Operations Research, Systems Engineering and Industrial Engineering Commons^™

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 …

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 …

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 …

A Dual Perspective Towards Building Resilience In Manufacturing Organizations, Steven A. Fazio

Theses and Dissertations

Modern manufacturing organizations exist in the most complex and competitive environment the world has ever known. This environment consists of demanding customers, enabling, but resource intensive Industry 4.0 technology, dynamic regulations, geopolitical perturbations, and innovative, ever-expanding global competition. Successful manufacturing organizations must excel in this environment while facing emergent disruptions generated as biproducts of complex man-made and natural systems. The research presented in this thesis provides a novel two-sided approach to the creation of resilience in the modern manufacturing organization. First, the systems engineering method is demonstrated as the qualitative framework for building literature-derived organizational resilience factors into organizational structures …

Predicting Zero Bin In The Semiconductor Manufacturing Industry: Machine Learning Algorithms, Yazmin Montoya

Open Access Theses & Dissertations

The semiconductor industry has faced supply chain manufacturing shortages that ultimately led to a worldwide chip shortage during the COVID-19 pandemic. These chip manufacturers use sophisticated and advanced manufacturing machinery in their fabs to manufacture chips. As experienced during the pandemic, manufacturing unavailability is often due to the lack of critical manufacturing-related spare parts. This thesis evaluates the effectiveness of machine learning algorithms to identify significant factors contributing to manufacturing part outages (i.e., zero-bin) to keep manufacturing equipment running at total capacity within the organization. We propose clustering methods to segment the data and use logistic regression, logistic lasso regression, …

Strategies For Implementing Internet Of Things Devices In Manufacturing Environments, Todd Efrain Hernandez

Walden Dissertations and Doctoral Studies

The Internet of Things (IoT) has been exploited as a threat vector for cyberattacks in manufacturing environments. Manufacturing industry leaders are concerned with cyberattacks because of the associated costs of damages and lost production for their organizations. Grounded in the general systems theory, the purpose of this multiple case study was to explore strategies electrical controls engineers use to implement secure IoT devices in manufacturing environments. The study participants were eight electrical controls engineers working in three separate manufacturing facilities located in the Midwest region of the United States. The data were collected by semistructured interviews and 15 organizational documents. …

Size And Cost Reduction Of The Antenna 3000, Mario Mignott, Austin Deaver, Josh Madaris

Senior Design Project For Engineers

For our senior design project, we have partnered with Compass Technology Group to improve its Antenna 3000 manufacturing process. The Antenna we are working on is not actually called this, but due to NDA regulations, we will disguise it as the Antenna 3000. This will include finding a way to minimize material costs and labor hours involved to assemble this product together. Our minimum success criteria will be to reduce both the manufacturing time and materials' cost by 20%. Our primary approach to solving this problem will be to implement Lean Six Sigma practices such as the DMAIC principle.

Using …

Product Realization Capstone: Element Proof Safety Steps For Willie Price Lab School, Catherine Thomas, Allan Heuerman, Jared Mumme

Honors Theses

The purpose of this document is to describe the process we took to complete our capstone which paired the Center for Manufacturing Excellence with the Willie Price Lab School. The goal of the capstone was to remake step stools for the students of Willie Price, as the last stools failed to withstand weather damage. However, with the COVID-19 pandemic, plans were hindered, shifting the goal from actually producing the steps to creating instructions so that a younger Center for Manufacturing class could complete the production at a later date. Standardized Work Instructions, a detailed production plan, and engineering drawings were …

A Reinforcement Learning Approach To Sequential Acceptance Sampling As A Critical Success Factor For Lean Six Sigma, Hani A. Khalil

Theses and Dissertations

In the 21st century, globalization coupled with technological advancement and free trade has created competition among various businesses enterprises. This competition has led many businesses to adopt various management techniques such as acceptance sampling aimed at transforming their processes in order to remain competitive in the global market and adapt to new market demands. The successful implementation of acceptance sampling is highly dependent on what the academic literature refers to as acceptance sampling optimization. A literature review on the optimization of acceptance sampling has not shown any work that studied whether acceptance sampling and machine learning (ML) plans can be …

Development Of An Additive Manufacturing Compression Molding Process For Low Cost In-House Prototyping, Grant Forrester Warden

Industrial and Manufacturing Engineering

Composite parts can be manufactured using various processes. Generally, a mix of resin and fiber is formed into the desired geometry using a mold and pressure. One process used by Dr. Joseph Mello in his research is known as compression molding. Compression molds are generally made from large billets of aluminum or stainless steel, are machined by a CNC mill, and are then hand-finished with polishes and mold preparation products. This process is expensive, requires large machinery and experienced operators, and introduces long lead times relative to the design cycle of the part being manufactured. The nature of Dr. Mello's …

Slm Materials Development, Justin G. Reiner, Michael T. Schembri

Industrial and Manufacturing Engineering

The purpose of this project was to create a procedure to efficiently determine a “recipe” of parameter values that create a desired set of mechanical properties. Research was conducted into the laser powder bed fusion process with focus on underdeveloped materials. A design of experiment was used with a set of density correlated parameters to establish a method of producing nearly dense parts. Our methods include SLM printing, metrology, and statistical analysis. An experimental procedure for materials development was designed, but unable to be validated during the scope of this project, due to unforeseen safety issues (exposure to Chromium 6, …

Crystal Engineering Manufacturing Facility Analysis, Maximiliano Cortes, Eric Dustin Kornrumpf, Sthefano Alvarado

Industrial and Manufacturing Engineering

This report will encompass a two-quarter long senior project effort to provide a recommendation for the client, Crystal Engineering. Crystal Engineering is currently in the process of introducing three new products, one now and two within the next six months. However, their existing lines already occupy the available production space and as a result, they are unable to determine how to effectively incorporate new production lines within the facility. Therefore, the main objectives of this project were to deliver several facility redesign layouts backed by a holistic justification for each. The formulation of the facility redesign layouts incorporated several industrial …

Theory And Practice Of Supply Chain Synchronization, Michael Prokle

Doctoral Dissertations

In this dissertation, we develop strategies to synchronize component procurement in assemble-to-order (ATO) production and overhaul operations. We focus on the high-tech and mass customization industries which are not only considered to be very important to create or keep U.S. manufacturing jobs, but also suffer most from component inventory burden. In the second chapter, we address the deterministic joint replenishment inventory problem with batch size constraints (JRPB). We characterize system regeneration points, derive a closed-form expression of the average product inventory, and formulate the problem of finding the optimal joint reorder interval to minimize inventory and ordering costs per unit …

Life Cycle Sustainability Analysis (Lcsa) Of Polymer-Based Piping For Plumbing Applications, Andy J. Rivas Bolivar

Senior Honors Projects, 2010-2019

Water conveyance systems play a critical role in modern developed areas. Polymer pipes have been used for about a century, and their convenient physical properties have positioned polymers as the leading material in the piping industry. Having such influence in the market means that changes in current material selection and manufacturing could lead to significant reductions in the footprint associated with their products. Currently, there are no comparative lifecycle assessments that evaluate the different polymer selections commercially available, which makes it hard to determine what products have the least impact on the environment. Understanding how such impacts are relative to …

A Study Into The Production Efficiency Of Cal Poly Chocolates, Fernando Calderon

Industrial and Manufacturing Engineering

The project objective was to: identify ways to reduce the production cost of Cal Poly Chocolates. The project was executed through the DMAIC approach, a data driven improvement cycle. Using several industrial engineering tools, six improvement opportunities were found. Three project deliverables were created and three process changes were recommended. The total annual savings, if recommendations are implemented, sum to $1700.

Best Matching Processes In Distributed Systems, Mohsen Moghaddam

Open Access Dissertations

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common …

Design For Manufacturability: Off-Road Toyota Bumper, Drew Donlon

Industrial and Manufacturing Engineering

The purpose of this project is to design a new off-road bumper that is improved from the stock form of a 1996-2002 Toyota 4Runner and a 1996-2004 Toyota Tacoma. The current state of the component is too weak to endure to off-road endeavors, and a kit bumper market is virtually untapped for these vehicles. The objectives of this project were met by redesigning the stock front bumper, conducting a finite element analysis on the model to test for strength, prototyping the bumper with CNC cut cardboard, and conducting a full cost analysis including the costs for waterjet and laser cutting …

Optimization Of Rfid System Coverage In A Manufacturing Environment, Scott D. Malatesta

Master's Theses

This paper compiles existing ideas, theories, and experiments across multiple disciplines to provide guidance for a company looking to implement an optimal RFID system in their production facility. The desire is to maximize the information received by the system while minimizing the cost. Four potential layouts of RFID antennas, two with overlapping antenna coverage and two with non-overlapping layouts, are first analyzed to understand the special coverage and the number of antennas required. The value of information is then quantified to determine whether higher coverage layouts are worth the additional costs associated with the higher number of antennas required. It …

Knowledge Reuse Through Electronic Knowledge Repositories: An Empirical Study And Ontological Improvement Effort For The Manufacturing Industry, Peter Panha Chhim

Wayne State University Dissertations

Knowledge management adoption is growing, and will continue to grow in no small part because of its recent inclusion into the ISO 9001 quality standard. As organizations look towards ways in which to manage their knowledge, the codification of explicit knowledge through Knowledge Management Systems (KMS) and Electronic Knowledge Repositories (EKRs) will undoubtedly gain more interest.

An EKR is a form of KMS that emphasizes the codification and storage of organizational expertise for the purposes of Knowledge Reuse (KRU). Unfortunately, the factors surrounding KRU are not well understood. While previous studies have viewed EKR usage from a narrow perspective, a …

Improving Machine Changeover/Setup Times By Increasing U.S. Manufacturers' Knowledge Of 5s, Nicole Schra-Martin

Walden Dissertations and Doctoral Studies

The 5S process is one of the techniques born out of Japanese manufacturing. Ohno, the developer of 5S, found that when manufacturing waste is eliminated, costs are reduced and profits increase. This is the bases of 5S and this research. The cost of U.S. manufactured products is higher compared to the cost of products from other global manufacturers that use 5S. This study was conducted to determine if implementing 5S in U.S. manufacturing could change U.S. manufacturing cost and if using 5S could impact U.S. manufacturing. The research questions focused on the relationship between 5S and changeover/setup times on production …

Heuristic Solution For Separated Manufacturing Process, James Dee Davis

Masters Theses

Downtime is a major issue for manufactures. Downtime may occur from breakdowns, quality issues, lack of manpower, lack of materials, or in this case a lack of storage containers. A manufacturing system was studied that consists of an injection machine that supplies two assembly lines. The injection machine suffered from frequent downtime from lack of containers. The process was analyzed for root cause of downtime. After analysis of the system it was found that the injection process had high variability in production quantity and quality. The scheduling scheme called for production until all available containers were full regardless of actual …

Wasco Environmental Chamber System Manifold, Steve Mark Yatco

Industrial and Manufacturing Engineering

This report details the process of designing and producing a manifold that connects ultra-high purity (UHP) pressure and vacuum switches to an air supply so that the parts may be tested in an environmental chamber. Using the DMAIC (define, measure, analyze, improve, and control) methodology of problem solving, progress on the project includes thorough research about the problem, preliminary design solutions, iterative prototyping, and testing specific functionalities. Manufacturing engineering topics of tooling, fixturing, metrology, quality, and machining with manual and computer numerical control (CNC) varieties of both mills and lathes are applied during the course of the project. The report …

A Framework For The Development Of A Model For Successful, Sustained Lean Implementation And Improvement, Julie Sisson

Electronic Theses and Dissertations

Lean is a business philosophy focused on shortening lead times by removing waste and concentrating on value-added processes. When implemented successfully, it not only allows for cost reduction while improving quality, but it can also position a company to achieve tremendous growth. The problem is that though many companies are attempting to implement lean, it is estimated that only 2-3% are achieving the desired level of success. The purpose of this research is to identify the key interrelated components of successful lean transformation. To this end, a thorough literature review was conducted and the findings indicate six key constructs that …

S&G Metal Fab Battery Tray, Matthew Nartatez

Industrial and Manufacturing Engineering

This report was written for the design of a battery tray and manufacturing process for S&G Metal Fab. The manufacturing steps of how to process the sheet metal to create the product are defined and documented in this report. This project began with constraints given by S&G and were all accomplished using coursework knowledge obtained as a manufacturing engineer student at Cal Poly San Luis Obispo. This report mainly covers parameters regarding the cutting, bending and, deforming of sheet metal to acquire the desired shapes and sizes. It also analyzes the costs that are associated with these processes and material. …

The Design, Testing, And Manufacturing Of A Pin Fin Extrusion Heat Sink, Arash Michael Mira

Industrial and Manufacturing Engineering

My senior project focuses on the design, testing, and manufacturing of pin fin extrusion heat sinks that are you used to cool simple electronic applications across a multitude of markets. Without the modern day heat sink, electronics that we have become familiar with throughout our everyday lives will cease to exist. I will design these heat sinks using Solid Works 3D CAD. I will then test the heat sinks using ICEPAK CFD software, where I will model the heat sink against a 5 watt application, inside of a cabinet that models the chassis of a computer. After receiving these results, …

High Speed Turning Of Compacted Graphite Iron (Cgi) Using Controlled Modulation, Tyler Paul Stalbaum

Open Access Theses

Compacted graphite iron (CGI) is a material which emerged as a candidate material to replace cast iron (CI) in the automotive industry for engine block castings. Its thermal and mechanical properties allow the CGI-based engines to operate at higher cylinder pressures and temperatures than CI-based engines, allowing for lower fuel emissions and increased fuel economy. However, these same properties together with the thermomechanical wear mode in the CGI-CBN system result in poor machinability and inhibit CGI from seeing wide spread use in the automotive industry.

In industry, machining of CGI is done only at low speeds, less than V = …

Process Optimization Of Boatmate Trailers, Llc, Jamie M. Smotherman, Jasmine L. Kelley

Chancellor’s Honors Program Projects

No abstract provided.

Identification Of Rework Station Location To Enhance Reworkability Using Design For Disassembly, Juan Alejandro Saavedra

Open Access Theses & Dissertations

Rework stations are commonly established as part of each assembly stations causing the material flow of the process to be constantly interrupted. Another option is to place the rework station at the end of the production, but this is not cost effective. This breakeven point between reworkability and cost methodology has been proposed in this thesis to identify the location of a single rework station in an assembly line in order to enhance reworkability using the Design for Disassembly (DfD) principles. The methodology uses the 17 guidelines of DfD in a manufacturing scenario in order to propose a reworkability index …

Extending Origami Technique To Fold Forming Of Sheet Metal Products, Ala Qattawi

All Dissertations

This dissertation presents a scientific based approach for the analysis of folded sheet metal products. Such analysis initializes the examination in terms of topological exploration using set of graph modeling and traversal algorithms. The geometrical validity and optimization are followed by utilizing boundary representation and overlapping detection during a geometrical analysis stage, in this phase the optimization metrics are established to evaluate the unfolded sheet metal design in terms of its manufacturability and cost parameters, such as nesting efficiency, total welding cost, bend lines orientation, and maximum part extent, which aides in handling purposes. The proposed approach evaluates the design …

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 …