Liberty Productivity Improvement

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INDUSTRIAL ENGINEERING - A , an education to Cost Engineer / Improvement Engineer

The education and training course  Integral Basic course Industrial Engineering - A, IBIE-A, provides participants with practical and applicable knowledge and skills on the fundamental business economical and operational basic techniques. These programs are originally designed for industrial organizations, but can be deployed in other fields and businesses as well. The total program consists of three more or less separate courses. “More or less” because of the logical order of the courses:
1. Work Study / Work Analysis,
2. Technical cost prices and technical cost price (pre)calculations, and
3. Investment - and Decision calculations.
For employees who (will) exercise a function in which an integral vision on the production process is necessary and/or preferable.

Goal of the eduacation and training
The pursuit for a lean and flexible (production) organization sets far-reaching demands for the integration of production processes, flexibility, quality of the processes and the relation with customers and suppliers. These demands are addressed by (teams of) employees from various disciplines.
The ultimate way of working on production floor will be highly standardized where improvements are being developped and implemented continuously. This concept makes it essential that an extensive knowledge base of methods and techniques is available and that skills are at hand and operational to analyse problems, to generate solutions and to choose and implement the right solution.
The “weight” of the education and training is the emphasis on methods and techniques and their many practical exercises. During the training attention is also being paid to the “softer” subjects, necessary for Teambuilding and Cooperation and Organization. At the end of the education the participant must be able to:
- apply various work study and operational methods and techniques, in the right way,
- identify problems, choose the right direction of investigation to define solutions and propose advantages and disadvantages (pros
  & cons), also financially,
- to implement the chozen solution or improvement till a lasting and imbedded improvement in the organization,
- to translate the influence of the improvement or change in terms of the technical cost price, and
- to indicate the influence of the improvement or change in terms of the variation in the decision dependent .i.e. the essential,

Target group
Employees, mainly working in the field of “organization and efficiency”, e.g. future industrial engineers, work study analists-to-be, work planners, calculators a.t.l. who will and should support “middle management” in business economical issues in a (changing) organization with the purpose to safeguard the continuity as much as possible by continuous improvement of the productivity of the manufacturing process. Also emplyees who (will) act as a central focal point and acting responsibly as “pivot” in the “mini company” concept.
Participants of the different programs mostly have an intermediate or higher vocational education or an university background. They are or will be involved in activities to analyse and improve existing production processes and the analysis and implementation of new processes. They are working or will work a.o. in the function of Work Planner, Work Study analist, Cost Engineer. Improvement Engineer or Industrial Engineer.

Work Study, WS
Work Study is engaged in the investigation of human labour activities in its direct environment and its relation with fellow man, machines and processes. The aim is to increase the productivity: it can be better always. These educations offer knowledge and insights in the fields of work study analyses mainly on the sub-areas method study, time study and quality. The participant will learn how to improve the work or task in quality aspects and from a social and business economical point of view i.e. productivity.

Cost prices and cost price calculation or Technical Pre-Calculatie, TPC
This course provides insight in the various systems of cost price calculation and the allocation of costs and other connected costs and activities. Various subjects will be discussed during the course as: cost price technical thinking, objectives of budgetting and cost price calculation, translating plans into budgets, cost of overhead, capacity calculations, cost prices, cost price calculations, indexing & trend and postcalculation & management. A better insight will promote the effectivity of the work, being able to see the relation and coherence between organization, work study improvements and cost price.

Investments and Decision Calculations, DC
The course provides a profound knowledge and insight into the financial and business economical consequences of investment decisions in a company. Various subjects will be discussed during the course a.o.: business economical thinking, thinking in cash flows, decision criteria, generating alternatives, investment in machines, make or buy decisions or in- or oursourcing. Also will be discussed how to handle risks with the aid of pessimistic - optimistic approach, sensitivity analysis, decision trees and Monte Carlo simulation analysis. At the end of this eduaction, the participant will be able to provide management with solid advice on financial investment plans

The standard courses and trainings are build up in modules as indicated below in the table.
A custom made course or training may be composed of one or more of those modules.

IBIE-A --- Integral Basic course Industrial Engineering-A --- IBIE-A
Education and Training to Improvement Engineer - Cost Engineer

WS --- Work Study / Work Analysis --- WA

Method Study

Time Study

WS Techniques

Inprovement Techn.


Introduction WS
History WS
General Methods
- description of process
- gathering data
- line, surface diagram
- circle diagram
- bar, column diagram
- Pareto analysis
- fishbone diagram
- Deming, PDCA
- brainstorming
Reduction of Waste
Control Loops and PI's
Productivity, Efficiency
  and Effectivity
Process analysis - A
- manufacturing scheme
- process scheme
- routing scheme
Process analyis - B
- flow process chart,
. PI-throughput time
. PI-WiP
- bottle neck
- productivity
- Kipling analysis
Operation analysis
- man scheme
- multi-scheme
- man-machine-scheme
- combi-scheme
- Kipling analysis
Motion analysis
- 2-Hands analysis
- Kipling analysis
- rules of Barnes

Working methods-

Task Time TT or
  Basic Time BT
- stopwatch
- rating scales
- tempo rating
Task Setting TS or
  Standard Time ST
- AF for Divers
- AF for R+PC
- performance calcul.
Time Studie PMTS:
- Very easy WF
- VWF Information for
  Instructor, Developper
  Work planner
- VWF-software
Man-Machine Ratio /
- process time, PT
- exchange time, ET
- filling up time, FT
- man-machine ratio
O&E activities
- attitude
Calculation Time CT
- available time
- organizational
  impedements, NAF
- technical
  impedements, TEF
- rejects and
  reject factor, REJF
MMO - Multi Moment
  Observation Technique
Instruction Skills

GTT - Group Timing
Manual Skills
acc. to
- Wright and De Jong
- Van Daatselaar
- Work-Factor

Integral WS-problem
process yields
and bottle necks
- without rejects
- with rejects
  (rejects recuperable
  or not recuperable)
  Single Minute
  Exchange of Die
- basic activities
- on line/off line
- Fase 1
- SMED step 1
- Fase 2
- SMED step 2
- Fase 3
- SMED step 3
- Fase 4
- SMED case
- human-machine
- integrated design
- displays and controls
- environmental factors
- physical - and
  mental strain/load
- checklist, short
- vademecum
- NIOSH standards
- assessment list
Knowledge and

Visual Meetings

KAIZEN: 9 + 1
FMEA - Failure Mode
  and Effect Analysis
- on processes
- on products
Problem Analysis
- 5 x Why
- Keppner & Tregoe
Cooperation and
- in-house consultancy
Material Handling
- goods analysis
- routing analysis
- flow analysis
- relation-matrix
- MaHa method
Layout Planning
- relation form
- necessary space
- activities vrs relations
- space relations
- alternatives
Introduction to Logistics
- order systems
- MRP systems
- DBR systems
- JIT philosofy
Introduction TOC
- PQ Quiz
- planning on the BN

Allowances on

Process control
- histograms
- Cp and Cpk
- correlation, r1 and r2
- Statistical Process
  Control, SPC
  - warning lines
  - action lines
- 6 Sigma
Taguchi's approach
DOE - Design Of
  by Keki Bhote
- multi-vari charts
- component search
- paired comparison
- product/process search
- variable search
- full factorials
- "B" versus "C"
- scatter plots
- responsive surface
- ISO Plots
- pre-control charts
- post-DOE
Pre Control
- PC-charts

In blue:
Optional subjetcs

Poka - Yoke



Examination VWF


Integral Practice-
Assignment, PA

8 day shifts

8 day shifts

8 day shifts
excl. VWF exam

8 day shifts

8 day shifts excl.
presentation PA

Modalities of IBIE-A
Some particular parts or modules can be lectured in the Bedaux system as well as in the BSI system; mainly this
holds for the time study modules. As PMT-system a choice can be made between VWF and UAS.
A separate RWF or MTM-1 course may also be part of the education and training.
The course can be given in the Dutch language or in the English language.

You may also compose your own course or training, appreciation or refresh course,
from the subjects and modules mentioned above.
We would like to assist you.

--- IBIE-A ---



Cost Calculation

Decision Calculation

Goals & Targets
Budgets & Responsiblities
Activities & Costs allocation
- production centres method
- single allowance method
- multiple allowance method
Cost Price systems
- manufacturing cost price syst.
- direct costing
- activity based costing, ABC
- integral cost price system
Multi-Level Budgetting System
Material costs
Procurement- &
  Warehousing costs
Operational activities:         L
- labour costs
- machine costs
- specific costs
  . tools
  . packing
- calculation time, CT
Cost of Organization:         O
- regulating activities
- general activities
Total Manufacture costs: MLO
- financing
- research & development
- concern
- risks
- etc.
Total Concern Costs         CP
Index and Trend
- expenditures
- capacity utilization
  (fixed costs)
- efficiency

Business Economical Thinking
- cash flows
- decision dependency
Decision Calculations, DC
- decision process
- decision criteria:
  . profit margin, PM
  . pay out time, POT
  . EPBT
  . ROI and Rentability
  . Average Surplus
  . Internal Rate of Return, I.R.R.
  . NPV / DCF
  . Annuïties
  . Surplus Method
- projects
- post calculation
- generating alternatives
- uncertainty and risk analysis:
  . pessimistic - optimistic
  . sensitivity analysis
  . Monte Carlo simulation
  . decision trees
  . individual risk versus
     joint risk
  . submitting a tender
GAMMA-1 model and software
Dupont scheme:
- ROI and ROE
- EPR and WACC

Decision Analysis

Practice Assignment

Practice Assignment

12 day shifts excl.
examination and
excl. present. PA

12 day shifts excl.
examination and
excl. present. PA

Dutch and English

Dutch and English

You may also compose your own course from the subjects
and modules mentioned above.
We would like to assist you.


Reginald, how are we doing?

For more information you may apply for or read or download the extensive brochure.
By clicking the proper link you are directed to the Dutch or Englisg version.

Brochure IBIE-A Dutch

Brochure IBIE-A English

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