Operations Research, Systems Engineering and Industrial Engineering Commons^™

A Supply Chain Management Tool For Linking Courses In Manufacturing Engineering , Daniel Waldorf, Sema E. Alptekin

Industrial and Manufacturing Engineering

A Recent Society of Manufacturing Engineers (SME) grant received by Manufacturing Engineering Program at Cal Poly has provided funds to strengthen its curricular focus on supply chain management, flexibility, business skills, quality, and process controls. New courses and laboratories are developed in electronics manufacturing, information technology, and supply chain management. A functioning supply chain environment has been developed to provide vertical integration among several courses. A software tool being developed in-house integrates the activities of the students who play the roles of customers and suppliers. Details of the various components of this comprehensive project are presented in this paper.

Package Performance Testing Of Dangerous Goods In High Altitude Shipments, S. Paul Singh, Gary J. Burgess, Jay A. Singh

Industrial Technology and Packaging

This paper discusses the impact of high altitude shipments on package integrity. High altitude shipments are encountered when trucks travel over high mountain passes or when cargo and feeder aircraft transport packages in non-pressurized or partially-pressurized cargo holds. Both these types of transport methods will result in severe changes in pressure and temperature conditions as compared to packages being transported close to sea-level The testing of packages under these conditions is critical since package integrity may be compromised. The current shipping tests performed in test labs do not account for pressure changes and vibration together. This study showed that combination …

A Taxonomy Of Scheduling Problems In Semiconductor Device Test Operations, Tali Freed, Robert C. Leachman, Kenneth H. Doerr

Industrial and Manufacturing Engineering

Semiconductor device test facilities differ not only by production volume and tester brands. The complexity of the devices and the characteristics of the testers affect the scheduling methodologies as well. Goals and strategies vary from one firm to another, leading to a variety of objectives and performance measures. Due to random yield lot size is variable and lot priorities are common. Changeover times are oftentimes sequence-dependent. Since semiconductor device testing systems are very costly, scheduling methods that increase the throughput of the facility are financially significant. In this paper we describe a variety of semiconductor device testing environments, develop mathematical …

Computer-Aided Engineering For Tool Design In Manufacturing Engineering Curriculum, Daniel J. Waldorf

Industrial and Manufacturing Engineering

At Cal Poly – San Luis Obispo, a variety of tool design issues are covered in a junior-level manufacturing engineering course called Tool Engineering. In the course, designing fixtures – for any process – is a major component of the content. The process of designing a fixture is similar to the method a mechanical engineer would use to design a new product. The course is therefore an excellent opportunity to teach design principles to manufacturing engineers. This project involves an attempt to introduce computer-aided methods, including the finite element method (FEM), for analysis of tool design into the Tool Engineering …

Teaching Factory, Sema E. Alptekin, Reza Pouraghabagher, Patricia Mcquaid, Daniel Waldorf

Industrial and Manufacturing Engineering

Academia must develop a new approach to teaching in order to better prepare engineering students to function efficiently and adjust readily within the framework of the factories in the real world. Some engineering programs emphasize theory, while others emphasize application as isolated blocks. The "Teaching Factory" being developed at Cal Poly combines both theory and applications. It makes use of state-of-the-art industrial grade production equipment, computer hardware and software in the form of the following two systems: 1) a functioning "real" factory hardware environment, and 2) a Production Planning and Control Center.

The Effect Of Reliability Consideration On The Application Of Quality Index, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

Quality index (QI) has been proposed as a screening mechanism for machine-part matrices in the development of cellular manufacturing systems. In this paper the effect of reliability consideration on the application of QI and the relative sensitivity of job shop and cellular manufacturing systems to reliability changes are evaluated by simulation modeling. Performance measures such as mean flow time and work-in-process inventories are used in the comparative study of job shop and cellular manufacturing.

Plastic Solder Paste Stencil For Surface Mount Technology, Christopher K. Wong, Daniel Waldorf

Industrial and Manufacturing Engineering

Solder paste masks or stencils are an integral part of the manufacturing process for surface mount PCBs. This study examines the feasibility of a process for rapid creation of a solder paste stencil using thermoplastic material. CNC laser cutting of the stencil geometry is replacing traditional use of chemical etching on metal sheets to produce stencils. Laser cutting has been used to improve process speed, accuracy, and cost. This research attempts to continue to simplify and reduce costs in the stencil making process by proposing as the stencil material a common thermoplastic that can be cut easily and quickly using …

Product Flexibility In Selecting Manufacturing Planning And Control Strategy, Emine Persentili, Sema E. Alptekin

Industrial and Manufacturing Engineering

The manufacturing systems capable of producing several products simultaneously are frequently subject to changes in product types due to demand fluctuations. In such systems a product flexible manufacturing planning and control (MPC) strategy is needed to change from one product type to another with minimum deterioration to system performance levels. The objective of this research is to develop a systematic analysis and evaluation approach in order to compare the MRP-push and JIT-pull strategies quantitatively based on a product flexibility measure. A new product flexibility measure is developed based on the sensitivity to change concept and presented together with the implementation …

An Efficient Cnc Programming Approach Based On Group Technology, Manocher Djassemi

Industrial Technology and Packaging

Many studies and reports support the significant impact of the application of group technology on various aspects of product design and manufacturing. The fact that group technology is the common solution to similar problems is the main source of such impact. In this paper, one of the less frequently utilized features of CNC technology known as parametric part programming is used to implement the common solution feature of group technology in processing a set of similar parts. Using three part families, the advantages of blending the concept of group technology and parametric programming for CNC machining operations are illustrated. The …

Simtrainer: A Management Training Tool, Wade Stark, Sema E. Alptekin

Industrial and Manufacturing Engineering

Abstract published of poster paper presented at conference.

Scheduling Semiconductor Device Test Operations On Multihead Testers, Tali Freed, Robert C. Leachman

Industrial and Manufacturing Engineering

Past attempts to devise scheduling methods for the device test operations of semiconductor manufacturing firms fail to address a significant characteristic of multiple-head test systems—the dependency of processing rates on the lots processed simultaneously on the testers. Since the problem has never been modeled accurately in the scheduling literature, feasibility and performance of previously proposed scheduling methodologies for multihead testers may not be accurately assessed. In this paper, we describe the multihead tester scheduling problem, present an enumeration solution procedure, and illustrate the problems of previously suggested tester scheduling algorithms.

An Evaluation Of Ploughing Models For Orthogonal Machining, Daniel J. Waldorf, Richard E. Devor, Shiv G. Kapoor

Industrial and Manufacturing Engineering

An analytical comparison is made between two basic models of the flow of workpiece material around the edge of an orthogonal cutting tool during steady-state metal removal. Each has been the basis for assumptions in previous studies which attempt to model the machining process, but no direct comparison had been made to determine which, if either, is an appropriate model. One model assumes that a separation point exists on the rounded cutting edge while the other includes a stable build-up adhered to the edge and assumes a separation point at the outer extreme of the build-up. Theories of elastic-plastic deformation …

Gauge Repeatability & Reproducibility Study For A 3-D Solder Paste Inspection System, Jianbiao Pan, Gregory L. Tonkay, Robert H. Storer, Ronald M. Sallade, David J. Leandri

Industrial and Manufacturing Engineering

Due to the increased use of Ball Grid Arrays (BGAs) and fine pitch and ultra fine pitch Quad Flat Packages (QFPs), there is a dramatic increase in demand for solder paste inspection after the stencil printing process. The important response variables of the printing process are deposited solder paste volume, area, height and position. To identify and remove defects at the earliest possible process step, a 3-D solder paste inspection system should be used to monitor solder paste deposited on all pads on every board before component placement. An example is a fully automatic laser-based 3-D triangulation solder paste inspection …

Critical Variables Of Solder Paste Stencil Printing For Micro-Bga And Fine Pitch Qfp, Jianbiao Pan, Gregory L. Tonkay, Robert H. Storer, Ronald M. Sallade, David J. Leandri

Industrial and Manufacturing Engineering

Stencil printing continues to be the dominant method of solder deposition in high volume surface mount assembly. Control of the amount of solder paste deposited is critical for fine pitch and ultra-fine pitch SMT assembly. The process is still not well understood as indicated by the fact that industry reports 52-71% of SMT defects are related to the solder paste stencil printing process. The purpose of this paper is to identify the critical variables that influence the deposited solder paste volume, area, and height. An experiment was conducted to investigate the effects of relevant process parameters on the amount of …

Screen Printing Process Design Of Experiments For Fine Line Printing Of Thick Film Ceramic Substrates, Jianbiao Pan, Gregory L. Tonkay, Alejandro Quintero

Industrial and Manufacturing Engineering

Screen printing has been the dominant method of thick film deposition because of its low cost. Many experiments in industry have been done and many models of the printing process have been developed since the 1960's. With a growing need for denser packaging and a drive for higher pin count, screen printing has been refined to yield high resolution prints. However, fine line printing is still considered by industry to be difficult. In order to yield high resolution prints with high first pass yields and manufacturing throughput, the printing process must be controlled stringently.

This paper focuses on investigating the …

Industrial Engineering Made Simple, Deena Daggett, Sema E. Alptekin

Industrial and Manufacturing Engineering

Many high school students these days do not quickly recognize or identify Industrial Engineering (IE) procedures, practices, and products. Recruitment of qualified students into IE programs requires continuous planning, publicizing, and networking. Traditional recruitment efforts have included high school visits, brochures & flyers, and university-sponsored workshops. However, these techniques have only achieved mediocre success. Currently, a need exists for new promotional materials that utilize visual tools and provide a “hands-on” approach. We have developed several exercises that successfully introduce IE. Two such exercises are explained in this paper. The first exercise demonstrates the differences between Assembly line and Cellular Manufacturing …

Worn Tool Forces Based On Ploughing Stresses, Daniel Waldorf, Shiv G. Kapoor, Richard E. Devor

Industrial and Manufacturing Engineering

Recent work in modeling of the ploughing mechanism in basic metal machining may provide a means of estimating the additional forces to be expected when cutting with a worn tool. The results predict the rubbing stresses due to the finite radius of an unworn tool edge. Since an unworn tool can be thought of as a worn tool with a wear land width VB = 0, these stresses can make up part of a strategy for predicting the additional forces incurred by a worn tool. This paper develops a wear model by proposing a technique for utilizing the stresses predicted …

Screen Printing Process Design Of Experiments For Fine Line Printing Of Thick Film Ceramic Substrates, Jianbiao Pan, Gregory L. Tonkay, Alejandro Quintero

Industrial and Manufacturing Engineering

Screen printing has been the dominant method of thick film deposition because of its low cost. Many experiments in industry have been done and many models of the printing process have been developed since the 1960’s. With a growing need for denser packaging and a drive for higher pin count, screen printing has been refined to yield high resolution prints. However, fine line printing is still considered by industry to be difficult. In order to yield high resolution prints with high first pass yields and manufacturing throughput, the printing process must be controlled stringently.

This paper focuses on investigating the …

A Slip-Line Field For Ploughing During Orthogonal Cutting, Daniel J. Waldorf, Richard E. Devor, Shiv. G. Kapoor

Industrial and Manufacturing Engineering

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and …

Fuzzy Logic Control Of A Model Airplane, Jon C. Ervin, Sema E. Alptekin

Industrial and Manufacturing Engineering

Common uses of fuzzy logic control today are found in relatively simple applications in products. These applications only scratch the surface of the potential of fuzzy logic control in complex mechatronic systems. In order to demonstrate the utility of fuzzy logic in complex device control, a fuzzy logic fly-by-wire system has been developed for a model airplane. The model airplane is a complex system of several critical inputs that require rapid processing and action in order to maintain flight stability. In addition, payload and power constraints severely limit the size, weight and processing power of the hardware to be carried …

A Parametric Programming Technique For Efficient Cnc Machining Operations, Manocher Djassemi

Industrial Technology and Packaging

In this paper the application of parametric programming to CNC machining is discussed. As one of the less frequently utilized features of CNC machines, parametric programming has the potential to increase the efficiency of CNC operations. This feature is particularly beneficial to companies with group technology manufacturing where parts with similar design or operational requirements are processed within a machine cell. Using two case studies, the capabilities of parametric programming for CNC machines are illustrated.

Determination Of A Flexibility Range For Cellular Manufacturing Systems Under Product Mix Variations, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

One of the underlying assumptions in cellular manufacturing is that product mix is relatively stable over time. In this paper, a procedure for the sensitivity analysis of the performance of a cellular manufacturing system with respect to changes in the product mix is presented and a flexibility range representing the capability of the system in dealing with these changes is determined using simulation modelling. The simulation results in this study show that as the changes in the product mix increase the superiority of the performance of the cellular manufacturing system to the corresponding job shop system diminishes.

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 …

The Threshold Value Of A Quality Index For Formation Of Cellular Manufacturing Systems, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

The superiority of cellular manufacturing to job shop manufacturing has been questioned by a number of simulation studies. The initial structure of the machine-part matrix seems to play an important role in the failure of cellular manufacturing systems in these studies. In this paper a grouping measure called 'quality index - QI' will be used to evaluate the relationship between the quality of a machine-part matrix and the performance of the corresponding cellular manufacturing system. A simulation study will be conducted to demonstrate how the procedure can be used to determine the threshold value for QI beyond which the cellular …

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 …

Sensitivity Analysis In Cellular Manufacturing System In The Case Of Product Mix Variation, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

In this paper, performance measures such as mean flow time and work-in-process inventories will be used to determine the changes in the performance of a cellular manufacturing system due to product mix variations.

Improving The Performance Of Cellular Manufacturing By A Dynamic Part Assignment Approach, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

In this paper, a simple dynamic part assignment (DPA) procedure is introduced and its effects on the performance of cellular manufacturing systems is evaluated. In this procedure rerouting of parts among machine cells is allowed for better machine utilization. Three data sets are used to compare the performance of manufacturing systems under job shop and cellular manufacturing when DPA is employed. The results of simulation runs indicate that the proposed DPA method improves the performance of cellular manufacturing significantly by reducing the congestion in machine cells with long waiting lines.

A New Grouping Measure For Evaluation Of Machine-Component Matrices, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

The machine-component matrix is the main input to most machine-component grouping models used in cellular manufacturing. A number of measures have been developed for performance evaluation of machine-component grouping algorithms. In this paper, the relationship between these measures and the performance of the corresponding cellular manufacturing system is evaluated and a new grouping measure is developed which is more consistent in predicting the suitability of a manufacturing system for cellular manufacturing.

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 …

A Simulation Study Of Quality Index In Machine-Component Grouping, Hamid Seifoddini, Manocher Djassemi

Industrial Technology and Packaging

Simulation modeling is employed to determine the effectiveness of quality index in screening machine-part matrices for the development of cellular manufacturing systems.