Engineering Commons^™

Digital Performance Management: An Evaluation Of Manufacturing Performance Management Andmeasurement Strategies In An Industry 4.0 Context, Nathaniel David Smith

Theses and Dissertations

Manufacturing management and operations place heavy emphasis on monitoring and improving production performance. This supervision is accomplished through strategies of manufacturing performance management, a set of measurements and methods used to monitor production conditions. Over the last thirty years the most prevalent measurement of traditional performance management has been overall equipment effectiveness, a percentile summary metric of a machine's utilization. The technologies encapsulated by Industry 4.0 have expanded the ability to gather, process, and store vast quantities of data, creating opportunity to innovate on how performance is measured. A new method of managing manufacturing performance utilizing Industry 4.0 technologies has …

Assessment Of Defect Generation Mechanism In Welding Processes Using Phased Array Ultrasonic Testing (Paut), Caleb D. Williams

Honors College Theses

Welding is one of the major and most commonly used methods of material joining in industries around the world. The mechanisms of welding include complicated processes which can cause significant alteration in final properties and quality of the weld compared to the base materials. Due to these physical and chemical processes during the welding processes, defects and flaws can be generated. Observing such flaws over the years, leads engineers and researchers to investigate the methodologies to identify the cause and effect of defects and their effect on the quality of the welds. A better understanding of such parameters helps to …

The Influence Of Diversity Dimensions On Student’S Collaboration Success: What It Means For Workforce Development In Manufacturing, Oyinkansola Adeite

All Theses

Manufacturing productivity is measured by labor productivity which is the hourly output of the manufacturing economy. The recent reduction in productivity numbers by the United States Bureau of Labor Statistics emphasizes the need for workforce development. With globalization and technological advancements, diversity has emerged as a critical aspect for the workplace. By encompassing dimensions such as education, race, and age, diversity creates a tapestry of unique perspectives and experiences. This study’s aim is to figure out the effect of a diversity dimension on team performance using intelligent systems, and in addition, if extra dimensions of diversity further impact team performance. …

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

Parametric Bicycle Yoke, Colin Reay, Walter Minehart, Robby Harrigan, Jordan Olson

Mechanical Engineering

This report outlines the entire design, fabrication, and validation process of a parametric yoke design that addresses the packaging problem of the bottom-bracket chainstay junction in modern bicycle frames. The goal was to create an elegant, space-efficient solution that is accessible to the Cal Poly Bike Builders Club. The report includes documentation of the three-part fixture system, manufacturing process, and testing results for the yoke.

Our yoke design outperforms traditional round-tube weldments in torsional and vertical stiffness. Additionally, all manufacturing fixtures and machining operations function as intended, resulting in a finished yoke that meets all required tolerances in under an …

Crafting Comfort: The Design And Production Of A High-End Poolside Lounge Chair, John Hollis Tackett, Robert Griffis

Honors Theses

This report focuses on the development, design, and manufacturing of the Adjustable Lounge Chair, a high-end poolside lounge chair created to address un-met customer demand in the market. The investigation began with a market analysis to identify sought-after features not currently offered by competitors' products. This analysis drove the design of the chair, which was developed using CAD software, followed by the construction of a physical prototype to validate the concept.

The chair's innovative features include adjustable lumbar support and chair height, as well as a removable face-piece that enables users to comfortably lie prone without straining their necks. These …

Pour-Over Coffee Stand With Warmer, Francesca Patawaran

Honors Theses

This project sought to demonstrate the process of bringing a new product into the market, from the initial design and prototyping stage to marketing and, ultimately, mass production. As part of the curriculum of The Haley Barbour Center for Manufacturing Excellence (CME), the project team manufactured fifteen Pour-Over Coffee Stands with electric heating components. We first created a 3D model of the proposed design, ensuring that all components fit together in an assembly. Next, we worked with the lab technicians to create a prototype of the product. Then, we refined the manufacturing process to eliminate waste where possible. Throughout the …

Compositional Engineering Of Precursor Inks For Intense Pulsed Light Compatible Deposition Of Perovskite Solar Cells., Blake Martin

Electronic Theses and Dissertations

Perovskite solar cell (PSC) technology offers a promising alternative to silicon-based photovoltaics (PVs), but challenges of stability, module efficiency, and scalability hinder commercialization. This study aims to explore potential solutions to overcome scalability and cost limitations of PSCs, addressing technical barriers to commercialization. We adapt the conventional three-stage perovskite deposition process (deposition, translational phase formation, and annealing) for scalable platforms using wide-area depositions, meniscus coating methods, forced laminar airflow drying, and radiative annealing methods, making it more suitable for roll-to-roll fabrication. A technoeconomic analysis shows that large-scale operations can produce solar films at a cost of $0.04-$0.10 per watt, making …

Structural Design And Fabrication Of A Test Chamber To Test Ppes For Effective Particle Filtration, Matthew G. Adharsingh

Honors College Theses

This research project aims to design and fabricate a test chamber for testing Personal Protective Equipment (PPE) to ensure effective particle filtration. The chamber has a special purpose, which is to measure ultrafine and submicron particles concentration in the air and test the ergonomic design of PPE based on its effective filtration. The project also considers the environmental aspects of the chamber such as the level of noise and vibration. The chamber will be designed to measure upstream and downstream particle count. Initially, the chamber was going to be made from wood, but the research team encountered difficulties in the …

A Semantic Web Approach To Fault Tolerant Autonomous Manufacturing, Fadi El Kalach

Theses and Dissertations

The next phase of manufacturing is centered on making the switch from traditional automated to autonomous systems. Future Factories are required to be agile, allowing for more customized production, and resistant to disturbances. Such production lines would have the capability to reallocate resources as needed and eliminate downtime while keeping up with market demands. These systems must be capable of complex decision making based on different parameters such as machine status, sensory data, and inspection results. Current manufacturing lines lack this complex capability and instead focus on low level decision making on the machine level without utilizing the generated data …

Design And Development Of Smart Wardrobe Technology, Mikhail Filatov

All Graduate Theses, Dissertations, and Other Capstone Projects

The increasing demand for online shopping in the 21st century is causing rapid growth in technology and methods in marketing and sales fields. Present thesis work scrutinizes the process of design and development of the device that simplifies the process of trying on and buying clothes in online retail stores, the development of which is based on the known basics of operational, mechanical, and electrical designs for computational systems, with account for ergonomics and manufacturing sustainability. The following research represents the market analysis for competition identification, description of all operational modes of the system, list of mechanical and electrical components …

Strategies To Increase Competitive Advantage In The Automotive Manufacturing Supply Chain, Amber Willis

Walden Dissertations and Doctoral Studies

Some automotive manufacturing supply chain leaders lack strategies that are needed to implement information technology (IT) systems. Business leaders are concerned with implementing IT systems to achieve and maintain a competitive advantage. Grounded in the resource-based view theory (RBV), the purpose of this qualitative single case study was to explore information system strategies used by leaders in the automotive manufacturing supply chain to achieve competitive advantage. Participants were five leaders of an automotive manufacturing supply chain organization who implemented IT systems. Data were collected through semistructured interviews and a review of organization project documents. Through thematic analysis, five themes were …

Studying And Troubleshooting Lubricity Test On Pressure Wire X Proximal And Distal Coatings, Usama A. Khan

All Graduate Theses, Dissertations, and Other Capstone Projects

Coatings of guidewires used in medical device manufacturing industry are one of the most important element aspects. It defines its efficiency to penetrate through tightest of canals and curves. Guidewires are put through controlled environment to accelerate its age and tested for its mechanical features. Pressure Wire X failed the lubricity testing after being tested by multiple operators and at alternate sites. A cause-and-effect diagram shows all potential causes of test failure. The human factor involved in the test failure was investigated through multiple Gage R&R and training records. Calibration error with the lubricity tester DL1000 was identified and solved …

Impacts Of Ergonomic Conditions On Quality And Cycle Time In Automotive Shock Absorber Assembly, Val Urman

All Graduate Theses, Dissertations, and Other Capstone Projects

Earlier studies have demonstrated relationships between general ergonomic conditions in assembly and quality defects or cycle time. This study investigated the impacts of specific ergonomic conditions on the quality and cycle time of shock absorber assembly. Ergonomic conditions within a single manual assembly cell were controlled through three factors: assembly height, reachability, and standing surface. Experiments were conducted with varied workstation conditions to determine the impact on the time of assembly and multiple quality metrics. Reachability and standing surface affected the quality of the assembly. Additionally, cycle time of the assembly was impacted by reachability of the components.

An Augmented Reality Maintenance Assistant With Real-Time Quality Inspection On Handheld Mobile Devices, James Thomas Frandsen

Theses and Dissertations

With the advances of industry 4.0, augmented reality (AR) devices are being deployed across the manufacturing sector to enhance worker perception and efficiency. AR is often used to deliver spatially relevant work instructions on mobile devices for maintenance procedures on the factory floor. In these situations, workers use their mobile devices to view instructions in the form of 3D animations and annotations that directly overlay the equipment being maintained. Workers then follow the AR instructions and must ultimately rely on their own judgement and knowledge of the procedure as they progress from step to step. An AR assistant that could …

Productivity And Quality Evaluation In Assembly Using Collaborative Robots, Carlos F. Manzanares Vega

Open Access Theses & Dissertations

In Industry 4.0, various technologies have been applied to achieve automation for traditional manufacturing and practices. For this reason, Smart Manufacturing (SM) environments utilize collaborative robots for process optimization by integrating the Internet of Things (IoT). Cobots are equipped with sensors and/or other devices to be able to transmit data in real-time while performing their tasks. Consequently, such SM implementations improves the decision making and business development, such as supply chain and operations, by sharing real-time data from a plant operational level. The collaborative robots are also designed to safely interact and collaborate with humans to perform tasks and optimize …

Digital Twins In Advanced Manufacturing To Enhance Manufacturing Efficiency, Max Kirkpatrick

Theses and Dissertations

Digital Twins of manufacturing systems are an emerging tool for improvement, optimization, and monitoring of physical manufacturing systems. The idea of representing physical systems with digital depictions has been prevalent since the early days of Computer Aided Design (CAD), but recently the concept of a Digital Twin has been expanded to encapsulate more than just a digital model of a design. Instead, the Digital Twin offers a unique, comprehensive, and real-time toolset for analysis and improvement of physical systems. These tools can be used to improve system efficiency, perform “what-if” analyses, virtually commission manufacturing equipment, analyze system performance in real …

Assessing Readiness For Implementation Of Prognostics And Health Management In Small And Medium Enterprises, Sara C. Fuller

Theses and Dissertations

Prognostics and Health Management (PHM) refers to using robust sensing, monitoring, and control to detect, assess, and track system health degradation and failure modes, allowing for enhanced management and operational decisions. The need for PHM within a manufacturing facility has increased due to a variety of reasons, such as the increasing complexity of manufacturing equipment.

A lack of readiness for digital implementations is linked to failure. The literature highlights certain barriers and enablers that can signal whether a technology implementation will be successful, such as management and maintenance employees’ desire to change the existing process, an understanding and willingness to …

A Modification To The Skiving Process For The Manufacture Of Offset Geometry Strip-Fin Heat Sinks, Daniel Luberda

McKelvey School of Engineering Theses & Dissertations

High-powered electronics are extremely prevalent, and a vast majority of these devices use some form of heat sinks as either an active or passive cooling device. Although two-phase cooling technology has rapidly advanced to accommodate increasing heat loads on modern electronics, the added costs and complication inherent in two-phase cooling solutions makes effective air-cooled heat sinks potentially valuable.

A more effective heat sink can occupy a smaller footprint to dissipate the same heat flux, meaning material and packaging costs can be reduced. Aluminum heat sinks are produced through a variety of manufacturing processes, including machining, bonding, extrusion, casting, forging, 3D …

Hybrid Theory-Machine Learning Methods For The Prediction Of Afp Layup Quality, Christopher M. Sacco

Theses and Dissertations

The advanced manufacturing capabilities provided through the automated fiber placement (AFP) system has allowed for faster layup time and more consistent production across a number of different geometries. This contributes to the modern production of large composite structures and the widespread adaptation of composites in industry in general and aerospace in particular. However, the automation introduced in this process increases the difficulty of quality assurance efforts. Industry available tools for predicting layup quality are either limited in scope, or have extremely high computational overhead. With the advent of automated inspection systems, direct capture of semantic inspection data, and therefore complete …

Analysis Of A Full-Stack Data Analytics Solution Delivering Predictive Maintenance To A Lab-Scale Factory, Nathan Wesley Hoyt

Theses and Dissertations

With the developments of industry 4.0, data analytics solutions and their applications have become more prevalent in the manufacturing industry. Currently, the typical software architecture supporting these solutions is modular, using separate software for data collection, storage, analytics, and visualization. The integration and maintenance of such a solution requires the expertise of an information technology team, making implementation more challenging for small manufacturing enterprises. To allow small manufacturing enterprises to more easily obtain the benefits of industry 4.0 data analytics, a full-stack data analytics framework is presented and its performance evaluated as applied in the common industrial analytics scenario of …

B.A.C.O.N. (Battery-Powered Autonomous Cart Conversion) Autonomous Vehicle Design, Robyn C. Ribet, Damond Li, Tanner Hillman, Christopher Or

Mechanical Engineering

The goal of our project is to convert an electric go cart into an autonomous testing platform. We must enable autonomous braking, steering, and acceleration with electro-mechanical systems. We began the project with ideation to create our initial design and have since received ample feedback from faculty, students, and our sponsor. With this feedback we were able to refine our preliminary ideas and produce a detailed design supported with ample analysis, research, and external advice. We have developed our project in four main subsystems: Steering, braking, acceleration, and emergency braking. Following, we procured, manufactured, and assembled all of our designed …

The Take It All Tailgate Wagon: From Concept Through Prototype Development, Carly Huguley

Honors Theses

This text outlines the design process of the Take it All Tailgate from concept design through two prototyping stages. The Take it All Tailgate was designed for the every gameday tailgater who has a lot of tailgating equipment to haul from their vehicle to the tailgating area. With this in mind, a team of five members designed a wheeled storage space that also acts as a table in the tailgating area. Lean manufacturing was implemented to improve the build process and the overall design of the storage wagon.

Center For Manufacturing Excellence Capstone Project: Sec Rivals Checkers, Ward Winstead

Honors Theses

Each year, the seniors in the Haley Barbour Center for Manufacturing Excellence complete a capstone project. A team comprised of seniors in varying disciplines work to develop a business model focused on producing a specific product. This team, SEC Rivals Checkers, chose to produce wooden checker boards where each half of a board is custom to a specific SEC school. These halves were designed to be interchangeable, so a variety of different combination could be created when utilizing the product. Through initial marketing analysis, cost estimation, prototyping, and process development, the original SEC Rivals Checkers idea was developed into a …

Customized Sidearm Case: Leading A Cme Capstone Team From Concept To Production, Robert B. Sharp

Honors Theses

The goal behind this thesis is to document and analyze my performance as the project manager for the Customized Sidearm Case capstone team during the Center for Manufacturing Excellence’s senior capstone experience. The capstone experience begins the fall of students senior year where a select number of product ideas submitted by the students are chosen, and teams are built around these projects. The objective of the project is to walk a product from the concept phase through the entire design process resulting in a full-scale production run during the spring semester. My product pitch of a wooden sidearm case, customized …

Performance Evaluation Of A Label Manufacturer Using Simulation Modeling, Joshua Holguin

Open Access Theses & Dissertations

Currently, the Supply Chain has been affected by freight prices, material scarcity, demand forecasting, port congestion, and digital transformation which are causing high lead times and delaying deliveries in all industries, but specifically in the labeling/printing industry. The industry is currently affected by the lack of new research improvements, optimization methodologies, supply chain disruptions, and technologies implementations within the label industry. Labeling /Printing industry has been out in business for more than 50 years, where labeling technologies such as Flexographic, Digital, and Die Cutting have advance in performance, effectiveness, complexity, and dependability over the last years. The implementation of a …

Trajectory Planning Of Non-Gravity Aligned (Nga) Segments In Arbitrary Directions For Large Scale Additive Manufacturing Of Metals (Lsamm), James Logan Mcneil

Doctoral Dissertations

Traditionally, slicing and path planning are done along the gravity-aligned direction of a part, causing more complex geometrical shapes to have unsupported overhangs. Wire Arc Additive Manufacturing (WAAM) has typically handled overhangs with a robotic part positioner; but, to extend the current capabilities of LSAMM, a new framework for slicing and building parts out of gravity alignment has been developed. The proposed framework focuses on segmenting more complex geometrical parts into gravity-aligned (GA), non-gravity aligned (NGA), and transition zones to support tool-path generation. GA and NGA segments can be planned with traditional slicing techniques, but the NGA tool-paths must be …

Precast Concrete Manufacturing Business Plan, John F. Will Jr.

Construction Management

The Central Coast of California has been under development since the Great Recession of 2008. Throughout this development, there has been an exceedingly high demand for precast concrete products, specifically in the civil sector of the construction industry. These products are being utilized by more and more by contractors around the world. This demand has emerged from the lack of concrete product manufacturers in this region of California. This project introduces a business plan for a new precast concrete product manufacturer by the name of J.W. Concrete Products LLC. The objective of this business plan is to reflect the benefits …

Assessing Augmented Reality Instruction In Manufacturing Engineering Education, Janine Draper Price

Theses and Dissertations

Augmented Reality (AR) is fast-growing technology that has proved itself in many applications, including manufacturing environments. Manufacturing engineers benefit in an industrial environment by harnessing this technology in the workplace to guide workers through a variety of tasks. It is no longer a question on whether it is useful, but what are the best ways of applying the technology. Currently there are no published studies on ways to use augmented reality in a Manufacturing Engineering Educational Environment (MEEE). This study examines various ways that AR can be used in an MEEE setting and assesses the value of such applications. This …

Utilization Of Resin-Based Additive Manufacturing For Investment Casting, Matthew Frost, Isaiah Hong

Mechanical Engineering

Dr. Xuan Wang, an Industrial & Manufacturing Engineering (IME) professor at California Polytechnic State University, San Luis Obispo, has sponsored the resin-based 3D printing investment cast senior project. The objective of the project was to thoroughly research the process and document the findings of using a resin-based 3D printed part as the pattern for investment casting. While this manufacturing process is not necessarily a new idea, the lack of technical research and documentation limits its ability to be reproducible. The research portion of the senior project included analyzing the limitations to the printing/casting manufacturing process. Measurements of part thicknesses, hole …