Operations Research, Systems Engineering and Industrial Engineering Commons^™

Strider: Manufacturing Processes, Michael Warren-Angelucci

Industrial and Manufacturing Engineering

The goal of the Strider Project is to create a mobility device that can support a person with weakened leg strength and enable them to be supported and maintain a standing position. A prototype of the Strider was created by three Mechanical Engineering students as their senior project. The topic of this senior project was to analyze and create a manufacturing process for the manufacture of the Strider that will be ergonomic and cost effective.

There were many things that needed to be accomplished in order to create the manufacturing process. The first step was to verify that the prototype …

Chsr Clothing: How To Start A Small Business Clothing Line To Be Run Efficiently With Minimum Capital And Maximum Profit, Kayvon Banisalam

Industrial and Manufacturing Engineering

Executive Summary

Many clothing brands have failed because they did not design marketable products with a suitable business plan. Often times, clothing brand owners do not use the capital they possess in efficient ways. They can get caught off guard with unexpected costs and are not running the business in the most resourceful and professional way.

The goal of this project is to create a clothing brand that portrays distinctive designs to go along with an effective business model. This includes implementing decision analysis at several points of the planning phase, along with quality and cost controls. Creating quality products …

Design And Manufacture Of Natural Composite Canoe, Derek Baptista

Industrial and Manufacturing Engineering

Abstract

This report looks into the application and feasibility of manufacturing natural composite canoes. The main fabrics that were analyzed are flax, hemp, and jute. These were then compared to carbon fiber and fiberglass to see the difference in mechanical properties. It was found that the natural fibers have lower mechanical properties but that this could be overcome by designing a balsa wood core with ribs running up the walls. After manufacturing a hemp canoe, many lesson were learned and areas of interest were further explored. With the use of different natural fibers, these canoes can greatly reduce the carbon …

Process Improvements For Establishing Cmmi Certification At Company Xyz, Megan Farrell

Industrial and Manufacturing Engineering

CMMI stands for Capability Maturity Model Integration and is an enterprise-wide Process-Improvement model that provides a set of best practices that addresses productivity, performance, costs, and stakeholder satisfaction. This improvement model is generally used in computer software companied and not only does it improve their processes, but many contracts will only be awarded with those companies who are CMMI certified, so it is very important for Company XYZ. This goal of this project was to help improve the CMMI efforts at Company XYZ in 4 of the 20 distinct processes areas to attain a CMMI Maturity Level of 3. Improvement …

Facilities Planning For An Aerospace Manufacturing Company, William Petrossi

Industrial and Manufacturing Engineering

Absolute Technologies Inc. (ATI) has been growing for years, and is running out of space at their current manufacturing facility in Yorba Linda, CA. ATI will be moving to a much larger facility this winter. They are looking for an efficient way to utilize this space. The machine positions were taken as fixed, seeing as a lean expert was brought in to give advice on placement. With the machines fixed, the scope was narrowed to other areas.

A systematic approach to facilities design is utilized. First, a goal needs to be defined. The goal is to reduce the time wasted …

Consolidation Of Company Abc, Estelle Sillari-Owen

Industrial and Manufacturing Engineering

This project aims to solve Company ABC’s issues in order to keep the company afloat and to keep the company profitable. This was done by reducing Company ABC’s organizational and inventory build-up issues. The project aims to reduce the company’s dependence on outside storage, with plans of consistent inventory reduction over the next year. An implementation plan was created to ensure the company keeps on track to increase profits and prevent against increasing inventory costs.

Consumer Attention To An Over-The-Counter Warning In Four Different Styles Of Design, Abhishek Gawasane, Laura Bix, Javier De La Fuente, Raghav Prashant Sundar, Timothy J. Smith

Industrial Technology and Packaging

The study consisted of three objectives: (a) to test the relative prominence and conspicuousness of a warning required by US law to be conspicuous; (b) to explore whether or not the conspicuousness of the said warning can be enhanced graphically; and (c) to develop preliminary data for power analysis that would guide decisions related to sample size in future studies.

Seventeen subjects viewed four over-the-counter drug packages (each with a different style of warning) along with five other products while wearing an eye tracking device. Four styles of warning were used on the over-the-counter drug packages: no outline and no …

Reliability Analysis Of Low-Silver Bga Solder Joints Using Four Failure Criteria, Erin A. Kimura

Master's Theses

The appropriate selection of failure criterion for solder joint studies is necessary to correctly estimate reliability life. The objective of this study is to compare the effect of different failure criteria on the reliability life estimation. The four failure criteria in this study are a 20% resistance increase defined in the IPC-9701A standard, a resistance beyond 500 Ω, an infinite resistance (hard open), and a failure criterion based on X-bar and R control charts. Accelerated thermal cycling conditions of a low-silver BGA study included 0°C to 100 °C with ten minute dwell times and -40°C to 125°C with ten minute …

Work In Progress: Outreach Assessment: Measuring Engagement, Lizabeth Schlemer, John Oliver, Katherine Chen, Sophia Rodriguez Mata, Eric Kim

Industrial and Manufacturing Engineering

The Learn By Doing Lab (LBDL) at Cal Poly, San Luis Obispo is an on-campus laboratory where 5th through 8th grade students are taught by undergraduates who may be planning a careers in teaching. The two populations - elementary students and undergraduates - are equally important in the process. Since 2008, the lab has seen over 4000 elementary and junior high students and over 100 undergrads have participated. In most outreach assessment the number of individuals participating is an important metric, but this last Spring we experimented with a more in depth measure of effectiveness. As in any learning experience …

Warehouse Redesign, Cristine Carmel Dewar

Industrial and Manufacturing Engineering

A young, growing biomedical company is expanding its warehouse space to keep up with the increasing production. This project’s goals were to recommend a layout and improve a process that would minimize the distance traveled by the material handlers, increase the safety of the warehouse by implementing visual controls, implement ergonomics to reduce chance of injury, and save money for the company. To achieve this first I familiarized myself with their current processes and department and the space required for their current and future production levels. Next I created two alternative layouts, the first (Layout A) to minimize distance and …

The Effect Of Stretch Wrap Pre-Stretch On Unitized Load Containment, Evan A. Cernokus

Master's Theses

There are three main factors affecting the stability of a palletized load that is unitized by a stretch wrapping mechanism. These factors include the type of unitized load, wrapping configuration and shipping method. The wrapping configuration is determined on the basis of the type of unitized load and shipping method. For this study, the aforementioned components were referred to as the package, the product, and the distribution environment. These components come together to make up a stretch wrapping system. The package corresponds to the stretch wrap film that is packaging the unitized load and pallet. The product corresponds to the …

Blunt Impact Performance Evaluation Of Helmet Lining Systems For Military And Recreational Use, Jaclyn Siniora, Ryan Taylor, Darren Suey

Industrial Technology and Packaging

With the increasing problem in collegiate athletes experiencing injuries to the brain, different helmet liners where put to the test to see which liner provided athletes the greatest protection under specific conditions.

This senior project evaluates five different liners in football helmets. Each of the helmet liners were tested at three different temperatures: hot, cold, and ambient. Each helmet had seven different impact locations which were put to the test. The project was designed to be used to test ACH military combat liners as well. Due to shipping bottle necks the ACH combat liners have been left to future Cal …

Rfid For Inventory Of Medical Records, Johny Wu

Biomedical Engineering

The purpose of this project is to explore the feasibility and economic viability of the implementation of a radio frequency identification (RFID) system in a large-scale, medical office setting. Practitioners in fields such as; medicine, chiropractic, dentistry, nursing, pharmacy, allied health, and other care providers do not have a sufficient method for tracking filing forms. RFID has the potential to reduce wait time, improve checking-in time, and decrease the possibility of interchanging documents between patients.

The purpose of this RFID system is to improve upon the filing system already in place in any office setting. The major consideration behind this …

Comparative Analysis Of Erp Emerging Technologies, Ryan Engebrethson

Master's Theses

This Master's Thesis compares technologies used in the architecture of Enterprise Resource Planning (ERP) Systems to evaluate the benefits and advantages of emerging technologies. The emerging technologies, Cloud Computing, Software as a Service (SaaS) and Multi-Tenancy, could significantly alter the current ERP space and become a primary part of ERP Systems of the future. A survey was sent to industry professionals to obtain feedback on their company's ERP Systems and to collect their comments on these new technologies. The survey results and related analysis show that Emerging Cloud ERP Systems outperform Traditional Legacy ERP Systems in all important characteristics - …

Assessing Lean Systems Using Variability Mapping, Ahmed Deif

Industrial Technology and Packaging

A new approach to assess lean manufacturing based on system's variability is proposed. The assessment utilizes a new tool called variability source mapping (VSMII) which focuses on capturing and reducing variability across the production system. The new tool offers a new metric called variability index to measure the overall variability level of the system. Based on the mapping and the new metric, VSMII suggests a variability reduction plan guided by a recommendation list of both lean techniques as well as production control policies. An industrial application is used to demonstrate the new tool. Results show that VSMII managed to reduce …

Integrating Courses Through Project Based Learning, Lizabeth Schlemer, Sema E. Alptekin, Karen R. Bangs

Industrial and Manufacturing Engineering

Integrating three courses (one sophomore level, two senior level) through Project Based Learning (PBL) within the Industrial Engineering curriculum at the California Polytechnic State University, San Luis Obispo is presented. Three courses (IME 443 Facilities Planning and Design - senior level; IME 420 Simulation - senior level; and IME 223 Process Improvement Fundamentals - sophomore level) were linked by various mechanisms: Common industry projects, common students in two of the three courses; senior students having access to sophomores in their teams to carry out time consuming tasks such as time studies, and sophomores having access to seniors as team members, …

Effect Of Gold Content On The Microstructural Evolution Of Sac305 Solder Joints Under Isothermal Aging, Mike Powers, Jianbiao Pan, Julie Silk, Patrick Hyland

Industrial and Manufacturing Engineering

Au over Ni on Cu is a widely used printed circuit board (PCB) surface finish, under bump metallization (UBM), and component lead metallization. It is generally accepted that less than 3 wt.% Au in Sn-Pb solder joints inhibits formation of detrimental intermetallic compounds (IMC). However, the critical limit for Au content in Pb-free solder joints is not well established. Three surface-mount package platforms, one with a matte Sn surface finish and the others with Ni/Au finish, were soldered to Ni/Au-finished PCB using Sn-3.0Ag- 0.5Cu (SAC305) solder, in a realistic manufacturing setting. The assembled boards were divided into three groups: one …

The Morphology Evolution And Voiding Of Solder Joints On Qfn Central Pads With A Ni/Au Finish, Julie Silk, Jianbiao Pan, Mike Powers

Industrial and Manufacturing Engineering

In this paper, we report on a comprehensive study regarding the morphology evolution and voiding of SnAgCu solder joints on the central pad of two different packages – QFN and an Agilent package called TOPS – on PCBs with a Ni/Au surface finish. Samples were isothermally aged at the equivalent of 0, 2, 7 and 14 years service life. Representative solder joints were cross-sectioned and analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) in order to investigate the evolution of the solder joint morphology as a function of Au content and isothermal aging. IMC thickness was …

Dynamic Analysis Of A Lean Cell Under Uncertainty, Ahmed M. Deif

Industrial Technology and Packaging

One of the ultimate targets of lean manufacturing paradigm is to balance production and produce at takt time in production cells. This paper investigates the performance of a lean cell that implements the previous lean goals under uncertainty. The investigation is based on a system dynamics approach to model a dynamic lean cell. Backlog is used as a performance metric that reflects the cell’s responsiveness. The cell performance is compared under certain and uncertain external (demand) and internal (machine availability) conditions. Results showed that although lean cell is expected to be responsive to external demand with minimum waste, however, this …

Pico-Satellite Integrated System Level Test Program, Marcus A. Ruddy

Master's Theses

Testing is an integral part of a satellite’s development, requirements verification and risk mitigation efforts. A robust test program serves to verify construction, integration and assembly workmanship, ensures component, subsystem and system level functionality and reduces risk of mission or capability loss on orbit.

The objective of this thesis was to develop a detailed test program for pico-satellites with a focus on the Cal Poly CubeSat architecture. The test program established a testing baseline from which other programs or users could tailor to meet their needs. Inclusive of the test program was a detailed decomposition of discrete and derived test …

Measurement And Analysis Of Vehicle Vibration For Delivering Packages In Small‐Sized And Medium‐Sized Trucks And Automobiles, Vanee Chonhenchob, Sher Paul Singh, Jay Jagjit Singh, Joseph Stallings, Gary Grewal

Industrial Technology and Packaging

In distribution, packaged products are subjected to the variation in vibration levels from transport vehicles that vary in frequency and acceleration while moving to their destinations. This vibration may negatively affect the product or packaging. This study measured and analysed vibration levels in vehicles commonly used to transport packages in the last leg of the package delivery service that is used by single‐parcel carriers. Using data recorders, we monitored vertical, lateral and longitudinal vibrations over 75 h of travel time in five different types of small and medium package delivery vehicles. The study presents these data as power density (PD) …