Industrial Engineering Commons^™

A Study Of Visualized Diagnostics In Early Stage Digital Twin Implementation Of An Industrial Control System, Michael R. Kinzel

All-Inclusive List of Electronic Theses and Dissertations

Industrial Control Systems (ICS) are used for process control in almost all industries. An ICS combines Operational Technologies (OT) with Information Technologies (IT) to allow human supervision of a process through surveillance of process variables and manipulation of controlling elements such as valves to maintain stable process conditions. ICSs have been in-service for several decades and may remain operational past their technological service life. Organizational personnel interact with the ICS through visual displays that both indicate the process variables and also the controlling elements. The Human Machine Interface (HMI) allows visibility of the process and the ability to manipulate controlling …

Process Optimization Of Directed Energy Deposition Via Dmaic Methodology And Lean Manufacturing Principles, Erick Gerardo Molina Castaneda

Open Access Theses & Dissertations

Additive Manufacturing (AM), particularly Direct Energy Deposition (DED), has gained increasing relevance in industrial and research environments due to its capability to manufacture complex geometries and repair high-value components. However, despite its technological advantages, DED processes often lack standardization, clear documentation, and structured workflows, especially in academic laboratories. This research aims to optimize and standardize DED processes through the application of Lean Manufacturing principles using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. The study was conducted at the Keck Center for 3D Innovation, focusing on pre-printing and printing activities. Key issues were identified. Improvement actions included the implementation of …

Implementation Of Kansei Engineering Method In Designing Spreadable Cheese Packaging, Novi Purnama Sari, Mega Analisa, Suci Puji Lestari, Khofifah Nur Amalia

Makara Journal of Technology

Some spreadable cheese packaging uses flexible plastic without additional features and easily damaged boxes. This packaging causes several problems, such as difficulty in re-storage, loss of product information due to damaged box packaging, wasteful use of packaging materials, and making the product less hygienic. The purpose of this study is to develop packaging that focuses on consumer emotions. The packaging was developed using the Kansei Engineering method, supported by Principal Component Analysis (PCA) as a determinant of the design concept, and Quantification Theory Type 1 (QTT1) to identify design elements. This study produced 46 packaging samples and 40 Kansei words. …

Project Management Practices In Manufacturing: An Analytical Case Study, Margaret Randle, Robert Reynolds

Honors Capstones

Global industries are undergoing significant transitions in organizational models, technological innovation, and non-economic indicators of product quality, including sustainability and operational efficiency. The current workforce needs to not only develop competency of these technical skills, but also an adaptive, system-oriented approach to problem-solving as well. This case study, which highlights a manufacturing company’s project of increasing production efficiency, presents concepts learned through the textbook Project Management: Achieving Competitive Advantage by Jeffrey K. Pinto. The study thoroughly breaks down the full project lifecycle and the integration of systems of people, data, and initiatives in a framework that can be used to …

Ergonomic And Material Flow Improvements For A Medical Device Assembly Line, Matthew Kobus

Honors Theses

This project evaluated material handling inefficiencies and ergonomic concerns within Stryker’s Neptune medical device assembly line. Two primary issues were identified: lack of a standardized part-location system in the supermarket and excessive operator travel between subassembly and main assembly. These issues resulted in search waste, motion waste, lost production time, and increased ergonomic strain.

To address the labeling issue, a standardized bin labeling system was developed and tested. A time study comparing labeled and unlabeled conditions showed that average retrieval time decreased from approximately 120 seconds to 22 seconds, an 81% reduction. Statistical analysis confirmed that this improvement was significant …

Revitalising Tanzania’S Textile Industry Through The Uk Textile System’S Role, Charles M. Kahabi

Tanzania Journal of Engineering and Technology (TJET)

Currently, there is the environmental and social challenges emerging from the global clothing and textile industry, specifically on textile waste management.  Additionally, the flow of second-hand clothing (SHC) between European countries especially the UK and Tanzania is increasing. In the UK, rapid growth of second-hand clothing (mitumba) driven by fast fashion results in vast quantities of discarded garments, of which only a fraction is recycled, leaving the remainder in landfills. Conversely, Tanzania has long depended on imported SHC a practice that, while affordable, has undermined local textile industries and contributed to waste accumulation. By examining Tanzania’s textile landscape, the research …

Optimization Of Vehicle Mix For Three-And Four-Wheel Passenger Transportation System In Nigeria, Omotunde A. Muyiwa, Hamid A. Jimoh, Kolawole T. Oriolowo

Tanzania Journal of Engineering and Technology (TJET)

Efficient transportation systems are essential for reducing passengers waiting times in densely populated areas. However, there is a dearth of information on the optimization of vehicle mix for three-and four-wheel transportation systems in Nigeria. The present study was designed to optimize the vehicle mix for three-and four-wheel passenger transportation to improve transportation efficiency. Twenty purposively selected vehicles were observed, while a queuing model (M/M/s) was used to determine passenger arrival rates during different periods (morning, afternoon, and evening). An integer linear programming model was developed to minimize passenger waiting times. Data on vehicle types, capacities, travel cycles, and average passenger …

Implementation Of The Fourth Industrial Revolution Technologies In Tanzania’S Downstream Oil And Gas Industries, Vitalis John Mwinyi

Tanzania Journal of Engineering and Technology (TJET)

The advent of the fourth industrial revolution (IR4.0) has resulted in the digital transformation of multiple sectors of the economy due to the disruptive nature of the technologies driving the revolution. The technologies have already found their way into the oil and gas industries across the globe, especially in upstream, midstream, and downstream operations. However, the degree of implementation is not the same for these operations, considering the complexities involved, integrated process, the associated risk and investment cost, among others. This study aimed to establish the implementation level of IR4.0 technologies in the downstream operations. A survey method was employed …

Analysis Of Factors Enabling Organisational Governance Maturity For The Technical Audit Function In Tanzania, George C. Haule

Tanzania Journal of Engineering and Technology (TJET)

The study aimed to identify key factors contributing to Organisational Governance Maturity (OGM) of the Technical Audit Functions (TAF) in Tanzania.  The study employed a sequential approach as a research design.  The first step was to collect and analyse literature studies to identify factors enabling the OGM of the TAF.  Next, a questionnaire was administered to one hundred twenty-eight (128) respondents from seven (7) TAFs to rank the key enabling factors that were identified from the literature that influence the OGM of TAF in Tanzania.  Using data from a questionnaire administered to 128 respondents, a two-step strategy was employed to …

A Causal Inference Methodology For Root-Cause Diagnosis In Nonstationary Industrial Time Series, Cansu Yalim

Knowledge and Creativity Expo

Industrial fault diagnosis lacks a procedure that learns time-varying causal structure from observational time series, makes identifiability limits explicit, and uses intervention-based reasoning to support root-cause assessment under industrial constraints. Although predictive maintenance can reduce downtime, diagnosis is often expert-rule-based or association-driven; pipelines may elevate downstream symptoms alongside true drivers and provide limited guidance on which feasible action would change a fault trajectory under current operating conditions. Because operating phases and fault progression create regime shifts, industrial systems rarely follow a single stable mechanism. This study develops and evaluates a three-stage, regime-aware causal diagnostic protocol based on a time-varying Dynamic …

Optimizing Warranty Policies For Remanufactured Products: When Should They Be Longer, Shorter, Or Identical To New Product Warranties?, Kunpeng Li, Jun-Yeon Lee

Faculty Publications

Manufacturers adopt different warranty strategies for remanufactured products, offering shorter, identical, or longer warranty periods compared to new products. However, prior research has only focused on manufacturers offering either shorter or identical warranties. In addition, the existing literature has not captured the diminishing returns of warranties, i.e., as the warranty coverage increases, its incremental benefits begin to decrease but the costs continue to increase. To address these gaps, we develop an optimization model that jointly considers pricing and warranty decisions while accounting for warranty’s diminishing effect on consumer’s willingness to pay for remanufactured products. We show that all three observed …

Multi-Objective Optimization Of Waste Incineration For Minimal Carbon Monoxide And Sulfur Dioxide Emission And Rate Maximization: A Case Study Of Mbezi, Mkuranga-Pwani, Tanzania, Grangay M. Nyanghura, Enock W. Nshama

Tanzania Journal of Science

Incineration is widely employed for hazardous waste disposal, but results in harmful flue gas emissions. This study optimizes a double-chamber incineration process to reduce sulfur dioxide (SO2) and carbon monoxide (CO) emissions while maximizing the incineration rate. The effects of waste mass, primary chamber temperature (PT), and secondary chamber temperature (ST) were analyzed using a full factorial design of 27 experiments. ANOVA revealed that mass had the greatest impact on emissions and incineration time, ST had a moderate effect, and PT had little influence. Regression analysis provided models for incineration time, CO, and SO2 emissions. Single-objective optimization using sequential quadratic …

Layer-Wise Printing Parameter Optimization For Laser Powder Bed Fusion, Chaoran Dou, Rongxuan Wang, Raghav Gnanasambandam, Jianzhi Li, Zhenyu James Kong

Manufacturing & Industrial Engineering Faculty Publications

Additive manufacturing (AM) is a transformative technology that enables the fabrication of complex geometries layer by layer. However, metal parts produced via AM processes such as laser powder bed fusion (LPBF) are prone to various defects, including porosity and deformation. These defects often result from suboptimal printing parameter settings. Traditional approaches typically aim to reduce defects by optimizing a fixed set of parameters for the entire part. However, such methods do not account for layer-wise variations in printing conditions caused by changes in geometry, heat transfer, and re-heating effects. While optimizing parameters for each layer could improve part quality, it …

Reinforcement Learning For Imbalanced Data In Robotic Anomaly Detection Within Autonomous Manufacturing, Salma Messaoudi, Ahmed Bendaouia, El Hassan Abdelwahed, Mohammed Ameksa, Hajar Mousannif, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Ensuring reliable anomaly detection in industrial robots is critical for safe and autonomous manufacturing operations. However, it remains challenging due to temporal dependencies and class imbalance in sensor data. This study presents a reinforcement learning approach using Deep Q-Network (DQN) enhanced with Long Short-Term Memory (LSTM) and Gradient Boosting Machine (GBM) for robust anomaly detection in robotic systems. The proposed framework integrates an LSTM into the DQN policy to capture temporal patterns. It also introduces a novel GBM-based reward mechanism that mitigates class imbalance by applying SMOTE (Synthetic Minority Over-sampling Technique) after removing temporal dependencies. Experimental results demonstrate that this …

Leveraging Blockchain And Llms For Patient–Clinical Trial Matching, Diana Hawashin, Khaled Salah, Raja Jayaraman, Samer Ellahham, Ibrar Yaqoob

Industrial Engineering: Faculty & Staff Publications

Efficiently matching patients to clinical trials is essential for advancing medical research and ensuring reliable outcomes. However, current matching methods face several challenges. These include data integrity issues from tampered records, privacy risks caused by weak anonymization, and manual processes that delay recruitment. In addition, centralized systems lack transparency, expose sensitive patient data to security vulnerabilities, and suffer from single points of failure that reduce resilience and trust. In this paper, we propose a blockchain and Large Language Models (LLMs)-driven solution for secure, trustworthy, traceable, decentralized, and transparent patient-clinical trial matching. Blockchain ensures data integrity, security, and transparency by eliminating …

Enhancement Of Plastic Deformation In Ultrasound-Assisted Cold Spray Of Tungsten: A Molecular Dynamics Study, Md Tusher Ahmed, Farid Ahmed, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Tungsten (W) is widely valued for its exceptional thermal stability, mechanical strength, and corrosion resistance, making it an ideal candidate for high-performance military and aerospace applications. However, its high melting point and limited room-temperature plasticity pose significant challenges for processing W using additive manufacturing (AM). Cold spray (CS), a solid-state AM process that relies on high-velocity particle impact and plastic deformation, offers a promising route for additive manufacturing of W, yet conventional CS fails to induce sufficient plastic deformation for effective bonding. In this study, we employ atomistic simulations to investigate the effect of ultrasonic perturbation in …

Artificial Intelligence And Additive Manufacturing As A Coupled Design System: Rethinking Inference, Manufacturability, And Design Education, Charul Chadha, Garth Crosby, Sabit Ekin, Mohamed Gharib, Eman Hammad, Congrui Jin, Ali Ahmad Malik, Noemi Mendoza Diaz, Calahan Mollan, Monsuru Ramoni

Manufacturing & Industrial Engineering Faculty Publications

Artificial intelligence (AI) is becoming deeply integrated into additive manufacturing (AM) workflows, reshaping how designers approach geometry, materials, and process constraints. AI holds significant potential by accelerating design exploration, revealing complex patterns in AM behavior, and supporting earlier assessment of manufacturability. At the same time, it introduces new risks related to model transparency, data quality, physical validity, and the potential for overreliance by students and practitioners. This perspective examines these issues through four guiding questions that address the role of AI in AM-enabled design, the gaps that limit or enable AI contribution, the implications for engineering education, and the responsibilities …

Reinforced Scan: A Reinforcement Learning Enabled Optimal Laser Scan Path Planning In Laser Powder Bed Fusion Additive Manufacturing, Chaoran Dou, Jihoon Chung, Raghav Gnanasambandam, Yuhao Wu, Jianzhi Li, Zhenyu James Kong

Manufacturing & Industrial Engineering Faculty Publications

Additive Manufacturing is an innovative technology that fabricates parts layer by layer. However, in Laser Powder Bed Fusion (LPBF), printed metal parts often exhibit residual stresses, deformations, and other defects due to non-uniform temperature distribution during the printing process. To mitigate these issues, an optimized scan sequence within each layer can improve thermal uniformity. Traditional optimization methods, which rely on domain knowledge and employ trial-and-error or heuristic approaches, often fail to achieve optimal solutions due to the complex nature of the problem. One major challenge in improving scan strategies lies in the vast search space required to optimize the scan …

Harnessing Ml And Iiot For Traceability In Continuous Production Systems: A Conceptual Framework, Kholoud M. Abdelaal

Theses and Dissertations

In the era of rapid technological advancement, the manufacturing sector faces increasing pressure to leverage emerging technologies to enhance operational efficiency and minimize waste. In this context, traceability plays a pivotal role, as it provides complete visibility of processes and products throughout manufacturing systems, enabling them to identify areas for improvement and take corrective actions accordingly. Additionally, traceability ensures compliance, supports product recalls, provides a clear understanding of the system’s performance, and enables fact-driven decision-making in multiple aspects of the manufacturing system. Although the broad spectrum of traceability applications in batch production-based plants, traceability remains challenging to achieve in continuous …

Performance, Economic And Environmental Evaluation Of A Solar-Assisted Vacuum Deaeration Heating System., Liew Shan Kun

Student Works (2020-2029)

This research evaluates the performance of a solar-assisted heating (SAH) system for makeup water in a vacuum deaeration process. The system integrates solar energy into the heating process, with parametric analysis conducted across varying configuration of total solar radiation and water flow rates. The total solar radiation at the experimental site in Kuala Kangsar, Perak, Malaysia, characterized by tropical weather, fell within the range between 414W/m2 to 568W/m2. Performance analysis showed that a flow rate of 0.4 LPM achieved the target temperature of 61°C required for the deaeration process. Thermal efficiency peaked at 62.60% under a solar radiation of 900 …