Manufacturing Commons^™

Design Of An Effective And Timely Product Development Process For Medical Devices, Jean Benoit Almonor

Theses

Effective product development process is one of the most critical issues facing medical devices manufacturing today. There is a need to search for ways to improve or solve the cross organization and company boundaries to enhance the faster release of new medical products to the market. This thesis presents an integrated set of perspectives on the process of new product development of medical devices with dual goals of achieving marketing speed and meet customer satisfaction.

The Attribute Driven Specifications approach described in this thesis, is one of the most valuable tools in the approach to effective product development in medical …

Demanufacturing Metrics For Industrial Fasteners And Disassembly Process, Narendra P. Raj

Theses

As the society progresses towards ecological maturity, the issue of reducing the environmental burden imposed by used products becomes increasingly important Environmental issues are becoming increasingly relevant for product designers and manufacturers. Public awareness of the value and fragility of an intact ecology is constantly growing, and the traditional assumption that the cost of ecological burdens to be shared by a society, as a whole is no longer accepted. Environmental protection legislation requiring manufacturers to "take back" and recycle used products will be a commonplace throughout Europe and the U.S. in the near future.

Demanufacturing involves separating and disassembling a …

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.

An Evaluation Of The Aws Entry Level Welder Training Program, John R. Rice

Dissertations and Theses @ UNI

The purpose of this study was to evaluate the effectiveness of a training program for Entry Level Welders and to provide this information to the American Welding Society (AWS), industry, and educators. The problem of this study was to evaluate the AWS Entry Level Welder Training Program (ELWTP) by obtaining the opinions of faculty members who taught the program and welders who had completed the program.

Two groups comprised the research population for this study. The first group consisted of faculty members who were actually involved in teaching the course at institutions accredited by the AWS to offer the curriculum. …

Multi-Lifecycle Assessment Of Cathode Ray Tubes, Devendra Jayant Badwe

Theses

Over the past few years environmental issues and concerns have become more and more important, as they become a common part of most people's personal experience. In these regards, the electronics industry is facing substantial problems in terms of end-of-life management of its products, televisions and monitors in particular. The building blocks of this industry are usually viewed as relatively "clean". However, manufacturing by-products of the electronics industry and the disposition of electronics are becoming increasingly important technical, financial, and environmental issues.

Within the context of the above issues, environmentally responsible disposal of Cathode Ray Tubes (CRT's), which is still …

Development Of A Mechatronics Design Studio, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is a combination of mechanics, electronics and information technology intended to raise the intelligence level and flexibility of products and devices. There is a need to develop programs and laboratories in Mechatronics to create an understanding of how new technologies influence the traditional methods of designing products and manufacturing systems. A model "Mechatronics Design Studio" has recently been developed to support the Mechatronics and Manufacturing Automation courses offered at Cal Poly's Industrial and Manufacturing Engineering Department. Laboratory experiments have been developed and several student projects have been completed. In this paper, an overview of the design studio and select …

Finite Element Analysis Of Skin Injuries By Water Jet Cutting, Syed Muhammad Arif

Theses

High pressure water jets are used in industry for cleaning and cutting purposes. These devices can generate pressure up to 400 MPa. As high pressure water jets become more widespread in industry, injuries will be seen with great frequency. Penetrating injuries by these devices can produce minimal external evidence of extensive soft tissue injury. To know the extent of injury, it is important to study the relationship between operating parameters of water jet and the skin layers. A computational analysis is carried out using finite element method to find the effects of water jet pressure on the skin layer. Finite …

Parameters' Analysis Of 3d Random Stacking Palletization, Najeeb Syed

Theses

Palletization is a very important element of production, distribution and warehousing activities. The 3D random stacking palletization method is based on volume utilization instead of surface area optimization. Random stacking provides interlocking among the boxes and hence it improves the stability of the pallet load. Volumetric Pallet Utilization is normally the prime concern of any palletization process, with Work in Process and Palletization time being also important. This research uses data generated from a previous heuristic to establish mathematical relationships between the three mentioned performance indices and also three additional indirect variables, namely: Total Number of Sub Volumes, Partitioned Remaining …

An Integrated Approach To Simulation And Activity-Based Costing For Evaluating Alternative Manufacturing Cell Designs, Robert Williams, Paul Savory, Rodney Rasmussen

Department of Industrial and Management Systems Engineering: Faculty Publications

One effective technique for improving manufacturing efficiency involves the application of group technology part families and manufacturing cells. Selection of the best or optimum configuration of the manufacturing cell relies on the experience and judgment of the cell designer. This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model and be used to evaluate manufacturing cell configurations. The output of the combined ABC simulation model provides a detailed “Bill of Activity” which allows the cell designer to consider costs as a critical factor in the cell design problem. Alternative cell configurations studied in this …

Preparing The Leaders For Mechatronics Education, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is the synergetic combination of precision mechanical engineering, electronic control and systems thinking in the design of products and processes. There is a need to develop interdisciplinary programs in Mechatronics that better prepare our graduates to design, build, and operate the products and systems of today and tomorrow. To address this need, National Science Foundation funded a project entitled "Preparing the Leaders for Mechatronics Education" undertaken by Cal Poly in 1995 - 1996. In this paper, the activities that took place during this two-year program is outlined. Several courses and course modules have already been developed and implemented by …

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.

Recent Developments In Extrusion Freeform Fabrication (Eff) Utilizing Non-Aqueous Gel Casting Formulations, Greg Hilmas, John L. Lombardi, Robert A. Hoffman, Kevin Stuffle

Materials Science and Engineering Faculty Research & Creative Works

Extrusion Freeform Fabrication (EFF) was shown to be an extremely versatile method for fabricating Functionally Graded Materials (FGMs) The approach is inexpensive and potentially feasible for grading between any thermodynamically compatible ceramic-metal, ceramic-ceramic, or metal-metal material combination. Several material systems were investigated in this study including alumina-304 stainless steel, zirconia-304 stainless steel, alumina-Inconel 625, zirconiaInconel625, alumina-nickel aluminide, zirconia-nickel aluminide, titanium carbide-InconeI625, titanium diboride-nickel aluminide, and tungsten carbide-nickel aluminide. A controlled gradient was demonstrated between the end members for all of the above compositions. The FGMs were hot pressed to achieve near theoretical densities, providing flexural strengths as high as 1000 …

Top Gear Manufacturing, B Mahadevan

IIMB Management Review

No abstract provided.

Relay Ladder Logic And Petri Nets For Discrete Event Control Design : A Comparative Study, Edward Twiss

Theses

In the 1960's and earlier discrete event systems (DES) were controlled by hardwired electromechanical relay systems. In 1969 an electronic programmable logic controller (PLC) was introduced. PLC's have been programmed utilizing relay ladder logic (RLL). RLL is a graphical programming language with software "devices" used to emulate electromechanical devices. RLL programs, however, often become large and difficult to understand because its graphical representation of physical switching devices obscures the discrete event dynamics inherent in the process to be controlled. Petri nets are a methodology for modeling discrete event systems (DES). Using a Petri net based controller, a control strategy could …

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 …

A Study Of Kanban Based Production System In Cellular Manufacturing Environment, Sanjay Bhargava

Masters Theses

The study of effects of production data variabilities on Kanban based cellular manufacturing system is vital before its design and implementation because it would give better understanding of their uncertain behavior.

In this research, a detailed analysis of a Kanban system, with subcell scenario, under dynamic operating conditions is performed. The Control variables considered were number of Kanbans, processing time variability, demand variability and machine breakdown. The performance parameters considered were profit, production lead time, machine utilization and material processing lead time.

Approximately 200 simulation runs were made with 3 replications each by varying one control variable at a time. …

Design For Quality Manufacturability Analysis Of Total Nonconformity Damaged Parts, Samir R. Gami

Theses

The competitive nature of modern manufacturing, demands that innovative approaches be applied in order to have a competitive edge. Shortening the product development cycle, the period from initial design to full production, is a priority for most manufacturers today. The DFQM methodology addresses the issue of quality manufacturability (QM) - the likelihood that defects will occur during manufacture of a product in a standard plant. As a consequence, DFQM helps to shorten the design cycle time. The DFQM architecture identifies a variety of design factors and variables that influence specific defects. This process of influencing defects can be described by …

Design And Analysis Of Environmentally Safe Cooling Systems For Machine Tools, Haiping Xu

Theses

Many cooling systems of metal cutting and both their advantages and disadvantages have been reviewed. The cutting forces' relationships, stress distribution, energy consumption and heat generation of orthogonal processes are discussed. A two-dimensional finite element model has been developed to design and analyze a new proposed cooling device, which comes from the idea of "A Novel Cooling Device" proposed by Billatos et al. First, a thermal calculation is completed to compare the temperature difference between two different shapes of coiled pipe. Then, three different cutting conditions, which were considered in the experiments by Childs et al, are conducted under three …

Knowledge-Based System For Casting Process Selection, Ahmet Er, Edward Sweeney, Voya Kondic

Articles

Design of casting entails the knowledge of various interacting factors that are unique to casting process, and, quite often, product designers do not have the required foundry-specific knowledge. Casting designers normally have to liaise with casting experts in order to ensure the product designed is castable and the optimum casting method is selected. This two-way communication results in long design lead times, and lack of it can easily lead to incorrect casting design. A computer-based system at the discretion of a design engineer can, however, alleviate this problem and enhance the prospect of casting design for manufacture. This paper proposes …

An Investigation Of Diameter Measurement Repeatability Using A Coordinate Measuring Machine And A Multi-Baseline Repeatability Assessment Methodology, Bruce Marsh

Dissertations and Theses @ UNI

The need for reliable and consistent measurement has become more acute with the use of statistical process control (SPC), gage repeatability and reproducibility (Gage R&R) assessment, and high precision, computer-controlled gaging systems. Although it is often overlooked, the inspection methodology under which various features are inspected has an impact on Gage R&R results. This notion was confirmed when a 1993 thesis study substantiated inspection methodology as a source of measurement variability in direct computer-controlled, coordinate measuring machines (DCC/CMMs). Although this study explored a methodology to bring measurement variability under statistical control, the tested assessment methodology--single baseline repeatability assessment--was not validated. …

A Psychological Perspective On Service Segmentation Models: The Significance Of Accounting For Consumers' Perceptions Of Waiting And Service, Ziv Carmon, J. George Shanthikumar, Tali F. Carmon

Industrial and Manufacturing Engineering

We examine how service should be divided and scheduled when it can be provided in multiple separate segments. We analyze variants of this problem using a model with a conventional function describing the waiting cost, that is modified to account for some aspects of the psychological cost of waiting in line. We show that consideration of the psychological cost can result in prescriptions that are inconsistent with the common wisdom of queuing theorists derived according to the conventional approach (e.g., equal load assignments). More generally, our intention in this paper is to illustrate that aspects of the psychological cost of …

Analysis Of Cim Performance Using Different Lan Structures A Simulation Approach, Kirk Rawle

Theses

This research illustrates a systematic procedure for modeling and performance analysis of the integration effect of communication network to the physical system. The concept is to model different layouts of Computer Integration Manufacturing (CIM) using different Local Area Network(LAN) structures. The steps to accomplish this concepts are, a) To determine the performance measures for physical layouts and the communication network, in order to obtain a performance analysis. b) Modeling the physical layout using Promodel simulation package. c) Extracting results from the outcome of the simulation of the physical layout and using this as input to the communication network simulation. d) …

Auditing & Measuring The Need For Flexibility In A Manufacturing Facility, Kartika-Sari Stroman

Theses

Flexible manufacturing was created out of the need for facilities to be able to efficiently respond to changes in their environment so as to build a competitive advantage. Flexible manufacturing (FM) is currently viewed as a way for facilities to be able to introduce and produce multiple products quickly and more efficiently. In this research we will present some new tools to help managers address the changes that are affecting the facility.

An audit was developed to help system designers identify the changes that are impacting the facilities. The audit provides the opportunity to understand the changes that are occurring …

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 …

Development Of A Knowledge-Based System For Generating Process Plans Using Group Technology: A Study For Norfolk Naval Shipyard, William P. Keene Jr.

Engineering Management & Systems Engineering Theses & Dissertations

The purpose of this research was to study and analyze the Norfolk Naval Shipyard's manufacturing methods of determining part families and generating part process plans for parts in the machine shop. A knowledge-based decision support system was designed based on knowledge acquired from machinist experts and documented sources of the Norfolk Naval Shipyard. The system interprets specific part information provided by the user, categorizes parts into part families and generates process plans to manufacture the parts. The system was evaluated and tested for parts provided by Norfolk Naval Shipyard.

Development Of An Expert System To Facilitate A Pump Manufacturing/Warehouse Facility, Muhammad Mutahir Ghauri

Theses

The objective of this study is to evaluate the effectiveness of utilizing an expert system technology as it relates to manufacturing. It appears that our industries are still uncertain about this technology. In the first phase of this study, procedure for deployment of this technology is discussed. Secondly a knowledge-based expert system is developed, using a VP-Expert microcomputer shell. The system is made of three modules, inventory module, cost analysis module, and decision making module (for the selection of pumps).

A warehouse was selected for the analysis, which carries the finished product in the form of pumps. The quantities and …