual controls
- Develop Sustain audit program and recognition system

**Outputs:**
- 5S assessment baseline scores
- Red tag log and disposition records
- Workplace layout drawings with labeling standards
- Cleaning and inspection checklists
- 5S audit forms and scoring system
- Visual management standards

---

### 8. Standard Work Development

**Description:** Document and implement standard work to establish the current best method, ensure consistent quality, and provide a baseline for improvement.

**Key Activities:**
- Observe and time multiple operators performing the work
- Identify the safest, highest quality, most efficient method
- Document work elements with sequence and timing
- Create standard work combination sheet and layout
- Train operators and supervisors on standard work
- Establish audit process for compliance

**Outputs:**
- Time observation forms and analysis
- Standard work combination sheet
- Standard work layout diagram
- Job instruction breakdown sheets
- Training materials and competency verification
- Audit checklist and schedule

---

## Quality Engineering

### 9. Statistical Process Control Implementation

**Description:** Design and implement SPC systems to monitor process stability, detect special cause variation, and enable data-driven process improvement.

**Key Activities:**
- Identify critical quality characteristics for monitoring
- Conduct measurement system analysis (Gage R&R)
- Collect baseline data and assess process stability
- Select appropriate control chart types
- Calculate control limits and set up charting system
- Train operators on SPC interpretation and response

**Outputs:**
- Critical characteristic identification matrix
- Measurement system analysis reports
- Process capability analysis
- Control chart specifications and reaction plans
- SPC training materials
- Out-of-control action plans (OCAP)

---

### 10. Design of Experiments Execution

**Description:** Plan and execute designed experiments to identify significant factors, optimize process settings, and reduce variation using factorial and response surface methods.

**Key Activities:**
- Define experimental objectives and response variables
- Identify factors and levels based on process knowledge
- Select appropriate experimental design
- Randomize and execute experimental runs
- Analyze results with statistical methods (ANOVA, regression)
- Validate optimal settings with confirmation runs

**Outputs:**
- Experiment planning document
- Design matrix and randomization schedule
- Data collection forms and raw data
- Statistical analysis report with factor effects
- Optimization recommendations
- Confirmation run results

---

### 11. Failure Mode and Effects Analysis

**Description:** Conduct systematic FMEA to identify potential failure modes, assess risks, and prioritize actions to prevent failures before they occur.

**Key Activities:**
- Assemble cross-functional FMEA team
- Define scope and identify process steps or components
- Brainstorm potential failure modes for each item
- Assess severity, occurrence, and detection ratings
- Calculate Risk Priority Numbers (RPN)
- Develop and track mitigation actions for high-risk items

**Outputs:**
- FMEA scope definition
- FMEA worksheet with failure modes and ratings
- Pareto analysis of risk priority numbers
- Action plan for high-risk items
- Updated FMEA after action completion
- Lessons learned documentation

---

### 12. Root Cause Analysis Investigation

**Description:** Conduct structured root cause analysis investigations using systematic problem-solving methods to identify and eliminate the true causes of problems.

**Key Activities:**
- Define problem clearly with is/is not analysis
- Collect and verify data about the problem
- Develop possible cause theories
- Test causes against evidence
- Identify root causes through 5 Whys or fault tree analysis
- Develop and verify corrective actions

**Outputs:**
- Problem statement and containment actions
- Data collection and analysis summary
- Cause and effect diagram (fishbone)
- Root cause verification documentation
- Corrective action plan with responsibilities
- Effectiveness verification report

---

## Ergonomics and Human Factors

### 13. Ergonomic Risk Assessment

**Description:** Conduct comprehensive ergonomic assessments of workstations and tasks to identify musculoskeletal disorder risk factors and recommend improvements.

**Key Activities:**
- Screen tasks and prioritize for detailed assessment
- Conduct NIOSH lifting equation analysis for manual handling
- Apply RULA/REBA for posture assessment
- Evaluate repetition, force, and duration factors
- Document risk levels and affected body regions
- Develop engineering and administrative controls

**Outputs:**
- Task screening and prioritization matrix
- NIOSH lifting analysis worksheets
- RULA/REBA assessment forms
- Risk factor summary with body mapping
- Improvement recommendations with cost estimates
- Implementation tracking and reassessment plan

---

### 14. Workstation Design Optimization

**Description:** Design or redesign workstations applying ergonomic principles to optimize human performance, comfort, and safety while meeting production requirements.

**Key Activities:**
- Analyze work tasks and operator anthropometrics
- Define reach zones and work surface heights
- Design tool and material presentation
- Specify adjustable features for accommodation
- Create prototype and conduct user testing
- Document final design specifications

**Outputs:**
- Task analysis and work content documentation
- Anthropometric analysis and accommodation targets
- Workstation layout drawings (2D and 3D)
- Material and tool presentation specifications
- User testing feedback and iterations
- Final workstation design package

---

## Supply Chain and Logistics

### 15. Demand Forecasting Model Development

**Description:** Develop and implement demand forecasting models using statistical and machine learning methods to improve inventory planning and supply chain responsiveness.

**Key Activities:**
- Collect and cleanse historical demand data
- Identify demand patterns (trend, seasonality, intermittency)
- Select and fit appropriate forecasting models
- Evaluate forecast accuracy with holdout testing
- Implement forecasting system with error tracking
- Establish forecast review and adjustment process

**Outputs:**
- Data quality assessment report
- Demand pattern analysis
- Model selection and parameter documentation
- Forecast accuracy metrics and comparison
- Forecasting system implementation
- Forecast review procedures

---

### 16. Inventory Optimization Analysis

**Description:** Analyze and optimize inventory policies including safety stock, reorder points, and order quantities to balance service levels with inventory investment.

**Key Activities:**
- Classify inventory using ABC/XYZ analysis
- Analyze demand variability and lead time data
- Calculate optimal safety stock by service level target
- Determine economic order quantities
- Model total inventory costs under different policies
- Recommend policy changes with expected benefits

**Outputs:**
- ABC/XYZ classification matrix
- Demand and lead time variability analysis
- Safety stock calculations by SKU
- EOQ analysis and ordering policy
- Cost-service level tradeoff analysis
- Implementation recommendations

---

### 17. Warehouse Layout and Slotting Optimization

**Description:** Design warehouse layouts and optimize product slotting to minimize travel time, improve picking productivity, and maximize space utilization.

**Key Activities:**
- Analyze order profiles and picking patterns
- Evaluate product velocity and cube characteristics
- Design zone layout and flow patterns
- Develop slotting strategy based on velocity
- Create slot assignment recommendations
- Measure baseline and post-implementation performance

**Outputs:**
- Order and pick profile analysis
- Product velocity classification
- Warehouse layout drawings
- Slotting strategy document
- Slot assignment database
- Performance improvement metrics

---

### 18. Transportation Route Optimization

**Description:** Optimize transportation routes and vehicle assignments to minimize cost and time while meeting delivery constraints using routing algorithms and tools.

**Key Activities:**
- Define delivery network and constraints
- Collect location, demand, and time window data
- Model routing problem (VRP, VRPTW variants)
- Solve using optimization algorithms or tools
- Analyze solutions for practical feasibility
- Implement routes with driver feedback loop

**Outputs:**
- Network and constraint definition
- Location and demand database
- Routing model formulation
- Optimized route plans
- Performance comparison vs. baseline
- Implementation and tracking system

---

## Production Planning and Scheduling

### 19. Capacity Planning Analysis

**Description:** Analyze production capacity against demand forecasts to identify constraints, plan capacity adjustments, and support strategic planning decisions.

**Key Activities:**
- Define planning horizon and demand scenarios
- Document available capacity by resource
- Calculate capacity requirements from demand
- Identify capacity gaps and constraints
- Evaluate capacity options (shifts, equipment, outsourcing)
- Develop capacity plan recommendations

**Outputs:**
- Demand forecast by product family
- Resource capacity documentation
- Capacity requirements calculations
- Gap analysis and bottleneck identification
- Capacity options evaluation
- Capacity plan with recommendations

---

### 20. Production Scheduling Optimization

**Description:** Develop and implement production schedules that optimize due date performance, throughput, and resource utilization using scheduling algorithms and tools.

**Key Activities:**
- Define scheduling objectives and constraints
- Model production system structure and routings
- Collect job release and due date information
- Apply scheduling rules or optimization algorithms
- Generate feasible schedules with performance metrics
- Implement schedule execution and tracking

**Outputs:**
- Scheduling model documentation
- Job and resource data structure
- Schedule generation methodology
- Schedule performance analysis
- Visual schedule displays (Gantt charts)
- Schedule adherence tracking system

---

### 21. Overall Equipment Effectiveness Improvement

**Description:** Measure and improve OEE by analyzing availability, performance, and quality losses to maximize productive equipment time.

**Key Activities:**
- Establish OEE measurement system and data collection
- Calculate OEE components and identify loss categories
- Pareto analyze losses by equipment and category
- Conduct focused improvement on top losses
- Implement autonomous maintenance activities
- Track OEE trends and improvement progress

**Outputs:**
- OEE data collection procedures
- OEE calculations by equipment
- Loss categorization and Pareto analysis
- Improvement action plans
- Autonomous maintenance checklists
- OEE dashboard and trend reports

---

### 22. Line Balancing Analysis

**Description:** Balance workload across workstations to minimize cycle time, optimize labor utilization, and achieve production rate targets.

**Key Activities:**
- Document work elements and precedence relationships
- Time work elements and calculate total work content
- Determine takt time from production requirements
- Assign elements to stations minimizing idle time
- Evaluate balance efficiency and alternatives
- Implement balanced line with standard work

**Outputs:**
- Work element breakdown
- Precedence diagram
- Time study data
- Line balance alternatives
- Balance efficiency calculations
- Standard work for balanced line

---

### 23. Setup Time Reduction (SMED)

**Description:** Apply Single Minute Exchange of Die methodology to dramatically reduce changeover times and enable smaller batch production.

**Key Activities:**
- Select target changeover and document baseline
- Videotape and analyze current changeover process
- Separate internal and external activities
- Convert internal to external where possible
- Streamline remaining internal activities
- Standardize and sustain improved changeover

**Outputs:**
- Baseline changeover documentation
- Video analysis and element breakdown
- Internal/external separation analysis
- Improvement action list
- New standard changeover procedure
- Before/after time comparison

---

## Summary

This backlog contains **23 processes** organized into six categories:

| Category | Process Count |
|----------|---------------|
| Operations Research and Optimization | 4 |
| Lean Manufacturing and Continuous Improvement | 4 |
| Quality Engineering | 4 |
| Ergonomics and Human Factors | 2 |
| Supply Chain and Logistics | 4 |
| Production Planning and Scheduling | 5 |
| **Total** | **23** |

These processes represent the core analytical and improvement activities performed by industrial engineers across manufacturing, service, and supply chain environments. Each process combines quantitative methods with practical implementation to deliver measurable operational improvements.

## Priority Recommendations

### High Priority (Foundational)
1. Value Stream Mapping and Analysis
2. Statistical Process Control Implementation
3. Standard Work Development
4. Root Cause Analysis Investigation
5. Capacity Planning Analysis

### Medium Priority (Advanced)
6. Discrete Event Simulation Modeling
7. Design of Experiments Execution
8. Inventory Optimization Analysis
9. OEE Improvement
10. Kaizen Event Facilitation

### Lower Priority (Specialized)
11. Linear Programming Model Development
12. Multi-Criteria Decision Analysis
13. Transportation Route Optimization
14. Ergonomic Risk Assessment
15. Setup Time Reduction (SMED)
