Manufacturing Commons^™

Model-Based Predictive Controller Design, Soheil Sadeghi

Graduate Research Papers

Process control in industries is becoming more critical due to demands on reducing consumed energy, reducing cost, and improving system efficiency and performance. In this work, a well-developed, model-based controller is introduced and implemented in one of the most common processes in the industry. Model Predictive Controller (MPC) has been studied for ten years, but recently has emerged into small industries as the number of current applications grows. These controllers need a process model in the forms of transfer functions, step response, or state-space. Although obtaining a process model can be a cumbersome task, it is worth having it (the …

Management Theories In Manufacturing, James Nathan Webster

Graduate Research Papers

The principles and ideology of management have been around for thousands of years. "Before industrialization, organizations were primarily the household, the tribe, the church, the military, and government" (Wren, 1987, p. 13). It was very rare for people to gather and organize outside of these structures prior to the industrial revolution. As mankind and civilization have progressed, the power of organizations has shifted throughout time. In the time of Confucius, government positions were of the utmost respect, and Confucius taught that positions of power "should go to men of proven merit and ability" (Wren, 1987, p. 14). The ancient Egyptians …

Manufacturing Companies And The Information Age In The U.S., Marcos Reynero

Graduate Research Papers

The purpose of this research paper is to analyze the relationship between the amount of indirect labor and value added in manufacturing companies. Companies are moving manufacturing sites overseas in order to reduce cost. The cost of direct labor in countries like China is relatively lower in comparison to the cost of labor in the U.S. Edward Hill, professor at Cleveland State University's College of Urban Affairs, states that an hour of a manufacturing plant in the U.S. costs $150 versus $1 in China (Scherer, 2005). Companies are making strategic decisions based on reducing cost in order to improve profits. …

Automated Casting Cleaning, Chris Anderson

Graduate Research Papers

The dilemma facing all foundries today is finding a cost effective, efficient, and safe manner in which to clean castings. At the same time produce a cleaned casting that meets consistent quality and delivery expectations. Today nearly 90% of all casting produced are cleaned by the use of manual labor via chipping an grinding. This manual method has proved to be very labor intensive, costly, lacking consistent quality, and carry high rates of injuries. The use of automation to clean castings is in its embryo stage in the foundry industry. The use of automation in the foundry industry, products currently …

Riser Design For Green Sand And Ductile Iron Castings, K. Michael Kuebler

Graduate Research Papers

Shrinkage defects in ductile iron riser contacts has long been one of the most frustrating defects to eliminate for the foundry engineer. While process variation can definitively contribute to the occurrence of these defects most can be prevented if the risers are properly designed and/or applied to the castings to be fed. There are several proven methods for the designing risers some of which go back over 40 years ago. There are also new methods available today with the advancements of simulation software. Four of these riser design methods were evaluated for their ability to produce an internally sound casting …

Comparison Study Of Cooling Fins And Chills Effectiveness In Aluminum Sand Mold Casting, Vladimir E. Kouznetsov

Graduate Research Papers

Besides proper design of gating and risering systems, there are several methods used to control and modify solidification behavior of cast alloys. Within these methods, the most widely used are local cooling aids employing cooling fins (thin segments attached to problematic areas of casting) or external chills (metal inserts placed into mold walls to accelerate heat withdrawing from potential hot spot). The later helps to promote directional solidification when traditional methods are not possible to use due to limitations related to the casting design. Despite relatively wide application in aluminum foundries, there are no specific recommendations on cooling aids parameters …

Relationship Between Cost Of Technical Training And Cost Reduction Of Internal Defects At John Deere Waterloo Foundry, John Brackin

Graduate Research Papers

Can the cost of technical training at John Deere Waterloo Foundry pay for itself in the reduction of internal defects? This research compared training costs to the savings from reduced internal defects on Molding Unit 801 located in the John Deere Waterloo Foundry. Training was the independent variable of this research. The results of this research identified a correlation between training costs ( operational definition on page 10) and defect reduction costs. A correlation between these two established a break even point for training dollars spent.

The dependent variable was the dollar savings based on reduction of internal defects. There …

An Introduction To Web-Based Training For Statistical Process Control (Spc), Richard A. Juel

Graduate Research Papers

John Deere Waterloo Works had been using statistical process control in its manufacturing and assembly operations since the mid-nineteen seventies. Over the years this process had evolved from using hand-written paper control charts to using computer devices to collect data and generate charts. A variety of computer hardware and software products were being used. Training on statistical concepts and use of the various devices had deteriorated to the point that it was no longer a formal process. SPC training passed from one employee to another in the course of break-in to perform a specific job.

A team had been formed …

An Evaluation Of John Deere Waterloo Works Internal Quality System Audit Process With Recommendations For Improving Its Effectiveness, Karl J. Bultsma Sr.

Graduate Research Papers

The objective of this paper is to evaluate the internal quality system audit process at the John Deere Waterloo Works. This evaluation is necessary to identify improvements to ensure continued quality system registration and make the auditing process as efficient and effective as possible for improved business performance.

Investigation Of Torque Control Systems For Pump Assembly, Donald E. Lynch

Graduate Research Papers

The purpose of the study was to determine which of three types of torque systems would best meet the torque specifications required in the assembly of hydraulic pump outlet valve plugs. Each torque system was evaluated in regards to expense, reliability, and effectiveness.

Degree Of Manufacturer Readiness For Skill-Based Pay Programs, Michael R. Willett

Graduate Research Papers

The purpose of this study is to determine the degree of readiness of manufacturing companies in Black Hawk County, Iowa, to adopt a skill-based pay plan. Readiness, or change orientation, will be determined by comparing current characteristics of companies in this sample to those characteristics of American companies that have already implemented successful skill-based pay plans.

A Fluid Flow Analysis Of Aluminum 356.0 In The Vacuum Assisted Countergravity Method, John Launstein

Graduate Research Papers

The purpose of this study is to determine the fluid flow pattern obtained through the use of the countergravitaional process. The physical fluid flow model assists design engineers in their casting design of parts utilizing the LS-Vac technology thereby reducing tooling costs and time losses.

Development Of A Simple, Analytical Method To Optimize Machining Cycles For Non-Cnc Gear Hobbing Machines, Steven M. Klabunde

Graduate Research Papers

The purpose of this research project was to develop a simple, analytical method for the optimization of hobbing cycles on non-CNC gear hobbing machines. Such a method would allow manufacturers to optimize hobbing cycle times, reduce part costs, and improve productivity. There have been many advances in gear cutting tool technology. Because of these advances, the capabilities of modern cutting tools are beyond the capabilities of non-CNC machines designed more than fifteen years ago. The majority of the machines used today in gear manufacturing are of this vintage. The cycles on these machine tools are machine-limited, which is much more …

The Characteristics Of Agile Manufacturing That Can Be Implemented In The Manufacture Of Agricultural Equipment, Irvin L. Wilhelms

Graduate Research Papers

The problem of this study was to determine the characteristics of agile manufacturing and their applicability to a manufacturer of heavy agricultural equipment.

An Investigation Into The Use Of Expanded Polystyrene Patterns With The Loose-Sand, Vacuum Assisted Counter Gravitational Casting Process, John B. Vandersall

Graduate Research Papers

"Considered for years as a metal casting renegade, Expendable Pattern Casting (EPC) is believed by some to be tomorrows long-term casting future. Others, however, see it as an unproven headache-ridden process that makes the simple art of metal casting unnecessarily complex." (Lessiter, 1994, p. 36). The complexity of this process has been largely due to the lack of knowledge surrounding the interaction of the metal front and the dissipating polystyrene pattern.

Since the discovery of EPS as a pattern material, numerous applied research projects have been performed to gain a better understanding of the thermal breakdown characteristics of the material. …

First Line Supervisor Perceptions: The Effectiveness Of Specific Safety Training Materials, Cynthia Houlson

Graduate Research Papers

The problem of this study was to determine whether first line supervisors, who have been exposed specifically to Safety Focus Topics, perceived them as an effective tool in filling their role as a safety trainer.

Comparison Of Rapid Prototyping Systems For Implementation Into The Product Development Cycle, Daniel S. Koenig

Graduate Research Papers

The problems with the implementation and use of RP technology is choosing the best system from the fifteen or more RP systems commercially available and more than 20 other systems under development throughout the world (Wohlers, 1993). The problem of this study was to evaluate each of six preselected RP systems based on key characteristics. This study provides pertinent data so that those teams and individuals involved in the implementation and the use of a RP process can make sound decisions.

An Analysis Of The Disposition Of Used Foundry Sand With Thermal Reclamation, Douglas Miller

Graduate Research Papers

The purpose of this study was to identify the economic and environmental concerns for the disposal, reuse, or reclamation of used foundry sand and show how foundries have developed options to landfills. The sand type and the reclamation processes available are the factors to use in determining whether disposal, reuse, or reclamation is appropriate. The continued use of landfills for disposal of used sand strongly indicates that reclamation and reuse techniques were either not understood or not as economical as disposal. Public concerns and new environmental laws demand that alternate means of disposal for used foundry sand should be developed …

A Market Profile Of Epc Foundries In North America, Jennifer D. Ballacchino

Graduate Research Papers

The purpose of this study is to discover what successes foundries are having with the EPC process and promote these successes. The EPC casting industry can use this information to encourage adoption of the process and thereby stimulate component conversion and application. Information gathered during this study will be consolidated into promotional materials about the EPC process. The materials will provide information to individuals in the industry, including foundries, suppliers and, most importantly, designers. Through sharing of information about the process, it can be better understood and acceptance may increase.

A Study Of The Manufacturing Costs Of Grille And Side Screens On John Deere Tractors, John M. Beierschmitt

Graduate Research Papers

The problem discussed in this paper was the development of a process for the manufacture of a new, low cost, quality grille screen that previously had been made on conventional tooling, and now can not be made with the conventional process or tooling. The research comparison in this paper was done to show the financial advantage of this type of tooling.

An Examination Of The Labor Time Of A Robot Weld Cell, Chris S. Conrad

Graduate Research Papers

The purpose of this study was to determine the labor time differential, if any, of a robot weld cell as compared to manual welding methods. Also, the variability of labor time differential between part numbers was to be examined.

The results of the study was intended to assist future investment decision makers in maximizing the return on capital expenditures. It was proposed that the labor time differential determined by this study be applied to the future labor and overhead rates in determining the return on investment for a robotic weld cell purchase. The variability of labor time differential between part …

A Technical Paper On Automated Pouring And The Selection Process Used By One North American Foundry, R. Stanley Weaver

Graduate Research Papers

This report on automated pouring focuses on the selection process used by one North American iron foundry. The problem facing this facility and any operation wishing to implement this technology lies in the number of variables which must be addressed in their quest for a suitable system.

An Investigation Of Cutting Tool Chatter Vibration In Machine Tools, Arneil Olson

Graduate Research Papers

The purpose of this study was to assemble and condense the research and background literature available on cutting tool chatter vibration. Another requirement was to translate the highly technical language of the researcher into a form readily understandable to shop floor personnel.

Support staff called upon to assist in the elimination of chatter problems have not been given the informational resources necessary to effectively deal with the phenomenon. This information should be gathered from university libraries and cutting tool experts and combined into one basic reference work.

If collecting the references were all that was required they could simply be …

An Investigation Into Manufacturing Quality Planning Concepts For New Manufactured Products With Recommendations For John Deere, Michael A. Henning

Graduate Research Papers

President Bush was quoted in 19 90 saying, "The improvement of quality in products and the improvement in services -these are national priorities as never before." (National, 19 9 0). Leadership through quality was also called the new competitive frontier by David Keams, Chief Executive Officer of Xerox Corporation (DeToro, 198 7) and 198 9 winner of the Malcolm Baldrige National Quality Award. For a manufacturing organization like Xerox a quality product is the result of many factors. Other corporations have come to the same realization of the importance of quality throughout their operations (Crosby, 19 9 1). He pointed …

An Investigation On The Skill Requirements Of A Manufacturing Engineer In A Computer Integrated Manufacturing Environment, Wayne E. Frost

Graduate Research Papers

The problem for this study centers on these questions:

What skills will a manufacturing company's manufacturing engineers require to : 1) Implement successfully computer integrated manufacturing. 2) How will they obtain these skills?

An Assessment Of Just-In-Time Manufacturing, Ronald E. O'Meara

Graduate Research Papers

Manufacturing of materials into useable products has changed dramatically since the Industrial Revolution. The United States dominated the manufacturing arena until the early 1970s. After that period, efforts of global competitors in such areas as quality control and productivity, started to surpass the efforts made by the United Stated in these same areas. For the first time, U.S. manufacturers started sensing the pressure of competition. The United Stated is using its competitive advantage over other nations in the manufacturing segment. Part of this loss is a result of the way the U.S. manufacturers are conducting their business. A larger part …

A Survey Of Material, Process, And Operator Requirements Of Midwestern United States Laser Job Shops, Eric Jaeckel

Graduate Research Papers

Managers of seven (7) midwestern United States laser job shops were interviewed to assess the material, process, and operator requirements of each particular shop. The seven shops were located in a six (6) state area including Illinois, Indiana, Iowa, Minnesota, Ohio, and Wisconsin,

It was found that mild steel and ceramic were the most common materials processed. Cutting, marking/scribing/etching, and drilling were the most common types of processing and gas lasers were six times more popular than solid state lasers. Operator training should include materials science, electronics, optics, and computer programming.

The Relative Importance Of Competencies Needed By Industrial Energy Managers From The Larger Manufacturers In Iowa, Timothy J. Eibes

Graduate Research Papers

The importance of identifying the competencies needed by energy managers is reflected in the seriousness of the energy problem and the impact it has on the industrial setting. The newness and ambiguity of EM, coupled with the increasing importance of the concept, add to the need for identifying the necessary competencies required in managing energy.

Ideally, once these competencies are identified, they should be the focus of those educational curriculums designed to produce energy managers. Currently there are only 25 post-high school institutions in the U.S. that have energy management curriculums (The College Blue Book, 1981). Less than half of …

Motivation And The First Line Supervisor: A Survey Of Techniques And Applications, Raymond H. Rannfeldt

Graduate Research Papers

Do first line supervisors differ in their beliefs concerning motivation or in the techniques they employ to motivate their personnel as a function of age, time in service with a company and/or time as a supervisor?

Desirable Combinations Of Electrode And Flux For Submerged Arc Welding Of Low Carbon Steel, James A. Husmann

Graduate Research Papers

The major purpose of this study was to provide information about desirable combinations of welding electrode and appropriate fluxes for submerged arc welding of low carbon steel. Other purposes were to:

1. Test a variety of combinations of available submerged arc welding electrodes and fluxes in welding low carbon steel.

a. Prepare specimens for tensile tests.

b. Conduct tensile tests.

c. Calculate tensile strength, yield point, break point, percent of elongation, and percent reduction of area.

2. Determine the most desirable combinations of electrode and flux for companies presently using or planning to use submerged arc welding for low carbon …