May 2, 2019

Total Industrial Engineering - H. Yamashina

Total industrial engineering is a concept identified by Yamashina as a part of his World Class Manufacturing Concept.

Total Industrial Engineering - Definition

by Yamashina

A system of methods where the performance of labor is maximized by reducing Muri (unnatural operation), Mura (irregular operation) and Muda (non-value added operation), and then separating labor from machinery through the use of sensor techniques.

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The above explanation of industrial engineering by Yamashina is the explanation for industrial engineering provided by Japanese scientific management pioneers. It is based on the precepts of Buddhism and also Japanese ideas regarding resource use.

Yamashina identified Total Industrial Engineering as an important components of the Toyota Production System which is the role model for World Class Manufacturing.  Total Industrial Engineering approach should be more properly credited to Alan Mogensen. From Alan Mogensen, it became part of supervisory training in USA during the second world war time. From this training, it was exported to Japan after the second world war. Toyota company conducted these training programs and substituted the improvement management module with a module from Japan Management Association and Shiegeo Shingo conducted these programs in Toyota Company. Total industrial engineering is involving supervisors and operations in industrial engineering projects in an active manner.

Total industrial engineering is a development in industrial engineering.When he proposed scientific management, which advocated improvement of efficiency by detailed study of work methods by the management, Taylor gave the opinion that both supervisors and operators are overburdened and therefore, a new cadre of staff specialists have to undertake it. That may be the right diagnosis at that time and a proper way to introduce a new management system. But thirty years later, Mogensen came to the conclusion, the time is appropriate to involve supervisors and operators actively in IE projects and successfully demonstrated its utility.

Elimination of three main enemies of Productivity

Muri - Difficult or unnatural operation - To be eliminated by motion study and motion analysis - Requires observation and study.

Mura - Irregular movement - To be eliminated by standard operation - To be observed for some time to recognize the problem.

Muda - Waste - To be eliminated by identifying and eliminating non value added activities - more easy to identify.


Existence of operational standards that assure quality, the operators follow them, there is a check on their following them and there is continuous improvement of those operational standards by operators.

Tools developed in TIE Philosophy

Muri, Mura, Muda
Multiskilled labor - Skill development
Video camera method
Standard operation
Pace monitor
Separation of labor from machinery
Separation of labor from operation and the one from transportation etc.

Safety Part of Total Industrial Engineering

Yamashina included Safety steps 1 -3 of his 7-step progression in the basic stage of IE.
Safety step 4 - 6 are included in intermediate stage.
Safety step 7 is included in the advanced stage.

Functions and Focus Areas of Industrial Engineering


Related Articles - Industrial Engineering
Principles of Industrial Engineering - Centenary Year
Contains the first chapter - Explanation of IE by Charles Going in 1911

World Class Manufacturing - Yamashina Way

Industrial Engineering Tool Kit

Industrial Engineering Definitions - 1911 to 2009

An article on TIE in Japanese. you can try translating with Google translate


Companies Utilizing Total Industrial Engineering Concepts

With the motto of "Quality People, Quality Products", PAC’s Total Industrial Engineering Dept. (TIE) annually holds the Quality Check Technical Skills Competition and In-House Quality Control Circle Competition.

There are also group learning circles, like the Quality Control Circle (also called Kaizen Circle) -- a group activity wherein members are challenged to solve problems according to the basic QC principles, using the QC tools. QCC activities improve the individual capabilities of each circle member resulting to performance improvement in the workplace and consequently, company development. (March 2008)

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Functions and Focus Areas of Industrial Engineering

You can read also

WCM - Japanese Way

Originally posted on Knol (3146)

Industrial Engineering Knowledge Revision Plan - One Year Plan

January - February - March - April - May - June


  1. Hi,
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    working hard to discover the things for real world peoples knowledge.

    Thanks, keep writing the wonderful post.
    Industrial Component Manufacturers