Operations Research, Systems Engineering and Industrial Engineering Commons^™

Manufacturing Process And Product Design For Mass Production Of Environmentally-Friendly Fishing Lures And Weights, David Ichlokmanian, Justin Jake Bert

Industrial and Manufacturing Engineering

The current industry standard for the manufacture of recreational fishing tackle uses lead-based weights and PVC or silicone-based lures. Both materials have serious negative effects on those who handle these products, waterfowl, fish, and other animals that may consume this discarded tackle. The goal of this project is to find and design an environmentally safe process and product alternative for this industry. To do this, we researched a large amount of viable safe materials for weights and lures and used decision matrices to decide on the best one. We found that brass would be the most suitable alternative and created …

Addressing The Existence Of Overcrowding In The Cal Poly Rec Center Exercise Rooms, Josue Alvarez, Robert Hemphill

Industrial and Manufacturing Engineering

Cal Poly’s Rec Center is a facility that has been extremely popular among students ever since its initial creation many decades ago. Despite its popularity being a positive quality in most ways, it does ultimately yield a certain issue for the users of the facility; the issue of overcrowding. This senior project aimed to analyze the problem of overcrowding at the Rec Center and improve upon its most critical areas of impact. Ultimately, we identified the Rec Center’s exercise rooms as the most impacted area, with the issue of equipment unavailability being the largest factor. Thus, we designed alternative equipment …

Design Of Standard Operating Procedures For Concrete Delivery And Pour Data Collection And Analysis, Andrew Willard, Mitchell Wilhelmsen

Industrial and Manufacturing Engineering

Webcor Concrete Group (WCG) is a self-perform subsidiary of Webcor Builders, a large general contractor in the state of California. Inefficiencies plague the construction industry, resulting in Webcor reaching out to the Cal Poly Industrial and Manufacturing Department and its students for help. The opportunity addressed in this report centers on a lack of concrete pour data collection. This gap results in a struggle to defend against, or pursue, backcharges with their concrete suppliers regarding additional labor costs or wasted material. The project objective is to provide WCG with a baseline data collection system and procedure, leading to increased back-charge …

Design For Waste Reduction And Efficiency Improvement For The Construction Usage Of The Tower Crane, George Merida, Roman Richard

Industrial and Manufacturing Engineering

Webcor Concrete Group’s on-site tower crane is currently experiencing unknown forms of inefficiency. The project team used the DMAIC methodology to implement Define, Measure, Analyze, Improve, and Control in order to guide and structure the project. After the project team formulated a problem statement, observations were collected of tower crane deliveries resulting in 470 individual data points. The data was then analyzed using basic statistics, histograms, and lean manufacturing tools in order to identify wastes and inefficiencies. Once the wastes and inefficiencies were identified, root cause analysis was performed. The identified root causes were then used as the basis for …

Designing An Information System To Efficiently Coordinate Film Screenings, Galen Dougherty

Industrial and Manufacturing Engineering

This paper explains the engineering concepts design efforts used to build an information system to efficiently coordinate film screenings. The market served is an emerging group of film makers and production companies that have limited resources. The application aims to save both time and money in coordination efforts for screening films in the local community. The project case examined is a small production start-up from Cal Poly San Luis Obispo named Yellow Glass Media. The design described in the paper specifically targets their needs which are assumed to be representative of the needs of the larger emerging market. The design …

A Constraint Programming Approach For The Team Orienteering Problem With Time Windows, Ridvan Gedik, Emre Kirac, Ashlea Bennet Milburn, Chase Rainwater

Mechanical and Industrial Engineering Faculty Publications

The team orienteering problem with time windows (TOPTW) is a NP-hard combinatorial optimization problem. It has many real-world applications, for example, routing technicians and disaster relief routing. In the TOPTW, a set of locations is given. For each, the profit, service time and time window are known. A fleet of homogenous vehicles are available for visiting locations and collecting their associated profits. Each vehicle is constrained by a maximum tour duration. The problem is to plan a set of vehicle routes that begin and end at a depot, visit each location no more than once by incorporating time window constraints. …

Mapping And Integrating Value Creation Factors With Life-Cycle Stages For Sustainable Manufacturing, P. Bilge, S. Emec, G. Seliger, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Instead of implementing each element individually, engineers must be aware of multiple interactions among all major value creation factors and their life-cycle stages. Interactions are analyzed by a set of factors and hierarchical levels within a production system based on empirical observations and described in analytical models. Such analyses and missing information about the current condition of the system and its parts remain limited to addressing specific aspects of interactions among factors and stages for multiple decision making. To build a case-based scope addressing the interactions among a set of factors and life-cycle stages, a comprehensive approach for mapping and …

Liquid Force Kite Control System Design, Brendan Kerr, Brodie Sutherland, Alden Simmer

Industrial and Manufacturing Engineering

Kiteboarding is an ocean sport wherein the participant, also known as a kiter, uses a large inflatable bow shaped kite to plane across the ocean on a surfboard or wakeboard. The rider is connected to his or her kite via a control bar system. This control system allows the kiter to steer the kite and add or remove power from the kite, in order to change direction and increase or decrease speed. This senior project focused on creating a new control bar system to replace a control bar system manufactured by a kiteboarding company, Liquid Force. The current Liquid Force …

Creating The Foundation For A Startup: Design And Implementation Of A Database System For An Electrical Bicycle Rental Company, Alejandro Martinez

Industrial and Manufacturing Engineering

BoltAbout was started by 4 Cal Poly students, and their COO is a fellow Industrial Engineering student that I met during the first half of the senior project series class. He presented the project to me and I decided to work with him in developing this new database for his startup company. BoltAbout’s customer base is growing and current operations are not fit to meet the demand of a growing company. More specifically, their data management system can’t be used by all current employees to perform essential tasks such as rental processing, bicycle and equipment organization, and customer data analysis. …

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.

Carbon Footprint Stock Analysis Of U.S. Manufacturing: A Time Series Input-Output Lca, Gokhan Egilmez, Khurrum Bhutta, Bulent Erenay, Yong Shin Park, Ridvan Gedik

Mechanical and Industrial Engineering Faculty Publications

The purpose of this paper is to provide an input-output life cycle assessment model to estimate the carbon footprint of US manufacturing sectors. To achieve this, the paper sets out the following objectives: develop a time series carbon footprint estimation model for US manufacturing sectors; analyze the annual and cumulative carbon footprint; analyze and identify the most carbon emitting and carbon intensive manufacturing industries in the last four decades; and analyze the supply chains of US manufacturing industries to help identify the most critical carbon emitting industries.

Work Zone Simulator Analysis: Driver Performance And Acceptance Of Missouri Alternate Lane Shift Configurations, Suzanna Long, Ruwen Qin, Dincer Konur, Ming-Chuan Leu, S. Moradpour, S. Thind, H. Nadathur

Engineering Management and Systems Engineering Faculty Research & Creative Works

The objective of this project is to evaluate MoDOT’s alternate lane shift sign configuration for work zones. The single signproposed by MoDOT provides the traveler with enough information to let them know that all lanes are available to shift around thework zone, whereas the MUTCD signs require drivers to see two signs. This research simulation project evaluates the drivers’ laneshifting performance and acceptance of the alternate lane shift sign proposed by MoDOT to be used on work zones as compared tothe MUTCD lane shift signs. Based on the study results, no difference was observed between MUTCD lane shift sign andMoDOT …

Advances In Composite Manufacturing Of Helicopter Parts, Tobias A. Weber, Hans-Joachim K. Ruff-Stahl

International Journal of Aviation, Aeronautics, and Aerospace

This study investigates and compares different methods for improving standard autoclave composite manufacturing in order to find suitable approaches to a more efficient composite production. The goal is not only a reduction in manufacturing times and costs but also quality enhancement. Improved part quality while decreasing costs enables a manufacturer of composite parts to expand its market share, especially in the helicopter market, which has been constantly shrinking over the last two years. Various approaches such as improved tooling technology, the use of automated systems for lamination as well as outsourcing are examined to provide an overview of possible advancements …

Modeling Of Selective Laser Sintering/ Selective Laser Melting, Xuan Wang, Connor West

Industrial and Manufacturing Engineering

Selective laser sintering and selective laser melting are powder based additive manufacturing (AM) process that can rapidly manufacture parts with comparable mechanical properties to conventional manufacturing methods directly from digital files. However, the processing recipe development and design optimization of AM parts are often based on trial and error which erodes the benefit of AM. Modeling is a powerful tool to enable faster development cycle by significantly reducing the experimental efforts. In this paper we discussed the current status of selective laser sintering/melting modeling, in which the laser and powder interaction was studied to understand and predict the process and …

Survey Of Lean Management Practices In Pakistani Industrial Sectors, Khurrum Bhutta, Gokhan Egilmez, Kamran Chatha, Faizul Huq

Mechanical and Industrial Engineering Faculty Publications

This research was undertaken to study the implementation and adoption of Lean management practices across several industrial sectors in Pakistan. A total of 100 companies were surveyed across five industries. The objective was to determine if there was disparity in the implementation of Lean practices and to provide a yardstick to measure that disparity. Furthermore, this study identified Lean management best practices across several industries in Pakistan, thus providing benchmarks for other industrial sectors. The data collected was analysed using various descriptive statistical methods. The results indicated robust adoption and implementation of Lean practices in Pakistani industry, though there were …

From Green Buildings To Green Supply Chains: An Integrated Input Output Life Cycle Assessment And Optimization Framework For Carbon Footprint Reduction Policy Making, N. Muhammad Aslaam, Gokhan Egilmez, Murat Kucukvar, M.Khurrum S. Butta

Mechanical and Industrial Engineering Faculty Publications

Purpose: This paper focuses on tracing GHG emissions across the supply chain industries associated with the U.S. residential, commercial and industrial building stock and provides optimized GHG reduction policy plans for sustainable development.

Design/Methodology/Approach: A two-step hierarchical approach is developed. Firstly, Economic Input Output-based Life Cycle Assessment (EIO-LCA) is utilized to quantify the GHG emissions associated with the U.S. residential, commercial and industrial building stock. Secondly, a mixed integer linear programming (MILP) based optimization framework is developed to identify the optimal GHG emissions’ reduction (%) for each industry across the supply chain network of the U.S. economy.

Findings: The results …

Built-In Bicycle Rack For Cars, Scott A. Hansberry

All Undergraduate Projects

Transporting a bicycle after riding somewhere and then needing to be pickup can be problematic. Bicycles will not fit in most vehicles without removing components. There is also the risk of damaging the inside of the vehicle. Expecting everyone to have a bike rack for their vehicle is unrealistic because the bike rack could be considered unappealing visually, take up to much space in the trunk, or limit the vehicle owner’s access to the trunk. The solution to this problem is a bike rack that mounts onto your car and then mounts your bike onto the rack. Most people don’t …

Models For The Residual Life Of Railroad Bearing Grease In Laboratory And Industry Applications, Douglas Timmer, Constantine Tarawneh, Robert Jones

Manufacturing & Industrial Engineering Faculty Publications

Adequate lubrication in railroad bearings is crucial to the safe operation of these components. An investigation of the residual life of railroad bearing grease was conducted in a laboratory setting. The data was collected using a split-split-plot design of experiments. The Oxidation Induction Time (OIT), which is the time required for the remaining antioxidants in a sample of grease to be consumed in a test, is the response variable for this study. Low values of OIT indicate small remaining amounts of antioxidants in the grease and thus small remaining residual life in the grease. OIT measurements were made using differential …

Condition Assessment Of End-Of-Use Products For Remanufacturing, Jovan Morgan

Research Opportunities for Engineering Undergraduates (ROEU) Program 2016-17

The goal of the project is to use the automated 3-D laser scanner using a Capnut as a test object to detect surface defects, corrosion and calculation error through offline quality inspection. potentially reducing labor time and cost for both consumers and manufacturers.

Target Read Operation Of Passive Ultra High Frequency Rfid Tag In A Multiple Tags Environment, Zi Qin Phua

Theses and Dissertations--Mechanical and Aerospace Engineering

Passive ultra-high frequency (UHF) radio frequency Identification (RFID) has emerged as a promising solution for many industrial applications. Passive UHF systems are relatively inexpensive to implement and monitor, as no line of sight is required for the communication. There are several advantages to using a passive RFID system. For example, no internal power source is required to activate the tags, and lower labor costs and efficient multitasking operations are expected in a long term scenario. However, due to factors such as tag-to-tag interference and inaccurate localization, RFID tags that are closely spaced together are difficult to detect and program accurately …

Adaptive Scheduling For Operating Room Management, Honghan Ye

Theses and Dissertations--Mechanical and Aerospace Engineering

The perioperative process in hospitals can be modelled as a 3-stage no-wait flow shop. The utilization of OR units and the average waiting time of patients are related to makespan and total completion time, respectively. However, minimizations of makespan and total completion time are NP-hard and NP-complete. Consequently, achieving good effectiveness and efficiency is a challenge in no-wait flow shop scheduling. The average idle time (AIT) and current and future idle time (CFI) heuristics are proposed to minimize makespan and total completion time, respectively. To improve effectiveness, current idle times and future idle times are taken into consideration …

Analytical And Boundary Element Solutions Of Bulk Reacting Lined Ducts And Parallel-Baffle Silencers, Jundong Li

Theses and Dissertations--Mechanical and Aerospace Engineering

Lined silencers of various configurations are used to attenuate the noise from building HVAC equipment, gas turbines, and other machinery. First-mode analytical solutions are presented for sound attenuation along rectangular lined ducts, parallel-baffle silencers, and circular lined ducts. The sound absorptive lining is treated using a bulk property model. The analytical solutions entail solving a nonlinear characteristic equation in the transverse direction after the rigid-wall boundary condition is applied. The solution is compared to the boundary element solution and a local impedance analytical solution for several test cases.

Sensitivity Analysis Method To Address User Disparities In The Analytic Hierarchy Process, Marie Ivanco, Gene Hou, Jennifer Michaeli

Mechanical & Aerospace Engineering Faculty Publications

Decision makers often face complex problems, which can seldom be addressed well without the use of structured analytical models. Mathematical models have been developed to streamline and facilitate decision making activities, and among these, the Analytic Hierarchy Process (AHP) constitutes one of the most utilized multi-criteria decision analysis methods. While AHP has been thoroughly researched and applied, the method still shows limitations in terms of addressing user profile disparities. A novel sensitivity analysis method based on local partial derivatives is presented here to address these limitations. This new methodology informs AHP users of which pairwise comparisons most impact the derived …

Chocolate Bar Wrapping Machine, Austin M. Hoff, Daniel R. Trepke, Caleb B. Krichbuam

Williams Honors College, Honors Research Projects

Gilbert Chocolates has proposed to manufacture a machine to wrap chocolate bars. This machine is intended to replace two people wrapping the chocolate bars by hand, which is a time consuming method. This is especially apparent between October and January when the workers are working long hours in preparation for the Christmas rush of customers. Currently wrapping a bar takes about a minute and Gilbert Chocolates wants this time reduced down to 20-30 seconds. The budget for this project is set at $1000, and is being funded by the company. This machine needs to fit in a cubic foot of …

Effect Of Local Magnetic Field Disturbances On Inertial Measurement Units Accuracy, Xavier Robert-Lachaine, Hakim Mecheri, Christian Larue, André Plamondon

Études primaires

Inertial measurement units (IMUs), a practical motion analysis technology for field acquisition, have magnetometers to improve segment orientation estimation. However, sensitivity to magnetic disturbances can affect their accuracy. The objective of this study was to determine the joint angles accuracy of IMUs under different timing of magnetic disturbances of various durations and to evaluate a few correction methods. Kinematics from 12 individuals were obtained simultaneously with an Xsens system where an Optotrak cluster acting as the reference system was affixed to each IMU. A handling task was executed under normal laboratory conditions and imposed magnetic disturbances. Joint angle RMSE was …

Energy-Climate-Manufacturing Nexus: New Insights From The Regional And Global Supply Chains Of Manufacturing Industries, Murat Kucukvar, Bunyamin Canseva, Gokhan Egilmez, Nuri C. Onat, Hamidreza Samadi

Mechanical and Industrial Engineering Faculty Publications

The main objectives of this research are to improve our understanding of energy-climate-manufacturing nexus within the context of regional and global manufacturing supply chains as well as show the significance of full coverage of entire supply chain tiers in order to prevent significant underestimations, which might lead to invalid policy conclusions. With this motivation, a multi region input–output (MRIO) sustainability assessment model is developed by using the World Input–Output Database, which is a dynamic MRIO framework on the world’s 40 largest economies covering 1440 economic sectors. The method presented in this study is the first environmentally-extended MRIO model that harmonizes …

Design And Implementation Of A Fixture For Robotic Welding, Isaac Nathaniel Williams

Industrial and Manufacturing Engineering

The Cal Poly IME department recently purchased a robotic welder. The faculty would like to see this robot incorporated into the welding class. The robot was capable of moving, but was not able to perform a weld prior to this project. This problem is addressed by creating a demonstration part for the welding class. The objectives that need to be complete for this to be possible is designing a part, designing a fixture, analyzing the cost of robotic welding, and implement welding the part in the class. The part is designed with specific requirements in mind. The fixture is designed …

Application Of Gearbox Drivetrains For Commuting Bicycles, Loren Sunding

Industrial and Manufacturing Engineering

People all over the world are beginning to ride their bicycles more often to destinations which include work, school, and local markets. Most bicycles being used for these activities have an external drivetrain exposed to the elements of the road including water, mud, dirt, and debris. External drivetrains are very fragile and when damaged, pedaling efficiency is greatly reduced and the overall riding experience diminishes.

One solution to this issue is a gearbox specifically designed for a bicycle frame. A gearbox has several mechanical mechanisms operating inside a protective housing. Since the housing is fully sealed, outside elements are not …

Assembly Line Kitting: Foam Mold Material Substitute, Samer Samy Saleh

Industrial and Manufacturing Engineering

Kitting is considered an incredibly innovative and effective solution intended to aid operators within a mixed model assembly line. However, it is a non-value added procedure and one that customers may not be willing to pay for. With this project, the goal is to examine opportunities to employ lean principles and provide a solution that further eliminates non-value added procedures, while also producing the potential for a flexible, mixed model assembly line.

To achieve the aforementioned purpose, the production of foam molds, located within industrial totes and sent to the assembly line, was found to be a major waste within …

Mri Upgrades At Radiology Associates, Patrick Cheung, Charlene Donlon

Industrial and Manufacturing Engineering

Problem Statement: The MRI machines at Radiology Associates are limiting the company’s ability to expand and compete within the local market. After discussing with technicians and managers at Radiology Associates, we decided to focus on hardware and software upgrades for the MRI machines. With 2 of the 3 locations purchasing new machines in the near future, our focus was on upgrades at the Santa Maria facility. The two machines at this location needed hardware and/or software upgrades to remain on par competitively both within the company and with local scanning options. Flexible coils are beneficial in terms of size, weight, …