Engineering Commons^™

A Study Of Solder Joint Failure Criteria, Jianbiao Pan, Julie Silk

Industrial and Manufacturing Engineering

One of the challenges in an experimental study of solder joint reliability is to determine when cracks occur in a solder joint or when a solder joint fails. Cracks in a real solder joint are difficult to identify using an X-Ray system. Cross-sectioning and scanning electron microscopy (SEM) is a destructive method. A common non-destructive test method is to monitor resistance increase in a solder joint or a daisy-chain. However, no scientific research has been done in establishing the relationship between the crack area of an interconnection and the change in resistance of the interconnection. This paper proposes a method …

Effect Of Gold Content On The Reliability Of Snagcu Solder Joints, Jianbiao Pan, J. Silk, M. Powers, P. Hyland

Industrial and Manufacturing Engineering

Electroplated Ni/Au over Cu is a popular metallization for printed circuit board finish as well as for component leads, especially wire-bondable high-frequency packages, where the gold thickness requirement for wire bonding is high. The general understanding is that less than 3 wt% of Au is acceptable in SnPb solder joints. However, little is known about the effect of Au content on the reliability of SnAgCu solder joints. The purpose of this paper is to determine the acceptable level of Au in SAC305 solder joints. Three different package platforms with different Au thicknesses were assembled on boards with two different Au …

Evolving A Summer Engineering Camp Through Assessment, Katherine Chen, Lizabeth Schlemer, Heather Scott Smith, Teana Fredeen

Industrial and Manufacturing Engineering

EPIC (Engineering Possibilities in College) is a one-week summer program for high school students (entering 9th-12th grades) to learn about engineering and experience hands-on labs in a university atmosphere. It's an opportunity for students to explore the different types of engineering available at many universities. The aim of EPIC is to expand the College of Engineering mission to K-12 students: "To educate students for careers of service, leadership and distinction in engineering or other fields by using a participatory, learn by doing, ‘hands-on’ approach".

The Inside-Out Classroom: A Win-Win Strategy For Teaching With Technology, Daniel J. Waldorf, Lizabeth Schlemer

Industrial and Manufacturing Engineering

As costs of higher education soar and many universities face uncertain funding models, institutional pressures have increased to improve instructor efficiency. At the same time, U.S. industry leaders and leading educators have called for improvements in engineering education based on more interactive, hands-on student learning experiences. Although many efforts have been made to take advantage of technology to either improve student learning or to maintain student learning while increasing instructor efficiency, few approaches have been shown to improve both learning and efficiency. A teaching method is proposed to improve student learning and increase student satisfaction while also addressing the instructors’ …

Design Projects With Out-Of-Town Companies, Lizabeth Schlemer

Industrial and Manufacturing Engineering

The capstone design class in the industrial engineering department at California Polytechnic State University, San Luis Obispo (Cal Poly) includes projects with companies. The projects are large ambiguous facilities design problems that allow students to incorporate many aspects of the IE curriculum. For the past 15 years students have been participating in these projects with local companies. Over the past several years, companies from out of town (200 miles to the north in Mountain View or 200 miles to the south in Oxnard) have participated. These out of town companies have presented certain logistical issues, but they have proven to …

Cal Poly Hydrogen Fuel Cell Senior Project Air Plane Galley Demonstrator, Laurel Fee, Adam Ferrarelli, Nick Hasheider, Jeff Massman, Alex Mosbacher, David Mravca, Brian Noland, Levi Sternberg

Industrial and Manufacturing Engineering

No abstract provided.

Ergonomic Improvement On The Farm/Garden Hoe, Yuan Chao Jiang

Industrial and Manufacturing Engineering

The hoes are widely used in the farms and home gardens in the United States. Many existing hoes are not ergonomically designed because they require a lot of back bending and wrist bending during use. Back bending often causes lower back injuries, and wrist bending often causes carpal tunnel syndrome. It can be very expensive to cure these injuries. The objective of this project is to reduce back bending and wrist bending by redesigning the hoe in an ergonomic perspective. In order to achieve the objective, ergonomics and human factors concepts are applied in the design. Two additional side handles …

Quality Of Life Plus (Ql+) 2011 Rideable Tour, Daniel J. Pelisek

Industrial and Manufacturing Engineering

Quality of Life Plus (QL+) does important work supporting members of the United States armed forces. Without significant funding, it is unlikely they could continue doing that work. Our goal was to hold a charity bike ride, the 2011 QL+ RideABLE Tour, to help them raise the funds they need. We approached the ride from two different perspectives, event planning and project management, with the hope that the two approaches could work in synergy towards a successful event. The project management approach focused on industrial engineering tools like work breakdown structures (WBS), cost analysis, and risk assessment. The goal was …

Radio Frequency Identification Classroom Management System, Andrew W. Wright

Industrial and Manufacturing Engineering

Professors who manage large classes are unrealistically expected to grade each student fairly and accurately. Even with all of the technological advancements that have occurred in the past thirty years, very little progress has been made in classroom management, and as a result, professors are not equipped with enough tools to successfully manage large class sizes. Because radio frequency identification (RFID) technology is making its way into student issued identification cards, there is an opportunity to use it as a tool to aid professors in the classroom. The focus of this paper is to discover an effective system that can …

Parker Aerospace Fluid Systems Division Product Support Facility Redesign, Sean Walker

Industrial and Manufacturing Engineering

With growing popularity for commercial air travel and aerial military operations comes an increase in demand for innovative, technological solutions of aircraft system components. As OEM sales of these components rise, this creates a burden on the aftermarket side of the business when these parts and systems require service in order to continue functioning properly. Parker Aerospace, Fluid Systems Division, and its Product Support Team are experiencing this growth burden and want to reconfigure necessary means within the layout to succeed in accommodating new program areas on the aftermarket side. During this process, cost reduction opportunities will be explored and …

Ackermann Steering Geometry Applied To A Skateboard Truck, Daniel D. Downs

Industrial and Manufacturing Engineering

Conventional skateboard trucks are currently unable to meet the challenges of the modern enthusiast. They are lacking in key performance metrics such as handling, stability, and traction. Longboard enthusiasts, whom rely heavily on handling performance, are hungry for new and innovative technology to help bring the sport to the next level. The aim of this project was to solve these problems by applying specific aspects of automotive steering geometry and best engineering practices. Three successive prototypes were designed, with the first two prototype sets being manufactured and extensively tested. The first prototype served as a proof of concept, but suffered …

Human Factor And Ergonomic Considerations And Improvements For A Table-Free Card Game Product, Enrique Daniel Aguirre

Industrial and Manufacturing Engineering

The purpose of this project is to design a table-free Yu-Gi-Oh! Card Game product that will make the transition of said game from table to user more fluid and intuitive, improving on past designs in the process. Despite there currently being many similar products in the market, there has not yet been one that adequately fulfills game requirements and comfortably adapts to the range of players associated with the game. Taking ergonomic and human factor considerations into account during the development of the design, a prototype was created as part of this project that was subsequently tested against a past …

Optimal Process Design For Recycled Pet Blends In Injection Molding, Perry H. Johnson

Industrial and Manufacturing Engineering

This case study on optimization of blends with process variables shows how application of advanced tools of Design of Experiments can simultaneously optimize a mixture formulation and processing conditions, taking advantage of complex interactions in the system. The effect of recycled PET and virgin PET on tensile strength and stiffness was studied. The optimal amount of mixture components to produce maximum recycled-content products is determined. As the results of doing systematic experimentation, using mixture experiments, the quality of recycled plastic products can be improved and becomes more robust to variations at the optimal thermal operating settings. This is done through …

Technological Advancement For Vehicles Operable By The Visually Impaired, Heather L. Brown

Industrial and Manufacturing Engineering

This senior project aims to provide blind persons with the ability to effectively experience driving. This report includes the project background, literature review, designs, methodologies, results, and conclusions with project management, human factors engineering, and electronic manufacturing focuses. Other universities and professionals have accepted the Blind Driver Challenge presented by the National Federation of the Blind (NFB) or studied systems to improve vehicle feedback. The Virginia Tech vehicle, named "Odin", includes tactile and audio interfaces in order to relay information to a blind driver about vehicle heading and speed. The QFD results reveal that the amount of available information from …

Continuous Improvement Efforts In J. Carrol's Screen Printing Process, Millan Arellano

Industrial and Manufacturing Engineering

The following report details the analysis and procedure taken not only to determine the issues limiting J. Carroll’s screen printing capacity, but also provides the solutions necessary to address these issues. The report addresses one crucial operation in the screen printing process, changeovers, which contribute to roughly 24% of the screen printing process time and more than any other operation in the screen printing process. Within the changeover operation two specific tasks appear to be plaguing long changeover times: they are test print and design approval. The report elaborates on the Fishbone Diagrams utilized to bring up the potential causes …

Improving Cal Poly Space Systems Infrastructure, Tyler Richier

Industrial and Manufacturing Engineering

The goal of this project was to increase the usable space for the club Cal Poly Space Systems to work on its projects, improve the safety for its members, and reduce the time it takes to manufacture its products. The project demonstrated the effectiveness of 5S in improving a workspace. Club members were measurably more comfortable in the work environment and spent less time looking for tools. Current rooms were made more professional by ridding the workplace of non-valued items and finding sensible locations for high-traffic items. Additional rooms were added and they should indisputably support club projects the upcoming …

Use Of Electroluminescent Wire For Monitoring Fatigue In Manual Materials Handling, Spencer Martinez, Chester Matkey

Industrial and Manufacturing Engineering

In the field of manual materials handling, millions of dollars are lost each year in accidents caused by physical fatigue. The purpose of this project is to design a device for monitoring fatigue in manual material handling operations. Combining our knowledge of electronics, new product design, ergonomics, and human factors, we were able to design and test a product to meet these specifications in hopes of developing a prototype for marketability. While we have only developed a prototype, the economic justification is performed for mass production of the product. Using statistics gathered on the percentage of injuries caused each year …

The Analysis Of Electure Creation & Distribution Systems At Cal Poly, Jason Carian

Industrial and Manufacturing Engineering

This report details the analysis of potential eLecture creation and distributions for Cal Poly San Luis Obispo. Specifically, this project will focus on a system for the College of Engineering. This project was completed using the Systems Engineering process and concentrated more specifically on the Systems Evaluation phase, in which the specifics for potential system solutions are discussed. The first step was to define the problem that must be addressed; Cal Poly currently uses eLectures in the classroom, but with the wide variety of eLecture creator and distribution alternatives available, there is no optimal system at the University. The next …

Human Resources Recruitment Management Plug-In For Enterprise Resource Planning Systems, Alex Riabov

Industrial and Manufacturing Engineering

Enterprise Resource Planning (or ERP in short) systems today are a backbone of most large United States and international corporations. Around the 1990s these companies transitioned from using different software packages for each business unit to using the modules of Enterprise Resource Planning system for the business unit’s specific needs. Some functionality was lost. Human Resource function of recruitment was one example of large functionality left out of Enterprise Resource Planning systems such as SAP or PeopleSoft. As a result, these large companies turned to 3rd party Applicant Tracking Systems to manage recruitment and subsequently created redundancies in workflow, increased …

Analysis Of The Effectiveness Of Passive Item-Level Rfid Tags Utilized In Inventory Counts, Joshua (Josh) Gilbert

Industrial and Manufacturing Engineering

In an effort to reduce the amount of manual labor associated with physical inventory counts of large warehouse type environments, a study was performed analyzing the effectiveness of item-level RFID to automate counts. Products were selected based off of certain characteristics and tagged with passive RFID tags. A design of experiment was developed specific to each product that best related to actual in store environments. Experiments were conducted in the Poly GAIT lab. Certain levels of analysis were performed and conclusions made specific to each product under question.

Setup Reduction Time At A Batch Manufacturing Plant, Mario A. Aguilar

Industrial and Manufacturing Engineering

This project documents the efforts to reduce setup times at a batch manufacturing culture media production plant. The company is one of the leading producers in medical and laboratory supplies, including culture media. In the production of culture media, the production line requires to switch between solutions once or twice a day depending on the production schedule.

The report provides the production plant with a concrete analysis of their current changeover method, which tends to be lengthy and complicated, and suggest alternatives in short and long term periods of time to reduce setup time.

After analyzing the time studies of …

Microfiche Digitization And Process Improvement For Cal Poly Senior Projects, Kyle Gaunt

Industrial and Manufacturing Engineering

This project addresses the need to digitize Senior Projects available on microfiche at the Cal Poly Robert E. Kennedy Library. Microfiche is an outdated document archival medium and is unfamiliar to most students, making Senior Project research inconvenient and frustrating to students. To make this process easier and more accessible to students, the University Library should consider digitizing its Senior Project collection and improving the current system in the mean time.

The Six Sigma DMAIC method was used to discover root cause problems of the current system, define performance metrics, and to develop data driven solutions for improving the current …

Ms Access Database Designed For Community Service Office, Juan P. Ojeda Pedraza

Industrial and Manufacturing Engineering

The purpose of this senior project is to reduce the number of data entry errors in the community service worker system at the EcoSLO office. EcoSLO is a community service office located in San Luis Obispo, CA that seeks to better the environment through various events and programs such as recycling projects and environmental clean-up projects. Currently the EcoSLO office uses Microsoft Excel to store and keep track of community service workers. A Microsoft Access database will be designed to help minimize data entry errors and to make it easier to generate reports that must be submitted to the San …

Emergency Response Manufacturing: Lead Time Minimization And Human Factors For Ozone Water Filter Assembly And Kitting Process, Travis Gary

Industrial and Manufacturing Engineering

In the unfortunate event of a natural disaster affecting San Luis Obispo, response from national entities cannot be relied upon for a timely or efficient response. Local disaster recovery is superior because it minimizes response time, the need for costly stockpiling and creates a solution that is uniquely suited to the community that empowers local people in their most troubled times. Extensive planning is required for local disaster recovery and this project aims to provide the research and recovery system design required to implement an effective recovery plan.

Potable water is the primary need for people in the disaster situations …

Efficient Operations And Procedures Of Children's Museums, Siobhan Sullivan

Industrial and Manufacturing Engineering

Due to the recent economic downturn, the San Luis Obispo Children’s Museum’s budget has been reduced by half. The entrepreneurial Museum Director is searching for ways to cut costs and increase revenue. This project aimed to apply Lean methodologies, traditionally used in manufacturing organizations, to the Museum, a non-profit service organization.

The project objectives were to have an organized storage area using principles of 5S; determine excess inventory; consolidate available exhibit information; create guidelines for exhibit production to ensure high quality exhibits with sufficient user documentation are created; perform a sampling of exhibit use in order to have a list …

Warehouse Design For Polygait, Colby Spear

Industrial and Manufacturing Engineering

Professor Tali Freed, advisor of POLY GAIT, needs a warehouse built to accommodate the testing of Radio Frequency Identification (RFID) technology with Automatic Storage and Retrieval Systems (AS/RS). This report explores a 5-step warehouse designing technique. The five steps are as follows: Overall Structure, Sizing and Dimensioning, Operation Strategy Selection, Equipment Selection, and Department Layout. Each of these is analyzed in turn to cover everything necessary in designing a warehouse. Furthermore, a cost analysis was conducted in order to give Professor Freed a better understanding on the cost required to build this warehouse. A smaller 25’x22’ foot is optimal because …

5s Implementation Plan For The Shipping Department At Helical Products Co., Eric William Walker

Industrial and Manufacturing Engineering

Helical Products Company is a business that manufactures flexure products, such as couplings and u-joints. As part of a movement towards lean manufacturing, Helical Products Company of Santa Maria, California is in need of a principle that will help them continuously improve their shipping department. A study of 5S, a lean principle focused on waste reduction, will be done to investigate opportunity for implementation. A literature review takes a peek on research of lean manufacturing history, lean workbook/ tutorials and lastly case studies and journal articles. The output of research provides a design plan for Helical using 5S and other …

San Luis Obispo Public Winery Transit System, Amanda Crissman

Industrial and Manufacturing Engineering

This project designs a small scale transit system that runs between five wineries in San Luis Obispo. San Luis Obispo County is known for its many wineries ranging up and down the central coast. Transportation options for wine tasters are limited to tour bus, limousine, taxi, and private cars. This does not leave an option for wine tasters who prefer a cheaper mode of transportation than limo, tour bus, or taxis, and do not want the hassle of driving and worrying about how much alcohol they consume. Selection criteria methods were used to choose bus stop locations at a specified …

Antique Aircraft Avionics Modernization: Process And System Design For A Transponder Installation In A 1946 Luscombe 8a, Nicholas Camacho

Industrial and Manufacturing Engineering

The general aviation population is full of vintage aircraft. Built in the heyday of personal aviation, these machines embody the spirit of aviation; freedom afforded from the everyday monotony of earthbound people. As technology advanced and air traffic became more congested, new requirements were set forth by governing bodies to ensure the safety of aircraft. These regulations limited the capability of vintage general aviation aircraft. This report was commenced to understand the necessary steps required to add modern technology to old aircraft, as well as design a system that would enhance the capability of vintage aircraft while keeping their antique …

New Product Development Project Construction, Implementation And Continual Improvement: A Case Illustration From Semiconductor Manufacturing, Philip Daniel Walker

Industrial and Manufacturing Engineering

Successful projects are the backbone of companies that lead their respective fields. Failed projects for one reason or another are more often than not the reason some companies fall further and further behind their counterparts. Projects are becoming more technologically advanced. Projects are more expensive and are receiving less funding than they used to due to a highly competitive economic climate. The projects in the second decade of 2000 have to meet the triple bottom line of cheaper, faster, and better than ever before. Due to these reasons projects have continued to fail at an alarming rate (nearly 70% in …