Operations Research, Systems Engineering and Industrial Engineering Commons^™

A Computer-Based Approach To Material And Process Selection Using Sustainability And Ecological Criteria, Manocher Djassemi

Industrial Technology and Packaging

Decision on selecting a material or process for a particular product is a common task in product engineering and facility planning. Such decision may have a significant impact on entire product life cycle including raw material acquisition, product manufacture, use, disposal, and environment. Traditional factors for decision making are economical, functional and aesthetical properties of the product. However, the issues of sustainability and environmental impact of materials and manufacturing processes have gained a growing attention in recent decade by general population as well as academicians and industrial practitioners. The objective of this study is to explore a software tool for …

Drop Impact Reliability Of Edge-Bonded Lead-Free Chip Scale Packages, Andrew Farris, Jianbiao Pan, Albert Liddicoat, Michael Krist, Nicholas Vickers, Brian J. Toleno, Dan Maslyk, Dongkai Shangguan, Jasbir Bath, Dennis Willie, David A. Geiger

Industrial and Manufacturing Engineering

This paper presents the drop test reliability results for edge-bonded 0.5 mm pitch lead-free chip scale packages (CSPs) on a standard JEDEC drop reliability test board. The test boards were subjected to drop tests at several impact pulses, including a peak acceleration of 900 Gs with a pulse duration of 0.7 ms, a peak acceleration of 1500 Gs with a pulse duration of 0.5 ms, and a peak acceleration of 2900 Gs with a pulse duration of 0.3 ms. A high-speed dynamic resistance measurement system was used to monitor the failure of the solder joints. Two edge-bond materials used in …

New Pressure Sensitive Device To Measure And Predict Package Drops, Sher Paul Singh, Jay Singh, Young Paek

Industrial Technology and Packaging

Pressurex^®, a tactile pressure sensor film which is manufactured by Sensor Product Inc. (East Hanova, NJ, USA), is one of the emerging materials that is convenient for measurements of the strength of pressure and pressure distribution profile between two contacting surfaces without any instrumentation. It immediately reveals impact distribution and magnitude based on intensity and dispersion of color. The intensity of this color is proportional to the amount of force applied allowing the user to actually quantify the stress characteristics across the impact surface. The objective of this paper was to examine free fall drop test results using …

Packaging Trends For Bottled Water, N. Noble, L. Paul, C. Mcminimee, M. Mallett, Jay Singh

Industrial Technology and Packaging

The Journal of Applied Packaging Research(JAPR) is an international forum for the dissemination of research papers, review articles, tutorials and news about innovative or emerging technologies for the packaging industry. In an effort to introduce research conducted by packaging students to the academics and industry professionals and to provide an outlet for these future stewards of the packaging industry to experience the world of publishing, JAPR, occasionally includes such work in its issues.

Bottled water is drinking water packaged generally in plastic bottles and regulated by national and local agencies. The Beverage Marketing Corporation defines the bottled water market …

Rfid Tag Readability Issues With Palletized Loads Of Consumer Goods, Jay Singh, Eric Olsen, Keith Vorst, K. Tripp

Industrial Technology and Packaging

Radio Frequency Identification (RFID) is an automatic identification technology, relying on storing and remotely retrieving data using devices called RFID tags. This technology is being used in enterprise supply chain management-related applications to improve the efficiency of inventory tracking and management. However, this technology has not been able to realize its promised potential because of several factors, such as lack of congruous worldwide standards, privacy issues and less than perfect read rates in supply chain applications. This research aimed to evaluate the readability issues commonly faced by tagged cases of palletized consumer products. The variables studied in this research were …

Design-An Opportunity In Reducing Corrugated Fiberboard Carbon Footprint, Jay Singh, R. Kisch, J. Chhun, Eric Olsen

Industrial Technology and Packaging

Telescoping Half Slotted Containers (HSC) and Diagonal Corner Bliss style containers are popular choices for packaging agricultural products such as apples, pears, citrus, potatoes, garlic and most vegetables. This study evaluated two unique corrugated container designs, Kisch Full Circle Tray (FCT) and Single V Kisch Bliss, which are both viable designs available to replace the presently used styles of boxes for produce distribution. This paper presents the compression strength results of Telescoping HSC containers as compared to two possible replacements and the Diagonal Corner Bliss designs when stored under standard, refrigerated and tropical conditions. It also compares the material savings …

Flexography Printing Performance Of Pla Film, J. Jacobson, Malcom Keif, Xiaoying Rong, Jay Singh, Keith Vorst

Industrial Technology and Packaging

During the past decade polylactide acid (PLA) polymer has been the subject of numerous researches aimed at comparing it with traditional petroleum based polymers for many packaging applications. PLA is biodegradable and derived from agricultural by-products such as corn starch or other starch-rich substances like maize, sugar or wheat.While PLA is currently being used in many packaging applications with well documented performance, little work has been done comparing printing processes and performance. This study presents PLA printing performance and sustainability findings using the common flexography printing process. Various analytical methods were used to evaluate performance and provide recommendations for optimized …

Teaming Multi-Level Classes On Industry Projects, Lizabeth Schlemer, Jose Macedo

Industrial and Manufacturing Engineering

For the past few years we experimented with teaming students from a sophomore-level class and a senior-level class to work on industry projects. The classes are “work design” and “facilities design.” Projects are selected to require the application of knowledge from both disciplines. In addition, the projects are selected from small local companies. The intent of this paper is to describe the benefits and difficulties associated with this methodology. While specific classes in this experience are typical of an industrial engineering curriculum, the lessons learned and benefits could translate to other disciplines.

Effect Of Transport Vibration On Quality Of Minimally Processed And Packaged Fresh-Cut Cantaloupe, Koushik Saha, S. Paul Singh, Bruce Harte

Industrial Technology and Packaging

This study was undertaken to determine the quality of packaged fresh cut cantaloupe subjected to transport vibration after treating with various anti-browning agents. Cantaloupe (Cucumis melo) pieces were dipped in two anti-browning solutions: Treatment- A (2% ascorbic acid + 1% calcium chloride + 0.5% citric acid) and Treatment-B (3% NatureSeal™) for 2 minutes and packaged in bio-based clamshell containers and vibrated for 60 minutes (ASTM 4169, Truck assurance level II). Vibration of cut-cantaloupe packaged in sample containers had a positive effect on the flavor and overall liking. The overall liking scores were higher than 6(slightly like) on a hedonic scale …

Optimization Of Engineering Tolerance Design Using Revised Loss Functions, Jeh-Nan Pan, Jianbiao Pan

Industrial and Manufacturing Engineering

Engineering tolerance design plays an important role in modern manufacturing. Both symmetric and asymmetric tolerances are common in many manufacturing processes. Recently, various revised loss functions have been proposed for overcoming the drawbacks of Taguchi's loss function. In this article, Kapur's economic tolerance design model is modified and the economic specification limits for both symmetric and asymmetric losses are established. Three different loss functions are compared in the optimal symmetric and asymmetric tolerance design: a revised Taguchi quadratic loss function, an inverted normal loss function and a revised inverted normal loss function. The relationships among the three loss functions and …

Design Of An 8-Channel Data Acquisition System For Measuring Diode Junction Temperature, Jason Maynard

Industrial and Manufacturing Engineering

The solid state lighting industry is striving to expand the use of light emitting diodes (LEDs) in more applications, particularly in high brightness applications. As the power of LEDs increase, heat removal becomes a critical issue. To improve device lifetime, quantum efficiency, and LED colour, the diode p-n junction temperature (Tj) must be kept to a minimum. Measuring this key parameter is difficult or impossible with direct methods, such as thermocouples and infrared cameras, due to the small size of LEDs. Fortunately, junction temperature can be measured indirectly by using a relationship between the diode forward voltage (Vf) and junction …

A Decision Support System For Capacity Management, Anton Slobodnik

Industrial and Manufacturing Engineering

Every manufacturer faces the challenge of managing production capacity. How effectively a company meets required capacity as compared to competitors will be a determinant of profitability and success.

This paper details the creation of a best of breed software that can act as a decision support system and help planners reschedule work, add shifts and make sure that the master production schedule is feasible before putting it into an MRP system.

As a part of my senior project I’ve created a Rough-Cut Capacity Tool that takes lead time into account and performs basic what if analysis on level loading a …

Finding And Optimising The Key Factors For The Multiple-Response Manufacturing Process, Jeh-Nan Pan, Jianbiao Pan, Chun-Yi Lee

Industrial and Manufacturing Engineering

With the advent of modern technology, manufacturing processes became so sophisticated that a single quality characteristic cannot reflect the true product quality. Thus, it is essential to perform the key factor analysis for the manufacturing process with multiple-input (factors) and multiple-output (responses). In this paper, an integrated approach of using the desirability function in conjunction with the Mahalanobis-Taguchi-Gram Schmit (MTGS) system is proposed in order to find and optimise the key factors for a multiple-response manufacturing process. The aim of using the MTGS method is to standardise and orthogonalise the multiple responses so that the Mahalanobis distance for each run …

Effects Of Reflow Profile And Thermal Conditioning On Intermetallic Compound Thickness For Snagcu Soldered Joints, Jianbiao Pan, Tzu-Chien Chou, Jasbir Bath, Dennis Willie, Brian J. Toleno

Industrial and Manufacturing Engineering

Purpose – The purpose of this paper is to investigate the effects of reflow time, reflow peak temperature, thermal shock and thermal aging on the intermetallic compound (IMC) thickness for Sn3.0Ag0.5Cu (SAC305) soldered joints.
Design/methodology/approach – A four-factor factorial design with three replications is selected in the experiment. The input variables are the peak temperature, the duration of time above solder liquidus temperature (TAL), solder alloy and thermal shock. The peak temperature has three levels, 12, 22 and 32°C above solder liquidus temperatures (or 230, 240 and 250°C for SAC305 and 195, 205, and 215°C for SnPb). The TAL has …

The Effect Of Ultrasonic Frequency On Gold Wire Bondability And Reliability, Jianbiao Pan, Minh-Nhat Le, Cuong Van Pham

Industrial and Manufacturing Engineering

This paper presents a systematic study on the effect of 120 KHz ultrasonic frequency on the bondability and reliability of fine pitch gold wire bonding to pads over an organic substrate with gold metallizations. The study was carried out on a thermosonic ball bonder that is allowed to easily switch between ultrasonic frequencies of 60 KHz and 120 KHz by changing the ultrasonic transducer and the ultrasonic generator. Bonding parameters were optimized through the design of experimental methodology for four different cases: 25.4 mm wire at 60 kHz, 25.4 mm wire at 120 kHz, 17.8 mm wire at 60 kHz, …

Lean Erp Systems: Existence And Viability In Today's Manufacturing Industry, Miroslav Djuric

Master's Theses

This thesis evaluates the existence and viability of lean ERP systems in today’s manufacturing industry. Results from the research show that current practitioners of lean – who also utilize ERP systems – do not have a strong enough link between the two to consider their ERP systems, and overall organizations, as being truly lean.

Few articles and research papers in today’s body of knowledge contain information on the concept of lean ERP. A survey, sent to numerous industry professionals and posted on lean manufacturing websites, provided the results necessary for statistical analysis. The conclusions obtained from this survey analysis provided …

Effect Of Truck Vibration During Transport On Damage To Fresh Produce Shipments In Thailand, V. Chonhenchob, S. Sittipod, D. Swasdee, P. Rachtanapun, S. P. Singh, Jay A. Singh

Industrial Technology and Packaging

The increase in global trade allows packaged products to be shipped across borders using inter-modal transportation. Trucks are still the most prevalent mode for surface shipments and time sensitive transport perishable products such as fresh produce. This study focused on measuring the transportation environment in truck shipments from various packing houses to major retail distribution centers in Thailand and then the subsequent distribution to regional stores in smaller trucks. Test measurements were compared to test methods used in North America and Europe. This study compared the quality of cabbage, lettuce, plums and pears after being shipped in truck transport by …

Performance Of Pre-Cut Lettuce Packaged In Biodegradable Film Formed On Commercial Vertical-Form-Fill-And-Seal Machines, J. Wyatt Brown, Keith Vorst, Shasta Palmer, Jay A. Singh

Industrial Technology and Packaging

The purpose of this study was to determine the feasibility of using biodegradable films suitable for fresh-cut lettuce with commercial vertical-form-fill-and-seal packaging machines (VVFS) equipped with heat-sealing bars. Biodegradable high-density polyethylene (BHDPE) and polypropylene (BPP) films were tested. Commercial bags of pre-cut Romaine sealed in a polyethylene/oriented polypropylene (PE/OPP) bag formed on a WFS machine were used as the control. All bags were held at 4.4°C, 80% RH and assessed for reduction in quality during storage per a commercial (in-house) standard utilized by a large pre-cut salad packer in Salinas, California. When the biodegradable films were sealed with a VFFS …

Emergence Of Multitasking Machining Systems: Applications And Best Selection Practices, Manocher Djassemi

Industrial Technology and Packaging

Purpose –Multitasking machining (MTM) systems have become increasingly sophisticated and expensive capital equipment. The lack of practical guidelines for selection of these machines can lead to significant undesirable machine attributes, application mismatch, and longer return on investment. The purpose of this paper is to provide an insight to numerous features and configurations of MTM systems and to present several application-based selection guidelines.

Design/methodology/approach –A taxonomy of MTM systems is developed based on the number of axes of motions, tooling and spindle systems. Practical guidelines for general and advance features are presented with special regard to multi-axis and multi-spindle …

Computer-Based Approach To Material And Process Selection, Manocher Djassemi

Industrial Technology and Packaging

Purpose – The purpose of this paper is to provide a perspective of computer-aided material and process selection (MPS) software tools for product development purpose and present a practical approach for manufacturers and other decision makers involved in MPS.
Design/methodology/approach – A multi-criteria deductive approach for MPS is applied to a case study by taking into account the technical performances and environmental constraints. A resource-based cost modeling is also deployed to examine the implication of selected material and process on overall product cost.
Findings – The paper demonstrates the capabilities and shortcoming of existing computerized MPS software tools in assisting …

A Study Of The Effect Of Pictorial Markings And Warning Labels On Handling Of Packages In The Dhl Single-Parcel Environment, Jay A. Singh, Sher Paul Singh, T. Voss, K. Saha

Industrial Technology and Packaging

Over the past two decades, there has been a heavy influx in the number of direct-to-consumer express shipments of packaged products. As a consequence, parcel delivery companies, such as DHL, FedEx and UPS, have strengthened their presence in air transport. This study measured and analysed the effect of moving single packages through air shipments in the USA using one of the newest service providers, DHL. The study also quantified the effect of placing pictorial markings and warning labels on mid-sized and lightweight packages when using Next-Day and 2nd Day services provided by the carrier DHL. Instrumented packages measuring 0.38 m …

Dynamic Modelling Of Reconfigurable Manufacturing Planning And Control Systems Using Supervisory Control, Ahmed M. Deif, Waguih H. Elmaraghy

Industrial Technology and Packaging

This research is concerned with studying the dynamic performance of reconfigurable Manufacturing Planning and Control (MPC) systems. Such goal requires two main tasks. The first task is to develop a dynamic MPC system model that has the ability to reconfigure to different MPC policies. The second task is to design a supervisory control unit that has as input the high level strategic market decisions and constraints together with a feedback of the current manufacturing system state and then select the optimal suitable operation mode or policy at these conditions. This paper addresses the first task of the proposed research and …

Optimization Of Lifeguard Towers, Equipment, And Sign Placement With Human Factors Considerations For The Cal Poly Recreation Center Expansion, Brian J. Henrikson

Industrial and Manufacturing Engineering

Cal Poly’s Recreation Center serves many faculty, students and alumni by providing them with a safe and fun environment to work out and swim. An overwhelming majority of students voted for a Recreation Center expansion to handle the increased usage of the Center over the past few years. The focus of this report is the safe and effective operations of the pool deck and the lifeguard staff. Three surveys were created to see what the lifeguard staff, as well as pool users, thought about the current pool deck and what they would like to see in the new pool deck …

Dynamic Analysis Of Less-Than-Truckload Shipments And Test Method To Simulate This Environment, Sher Paul Singh, E. Joneson, Jay Singh, G. Grewal

Industrial Technology and Packaging

This paper provides results from a comprehensive data measurement study that analyzed the vibration dynamics produced inside the trailers used for less-than truckload (LTL) shipments. The trailers used for this segment of the package transportation environment are very different in size and suspension than those used for full truckload shipments. This study measured the vertical, lateral and longitudinal vibration inside a trailer as a function of road surface. In addition, the study developed a video showing freight movement inside the trailer to determine physical displacement and shifting of the loads. A set of recommendations was developed to safely load and …

A Computer-Based Economic Analysis For Manufacturing Process Selection, Manocher Djassemi

Industrial Technology and Packaging

An important part of financial planning in product development is considering whether the capital expenditures meet volume and cost goals. A good business plan should provide investors with the implications of process selection on the company's bottom line. It is estimated that there are least 1000 manufacturing processes and sub-processes. Considering the number of process choices and quantity of cost data, an economic analysis for process selection may pose a challenge for decision makers. This paper provides an insight to Ashby’s cost modeling method for generating an estimate of unit product cost. The cost model provides a broad indicator for …

Drop Impact Dynamic Response Study Of Jedec Jesd22-B111 Test Board, Michael Krist, Jianbiao Pan, Andrew Farris, Nicolas Vickers

Industrial and Manufacturing Engineering

Mobile and handheld electronic devices are prone to being dropped. This drop event may result in failure of solder joints inside these devices. The need for RoHS compliant boards coupled with the demand for reliable electronics has resulted in the development of the JEDEC Standard JESD22-B111 to standardize the method of drop testing surface mount electronic components. However, there has been little study on the effects of additional mass on the board and rigidity of the board on drop test reliability. This paper examines the drop impact dynamic responses of the JEDEC JESD22-B111 board. Of interest are the effects of …

The Effect Of Ultrasonic Frequency On Gold Wire Bondability And Reliability, Jianbiao Pan, Minh-Nhat Le, Cuong Van Pham

Industrial and Manufacturing Engineering

This paper presents a systematic study on the effect of 120KHz ultrasonic frequency on the bondability and reliability of fine pitch gold wire bonding. The study was carried out on a thermosonic ball bonder that is allowed to easily switch between ultrasonic frequency of 60KHz and 120 KHz by changing the ultrasonic transducer and the ultrasonic generator. Bonding parameters were optimized through design of experiment methodology for four different cases: 25.4 μm wire at 60 kHz, 25.4 μm wire at 120 kHz, 17.8 μm wire at 60 kHz, and 17.8 μm wire at 120 kHz. The integrity of wire bonds …

Board Level Failure Analysis Of Chip Scale Package Drop Test Assemblies, Nicholas Vickers, Kyle Rauen, Andrew Farris, Jianbiao Pan

Industrial and Manufacturing Engineering

This paper presents the failure analysis results of board level drop tests. In this study, the test vehicle was designed according to the requirements of the Joint Electron Device Engineering Council (JEDEC) drop test board. The test vehicle was assembled with 15 chip scale packages (CSPs) each having 228 daisy-chained 0.5 mm pitch solder joints using Sn-3.0 wt% Ag-0.5 wt% Cu (SAC305) lead free solder. Assemblies were drop tested using three different peak accelerations of 900 G, 1500 G, 2900 G, with 0.7 ms, 0.5 ms, and 0.3 ms pulse durations, respectively. Scanning electron microscopy (SEM) with energy dispersive spectroscopy …

Work In Progress - Enhancing Student-Learning Through State-Of-The-Art Systems Level Design And Implementation, Albert A. Liddicoat, Jianbiao Pan, James G. Harris, Dominic J. Dal Bello, Lynne A. Slivovsky

Industrial and Manufacturing Engineering

The curriculum for undergraduate engineering programs is often partitioned into several courses that are taught in isolation followed by a single culminating senior design or capstone project experience. In the senior design class students being to synthesize the knowledge and skills that they acquired through the engineering curriculum. This paper presents lower and upper division course and curricular changes made to accommodate learning objectives that better prepare students for project-based learning. These learning experiences and skills include: systems level design, experience with state-of-the-art Computer Aided Design (CAD) tools, printed circuit board (PBC) design, design for manufacturability, electronics assembly, project management, …

Alternative Binder Carbide Tools For Machining Superalloys, Daniel J. Waldorf, Michael Stender, Scott Liu, Daniel Norgan

Industrial and Manufacturing Engineering

This study examines the performance of a new class of wear-resistant but economical cutting tools produced by varying the binder composition of standard cemented carbide composites. By replacing some or all of the cobalt binder with rhenium and nickel-based superalloy, a stronger composite tool results, potentially capable of machining heat-resistant superalloys at significantly higher cutting speeds. Sample tools with alternative binder were produced and compared to standard tools bound with cobalt only. Turning experiments on Inconel 718 were run to evaluate wear resistance and tool life for several grades. The experimentation also examined the effects of varying the relative proportions …