Engineering Commons^™

The Toyota Production System (Tps) In A Non-Traditional Manufacturing Environment: The Role Of Standardization In The Fast-Food Industry, Kevin Mccracken

Theses and Dissertations--Manufacturing Systems Engineering

The Toyota Production System (TPS), also known as Lean Manufacturing (LM), was founded in the automotive industry and has contributed to Toyota’s decades of success. This has brought much attention to TPS and how this system may be implemented in other industries. Focusing on the TPS foundational element of standardization, this study examines the impact of target cycle time (TCT) on process fluctuation in a fast-food environment. In order to observe the effects of TCT, team members within 3 production lines were timed. Times were measured before and after the addition of a TCT to the Standardized Work (STW) in …

Quantitative Methods For Total Lifecycle Risk Likelihood And Impact Assessment In Sustainable Product Design Decision Making, Christian Enyoghasi

Theses and Dissertations--Mechanical Engineering

Sustainable products promise significant economic, environmental, and societal benefits. Numerous methods are available for use during the new product development process to identify alternate product designs that optimize sustainability performance. Once any such design is selected and the product is launched, many uncertainties are likely to affect its performance over the total lifecycle. Such uncertainties give rise to risks that can influence the overall product sustainability performance. However, comprehensive quantitative methods to evaluate the likelihood or the impact of different risks to enable sustainable product design decision making are lacking.

This research aims to address this gap by developing a …

Balancing Trade-Offs In One-Stage Production With Processing Time Uncertainty, Jingjing You

Theses and Dissertations--Mechanical Engineering

Stochastic production scheduling faces three challenges, first the inconsistencies among key performance indicators (KPIs), second the trade-offs between the expected return and the risk for a portfolio of KPIs, and third the uncertainty in processing times. Based on two inconsistent KPIs of total completion time (TCT) and variance of completion times (VCT), we propose our trade-off balancing (ToB) heuristic for one-stage production scheduling. Through comprehensive case studies, we show that our ToB heuristic with preference =0.0:0.1:1.0 efficiently and effectively addresses the three challenges. Moreover, our trade-off balancing scheme can be generalized to balance a number of …

Tolerance Intervals For Time Series Models And Specifying Trimming/Winsorizing Cutoffs, Kedai Cheng

Theses and Dissertations--Statistics

Confidence intervals are used to capture a parameter of interest, usually a mean or a quantile, at a specified confidence level. Prediction intervals are another practical interval that aim at making sound predictions of future values with some confidence. Although these are useful inference tools, neither of them gives people a plausible range of the sampled population. Tolerance intervals are such an inference tool that captures a specified proportion of the sampled population at a predetermined confidence level. In this dissertation, tolerance intervals for an autoregressive process with order p are constructed. In addition, a method of utilizing tolerance interval …

Numerical Analyses And Integration Of Split Lot Sizing Using Lean Benchmark Model For Small Lot Manufacturing In High Mix Low Volume Production, Omkar Bhosale

Theses and Dissertations--Manufacturing Systems Engineering

As the global demand for automobiles has increased rapidly over the last fifty years, customers have become more particular about the characteristics of the autos they want. This change in demand, in part has pushed manufacturing to become more flexible and created a demand for alternative, more efficient processes like the High Mix Low Volume (HMLV) production of vehicles. During HMLV, manufacturers create production lot sizes and schedule to synchronize the production processes to meet customer demand on time. The demand for the automobile parts may not be uniform or parts may not be consumed by the customer immediately, Due …

Weld Penetration Identification Based On Convolutional Neural Network, Chao Li

Theses and Dissertations--Electrical and Computer Engineering

Weld joint penetration determination is the key factor in welding process control area. Not only has it directly affected the weld joint mechanical properties, like fatigue for example. It also requires much of human intelligence, which either complex modeling or rich of welding experience. Therefore, weld penetration status identification has become the obstacle for intelligent welding system. In this dissertation, an innovative method has been proposed to detect the weld joint penetration status using machine-learning algorithms.

A GTAW welding system is firstly built. Project a dot-structured laser pattern onto the weld pool surface during welding process, the reflected laser pattern …

Investigation Of Chip-Form And Tool-Wear In Turning Of Hardened Af9628 Alloy Under Various Cooling And Lubrication Conditions, Jason Wolf

Theses and Dissertations--Manufacturing Systems Engineering

Next generation defense and commercial applications for structural steels require new alloys that eliminate or reduce critical elements from their composition to lower cost and improve manufacturability, while maintaining or exceeding high strength and toughness requirements. A new alloy, denoted as AF9628, has recently been developed for this purpose and its manufacturing characteristics and the material response in component manufacturing must be fully understood.

In the present study, hardened AF9628 alloy was turned with a coated carbide cutting tool under fixed cutting speed, feed rate, and depth of cut parameters. This work focuses on chip-form and tool-wear analysis to understand, …

Curricular Optimization: Solving For The Optimal Student Success Pathway, William G. Thompson-Arjona

Theses and Dissertations--Electrical and Computer Engineering

Considering the significant investment of higher education made by students and their families, graduating in a timely manner is of the utmost importance. Delay attributed to drop out or the retaking of a course adds cost and negatively affects a student’s academic progression. Considering this, it becomes paramount for institutions to focus on student success in relation to term scheduling.

Often overlooked, complexity of a course schedule may be one of the most important factors in whether or not a student successfully completes his or her degree. More often than not students entering an institution as a first time full …

Trade-Off Balancing For Stable And Sustainable Operating Room Scheduling, Amin Abedini

Theses and Dissertations--Mechanical Engineering

The implementation of the mandatory alternative payment model (APM) guarantees savings for Medicare regardless of participant hospitals ability for reducing spending that shifts the cost minimization burden from insurers onto the hospital administrators. Surgical interventions account for more than 30% and 40% of hospitals total cost and total revenue, respectively, with a cost structure consisting of nearly 56% direct cost, thus, large cost reduction is possible through efficient operation management. However, optimizing operating rooms (ORs) schedules is extraordinarily challenging due to the complexities involved in the process. We present new algorithms and managerial guidelines to address the problem of OR …

An Analysis Of Resistance Spot Weld Quality Based On Acoustic And Electrical Signatures, Ivan Charles Butler

Theses and Dissertations--Manufacturing Systems Engineering

The union of a set of materials by way of Resistance Spot Welding is designed so that once fused together, a substantial amount of intentional, external force must be applied to separate the contents. Therefore, Resistance Spot Welding is often the preferred fusion method in high-volume manufacturing processes. The result of Resistance Spot Welding however is the formation of a weld nugget which is not visible to the naked eye. Destructive and/or ultrasonic methods applied off-line must be used to determine the quality of each weld; both inefficient and expensive processes. The following research analyzes the data fed back during …

Implementation And Analysis Of True Lean In A Startup Company By Using Pdca Model, A Case Study In A Manufacturing Venture, Ankit Jangid

Theses and Dissertations--Manufacturing Systems Engineering

The purpose of this research is to implement and analyze the true lean transformation in a manufacturing start-up organization. Often, lean transformations are observed in developed manufacturing organizations having sophisticated production lines and numerous employees, where lean tools are utilized to reduce waste while increasing profit. However, this type of transformation is narrowly focused on quantifiable process results and falls short of the ultimate goal, establishing a true lean culture within the organization. As a result, it is recommended that true lean principles, philosophies, culture, operations environment and tools be applied at the very beginning stages of an organization, or …

Two Essays On Whole Farm Modeling And Crop Marketing In Western Kentucky, Benjamin A. Martin

Theses and Dissertations--Agricultural Economics

This thesis is composed of two essays that investigate whole farm planning and crop marketing in western Kentucky. In the first essay, contracting decisions between food corn producers and a mill are analyzed to observe factors affecting the bushel amount farmers contract. Unbalanced panel data containing seven years’ worth of pricing and contract information are used with a fixed-effects model to generate parameter estimates and quantify their effect on bushels contracted. It was found that contract attributes, market condition, and relationship-specific assets had a significant effect on producers’ food corn contracting decisions. The second essay utilizes mixed-integer programming to optimize …

Regression Analysis Of Factors Impacting Problem Solving Engagement Within Lean Systems Implementation, David M. Parsley Ii

Theses and Dissertations--Mechanical Engineering

Organizations around the world have attempted to implement the concepts of the Toyota Production System (TPS), commonly referred to as Lean, with limited sustainable success. The central principles of TPS, continuous improvement and respect for people, are grounded in the Japanese values of Monozukuri and Hitozukuri. Monozukuri deals with creating or making a product, while Hitozukuri conveys the idea of developing people through learning. In order for organizations to adopt these values they must have a system that engages employees at all levels in applying problem solving to improve their work. This research uses organizational assessments obtained from a variety …

Experimental Investigation Of Reading Passive Uhf Tags In A Multi-Tag Environment, Yi Zhou

Theses and Dissertations--Mechanical Engineering

Recently, the Internet of things (IoT) has emerged as a promising solution for several industrial applications. One of the key components in IoT is passive radio frequency identification (RFID) tags which do not require a power source for operations. Specifically, ultra-high frequency (UHF) tags are studied in this paper. However, due to factors such as tag-to-tag interference and inaccurate localization, RFID tags that are closely spaced together are difficult to detect and program accurately with unique identifiers. This thesis investigates several factors that affect the ability to encode a specific tag with unique information in the presence of other tags, …

Adaptive Scheduling For Operating Room Management, Honghan Ye

Theses and Dissertations--Mechanical Engineering

The perioperative process in hospitals can be modelled as a 3-stage no-wait flow shop. The utilization of OR units and the average waiting time of patients are related to makespan and total completion time, respectively. However, minimizations of makespan and total completion time are NP-hard and NP-complete. Consequently, achieving good effectiveness and efficiency is a challenge in no-wait flow shop scheduling. The average idle time (AIT) and current and future idle time (CFI) heuristics are proposed to minimize makespan and total completion time, respectively. To improve effectiveness, current idle times and future idle times are taken into consideration …

Forecasting The Workload With A Hybrid Model To Reduce The Inefficiency Cost, Xinwei Pan

Theses and Dissertations--Mechanical Engineering

Time series forecasting and modeling are challenging problems during the past decades, because of its plenty of properties and underlying correlated relationships. As a result, researchers proposed a lot of models to deal with the time series. However, the proposed models such as Autoregressive integrated moving average (ARIMA) and artificial neural networks (ANNs) only describe part of the properties of time series. In this thesis, we introduce a new hybrid model integrated filter structure to improve the prediction accuracy. Case studies with real data from University of Kentucky HealthCare are carried out to examine the superiority of our model. Also, …

Analytical And Boundary Element Solutions Of Bulk Reacting Lined Ducts And Parallel-Baffle Silencers, Jundong Li

Theses and Dissertations--Mechanical Engineering

Lined silencers of various configurations are used to attenuate the noise from building HVAC equipment, gas turbines, and other machinery. First-mode analytical solutions are presented for sound attenuation along rectangular lined ducts, parallel-baffle silencers, and circular lined ducts. The sound absorptive lining is treated using a bulk property model. The analytical solutions entail solving a nonlinear characteristic equation in the transverse direction after the rigid-wall boundary condition is applied. The solution is compared to the boundary element solution and a local impedance analytical solution for several test cases.

An Efficient Heuristic To Balance Trade-Offs Between Utilization And Patient Flowtime In Operating Room Management, Feidi Dang

Theses and Dissertations--Mechanical Engineering

Balancing trade-offs between production cost and holding cost is critical for production and operations management. Utilization of an operating room affects production cost, which relates to makespan, and patient flowtime affects holding cost. There are trade-offs between two objectives, to minimize makespan and to minimize flowtime. However, most existing constructive heuristics focus only on single-objective optimization. In the current literature, NEH is the best constructive heuristic to minimize makespan, and LR heuristic is the best to minimize flowtime. In this thesis, we propose a current and future deviation (CFD) heuristic to balance trade-offs between makespan and flowtime minimizations. Based on …

Target Read Operation Of Passive Ultra High Frequency Rfid Tag In A Multiple Tags Environment, Zi Qin Phua

Theses and Dissertations--Mechanical Engineering

Passive ultra-high frequency (UHF) radio frequency Identification (RFID) has emerged as a promising solution for many industrial applications. Passive UHF systems are relatively inexpensive to implement and monitor, as no line of sight is required for the communication. There are several advantages to using a passive RFID system. For example, no internal power source is required to activate the tags, and lower labor costs and efficient multitasking operations are expected in a long term scenario. However, due to factors such as tag-to-tag interference and inaccurate localization, RFID tags that are closely spaced together are difficult to detect and program accurately …

Adaptive Multi-Objective Operating Room Planning With Stochastic Demand And Case Times, Vivek Reddy Gunna

Theses and Dissertations--Mechanical Engineering

The operating room (OR) is accountable for most hospital admissions and is one of the most cost and work intensive areas in the hospital. From recent trends, we discover an unexpected parallel increase in expenditure and waiting time. Therefore, improving OR planning has become obligatory, particularly regarding utilization, and service level. Significant challenges in OR planning are the high variations in demand, processing times of surgical specialties, the trade-off between the objectives, and control of OR performance in long-term. Our model provides OR configurations at a strategical level of OR planning to minimize the tradeoff between the utilization and service …

Multilevel Ant Colony Optimization To Solve Constrained Forest Transportation Planning Problems, Pengpeng Lin

Theses and Dissertations--Computer Science

In this dissertation, we focus on solving forest transportation planning related problems, including constraints that consider negative environmental impacts and multi-objective optimizations that provide forest managers and road planers alternatives for making informed decisions. Along this line of study, several multilevel techniques and mataheuristic algorithms have been developed and investigated. The forest transportation planning problem is a fixed-charge problem and known to be NP-hard. The general idea of utilizing multilevel approach is to solve the original problem of which the computational cost maybe prohibitive by using a set of increasingly smaller problems of which the computational cost is cheaper.

The …

Alternate Models For Natural Gas Transportation System Performance Optimization, Gnana Shekaran Arumugam

Theses and Dissertations--Manufacturing Systems Engineering

The Natural Gas market in the U.S is growing rapidly with evidence that the nation has enough shale reserves to power the country for the next century. To ensure continued economic benefits through the use of this environmentally desired energy source, it becomes important to optimize the transportation network system design. Transportation through pipelines is one of the most common methods used to distribute Natural Gas from source to destination. This transportation system, consisting of pipelines, compressors and other supporting equipment, must be optimized, considering all relevant parameters to minimize cost and increase profit. The research presented here improves on …

Mathematical Modeling For Platform-Based Product Configuration Considering Total Life-Cycle Sustainability, Tian Lan

Theses and Dissertations--Mechanical Engineering

Many companies are using platform-based product designs to fulfill the requirements of customers while maintaining low cost. However, research that integrates sustainability into platform-based product design is still limited. Considering sustainability during platform-based design process is a challenge because the total life-cycle from pre-manufacturing, manufacturing and use to post-use stages as well as economic, environmental and societal performance in these stages must be considered. In this research, an approach for quantifying sustainability is introduced and a mathematical model is developed for identifying a more sustainable platform. Data from life-cycle assessment is used to quantify environmental factors; criteria from the Product …

A Framework For Sustainable Material Selection For Multi-Generational Components, Ryan T. Bradley

Theses and Dissertations--Mechanical Engineering

The early stages of a product’s design are a critical time for decisions that impact the entire life-cycle cost. Product designers have mastered the first generation; however, they currently do not have the ability to know the impact of their decisions on the multi-generational view. This thesis aims at closing the gap between total life-cycle information and the traditional design process in order to harbor sustainable value creation among all stakeholders involved. A framework is presented that uses a combination of a life-cycle costing methodology and an evolutionary algorithm in order to achieve a sustainability assessment for a true multi-generational …

Engineered Surface Properties Of Porous Tungsten From Cryogenic Machining, Julius M. Schoop

Theses and Dissertations--Chemical and Materials Engineering

Porous tungsten is used to manufacture dispenser cathodes due to it refractory properties. Surface porosity is critical to functional performance of dispenser cathodes because it allows for an impregnated ceramic compound to migrate to the emitting surface, lowering its work function. Likewise, surface roughness is important because it is necessary to ensure uniform wetting of the molten impregnate during high temperature service. Current industry practice to achieve surface roughness and surface porosity requirements involves the use of a plastic infiltrant during machining. After machining, the infiltrant is baked and the cathode pellet is impregnated. In this context, cryogenic machining is …

A Multidisciplinary Techno-Economic Decision Support Tool For Validating Long-Term Economic Viability Of Biorefining Processes, Sumesh Sukumara

Theses and Dissertations--Chemical and Materials Engineering

Increasing demand for energy and transportation fuel has motivated researchers all around the world to explore alternatives for a long-term sustainable source of energy. Biomass is one such renewable resource that can be converted into various marketable products by the process of biorefining. Currently, research is taking strides in developing conversion techniques for producing biofuels from multiple bio-based feedstocks. However, the greatest concern with emerging processes is the long-term viability as a sustainable source of energy. Hence, a framework is required that can incorporate novel and existing processes to validate their economic, environmental and social potential in satisfying present energy …

Lean Fire Management: A Focused Analysis Of The Incident Command System Based On Toyota Production System Principles, Jeremiah S. Fugate

Theses and Dissertations--Mechanical Engineering

A primary role of the Incident Command System is to learn from past incidents, as illustrated by its origins in the wildland firefighting community. Successful emergency response operations under the Incident Command System has prompted its nationwide spread, this promulgation critically relies on the system’s capability to stabilize and continuously improve various aspects of emergency response through effective organizational learning. The objective of this study is to evaluate the potential to apply fundamental principles of the Toyota Production System (Lean manufacturing) to improve learning effectiveness within the Incident Command System. An in-depth review of literature and training documents regarding both …

Evaluating Food Safety Systems Development And Implementation By Quantifying Haccp Training Durability, Marienne A. Anandappa

Theses and Dissertations--Animal and Food Sciences

HACCP-based food safety programs have been widely acclaimed, accepted and implemented as an effective means of managing food safety risks. While HACCP training is a cornerstone of managing HACCP programs, there is little information about the effectiveness of HACCP training and the durability of HACCP knowledge. Findings reveal a link between involvement level in HACCP activities and the accuracy of HACCP knowledge over time. Opportunities for peer training in HACCP, irrespective of overall experience in the food industry provide favorable circumstances for maintaining accuracy of HACCP knowledge. The optimal window for engaging employees in HACCP is directly following the completion …

The Modeling, Analysis And Control Of Resilient Manufacturing Enterprises, Yao Hu

Theses and Dissertations--Electrical and Computer Engineering

The resilience of manufacturing enterprises is an important research topic, since disruptions have severe effects on the normal operation of manufacturing enterprises, especially as manufacturing supply chains become global. Although many case studies have been carried out to address resilience in organizations, a systematic method to model and analyze the resilience dynamics in manufacturing enterprises is not well developed. This study is intended to conduct research on quantitative analysis and control for resilience.

After reviewing the literature addressing resilience, a modeling framework is presented to characterize the resilience of a manufacturing enterprise responding to disruptive events, which includes inventory ow …

A Study Of Queuing Theory In Low To High Rework Environments With Process Availability, Adam J. Brown

Theses and Dissertations--Manufacturing Systems Engineering

In manufacturing systems subject to machine and operator resource constraints the effects of rework can be profound. High levels of rework burden the resources unnecessarily and as the utilization of these resources increases the expected queuing time of work in process increases exponentially. Queuing models can help managers to understand and control the effects of rework, but often this tool is overlooked in part because of concerns over accuracy in complex environments and/or the need for limiting assumptions. One aim of this work is to increase understanding of system variables on the accuracy of simple queuing models. A queuing model …