Operations Research, Systems Engineering and Industrial Engineering Commons^™

Dynamic Modelling Of Impact Of Lean Policies On Production Levelling Feasibility, Hoda Elmaraghy, Ahmed Deif

Industrial Technology and Packaging

A dynamic systems approach is proposed to investigate challenges of implementing production leveling and associated costs. A model of a lean cell is developed using system dynamics. The model captures various lean tools influencing production leveling. Comparative cost analysis between various leveling implementation policies for stochastic demand with multiple products is conducted. Results showed that determining the most feasible leveling policy is highly dictated by both capacity scalability cost and limitations. The developed model and revealed insights can help lean practitioners to better decide on when and how to implement production leveling as well as determine production lots sizes.

Dynamic Lean Assessment For Takt Time Implementation, Rehab M. Ali, Ahmed M. Deif

Industrial Technology and Packaging

Increasing volatility, global competitiveness, and sales crisis all force the manufacturers to commit to the journey of world-class manufacturing performance via adopting “lean systems” to enable economic success in difficult times. Among the journey to lean, one of the hardest steps is measuring the progress of lean polices implementation especially in this highly dynamic market. This paper presents a dynamic model to evaluate the degree of leanness in manufacturing firms. The model is based on system dynamics approach and presents a “leanness score” for the manufacturing system. In addition, it examines the dynamics associated with the application of “One-piece flow” …

Impact Of Dynamic Capacity Policies On Wip Level In Mix Leveling Lean Environment, Ahmed Deif, Hoda Elmaraghy

Industrial Technology and Packaging

Balancing demand's product variety in production planning is one aspect of variety management challenge. This phenomenon is described in lean systems as mix leveling. This paper approach product mix leveling problem from a dynamic perspective. A system dynamics model is developed to explore the dynamics associated with the WIP level performance at different mix leveling policies in a lean environment. The system captures different lean tools and policies. Results showed that the best WIP performance is sensitive to both the degree of lean tools implementation as well as the capacity scalability level of the system. The presented analysis showed that …

An Integrated Approach To Assess Manufacturing Greeness Level, Ahmed H. Salen, Ahmed Deif

Industrial Technology and Packaging

This paper proposes an integrated approach for relative greenness level assessment in selected manufacturing industries at the system level. The approach builds on existing methodologies to develop a multi-layer tool box called “Greenometer” which focus on the strategic comparison for cross industries evaluation as well as tactical comparison for intra-industries. The assessment tool captures the fundamental evaluation parameters of green manufacturing namely; Environment, Energy, Resources and Economy. In addition, the Greenometer employs geometric mean method (GMM) for the strategic layer and data envelopment analysis (DEA) for the tactical layer and will be used for different selected manufacturing disciplines. The proposed …

Design And Implementation Of Iso:9001 Standards At Sigma 6 Electronics, Inc., Robert Kirkpatrick, Dylan Geisen, Simon Schermerhorn

Industrial Technology and Packaging

ISO 9001 certification is a very long process that can take even the most dedicated team years to complete. For smaller companies such a process could be costly, confusing, and arduous. While many resources exist, it takes nearly the same amount of effort to tailor fit the examples as it does to create a whole new set.

The purpose of this senior project is to research examples and help fit them to a small manufacturing company, Sigma 6 Electronics, Inc. An interlinked, or combined, quality manual/procedures were chosen to aid Sigma 6 Electronics through making the documentation clear and perfectly …

Toughening Of Poly(L-Lactic Acid) With Cu3Btc2 Metal Organic Framework Crystals, Ajay Kathuria, Mohamad G. Abiad, Rafael Auras

Industrial Technology and Packaging

Poly(l-lactic acid) (PLLA) and metal organic framework (MOF) composites were prepared by melt extrusion of PLLA with 5, 10 and 20% w/w of activated Cu₃(BTC)₂ MOF. The morphology and stability of injection-molded samples were evaluated using thermogravimetric analysis, differential scanning calorimetry (DSC), gel permeation chromatography, X-ray diffraction, and scanning electron microscopy (SEM). The composites showed improved toughness during the tensile tests as compared to the neat PLLA matrix. Toughness mechanism of the composites was studied using SEM and rheological studies. SEM images indicated that cavitation induced by debonding at the interface of PLLA and MOF particles during …

The Effects Of Football Helmet Pressure On The Shock Taken During A Controlled Impact, Sullivan Grosz

Industrial Technology and Packaging

College and NFL football teams are focusing their efforts on protecting players more than ever before. With the recent attention on concussions and the troubling long-term effects of head injuries, more research is needed to find ways to ensure players have the adequate protection. The helmets being used have a hard polycarbonate shell with four inner pads that fit tight to the player’s head. These pads are filled with air.

The purpose of the testing and project is to find an ideal air pressure that helmets need to maintain in order to protect the player to the best of its …

The Effect Of Distribution On Product Temperature Profile In Thermally Insulated Containers For Express Shipments, Jay Singh, Sanjiv Jaggia, Koushik Saha

Industrial Technology and Packaging

An uninterrupted cold chain is a continual series of storage and distribution activities that maintain a specific temperature or temperature range. Cold chain solutions typically involve excessive packaging to ensure that the desired product temperature is maintained through the distribution process, thereby increasing the logistics-related costs. There is a myriad of solutions available for shipping temperature-sensitive products, including those constructed with a variety of packaging materials as well as refrigerants. Although static characteristics for thermally insulated packaging solutions such as the R-values of package systems as well as the melting points and heat absorption rates of various refrigerants have been …

Detachable Point Of Sale Material For Asparagus Shipper, Michael Thomas

Industrial Technology and Packaging

Gourmet Trading Company is a fresh fruit and vegetable distributor specializing in asparagus, blueberries, and blackberries. The company currently mails a 7” by 11” sign to be displayed with their asparagus which arrives in a 28 pound shipper. The signs are intended to be displayed in stores to give consumers information about the asparagus. Unfortunately, many of the signs do not get displayed since they are shipped separately. The purpose of the project is to redesign the 28 pound asparagus shipper to include a detachable point of sale sign.

A literature search was conducted to further understand the needs of …

Csp Desalination/Water Purification Unit, Sean Goodison

Industrial Technology and Packaging

An estimated 3.4 million people die each year from unsanitary water or inaccessible water supply. Most of these deaths take place in the developing, third world (99%). There is a dilemma arising on the world stage as well. The water demand/supply deficit is expected to increase significantly over the next 37 years if preemptive action isn’t taken. 97% of the world water supply is oceanic, making it an attractive solution to the water deficit. Providing autonomous, “deploy and watch” systems for utilizing sustainable energy to provide purified water for unitized low pricing has the potential to penetrate a large world …

Deterioration Of Metal–Organic Framework Crystal Structure During Fabrication Of Poly(L-Lactic Acid) Mixed-Matrix Membranes, Ajay Kathuria, Mohamad G. Abiad, Rafael Auras

Industrial Technology and Packaging

Poly(l-lactic acid) (PLLA) and metal–organic framework (MOF) mixed-matrix membranes were prepared by melt extrusion of PLLA with 5% (w/w) of either activated or water-saturated Cu₃(BTC)₂ (Cu₃(C₉H₃O₆)₂(H₂O)₃·xH₂O, HKUST-1). The morphology and the stability of injection-molded samples were evaluated using thermogravimetric analysis, differential scanning calorimetry, gel permeation chromatography, X-ray diffraction (XRD) and scanning electron microscopy (SEM). The presence of activated and saturated MOF crystals increased the cold crystallization onset temperature as compared to neat PLLA. This can be attributed to the …

Consumer Attention To An Over-The-Counter Warning In Four Different Styles Of Design, Abhishek Gawasane, Laura Bix, Javier De La Fuente, Raghav Prashant Sundar, Timothy J. Smith

Industrial Technology and Packaging

The study consisted of three objectives: (a) to test the relative prominence and conspicuousness of a warning required by US law to be conspicuous; (b) to explore whether or not the conspicuousness of the said warning can be enhanced graphically; and (c) to develop preliminary data for power analysis that would guide decisions related to sample size in future studies.

Seventeen subjects viewed four over-the-counter drug packages (each with a different style of warning) along with five other products while wearing an eye tracking device. Four styles of warning were used on the over-the-counter drug packages: no outline and no …

Blunt Impact Performance Evaluation Of Helmet Lining Systems For Military And Recreational Use, Jaclyn Siniora, Ryan Taylor, Darren Suey

Industrial Technology and Packaging

With the increasing problem in collegiate athletes experiencing injuries to the brain, different helmet liners where put to the test to see which liner provided athletes the greatest protection under specific conditions.

This senior project evaluates five different liners in football helmets. Each of the helmet liners were tested at three different temperatures: hot, cold, and ambient. Each helmet had seven different impact locations which were put to the test. The project was designed to be used to test ACH military combat liners as well. Due to shipping bottle necks the ACH combat liners have been left to future Cal …

Assessing Lean Systems Using Variability Mapping, Ahmed Deif

Industrial Technology and Packaging

A new approach to assess lean manufacturing based on system's variability is proposed. The assessment utilizes a new tool called variability source mapping (VSMII) which focuses on capturing and reducing variability across the production system. The new tool offers a new metric called variability index to measure the overall variability level of the system. Based on the mapping and the new metric, VSMII suggests a variability reduction plan guided by a recommendation list of both lean techniques as well as production control policies. An industrial application is used to demonstrate the new tool. Results show that VSMII managed to reduce …

Dynamic Analysis Of A Lean Cell Under Uncertainty, Ahmed M. Deif

Industrial Technology and Packaging

One of the ultimate targets of lean manufacturing paradigm is to balance production and produce at takt time in production cells. This paper investigates the performance of a lean cell that implements the previous lean goals under uncertainty. The investigation is based on a system dynamics approach to model a dynamic lean cell. Backlog is used as a performance metric that reflects the cell’s responsiveness. The cell performance is compared under certain and uncertain external (demand) and internal (machine availability) conditions. Results showed that although lean cell is expected to be responsive to external demand with minimum waste, however, this …

Measurement And Analysis Of Vehicle Vibration For Delivering Packages In Small‐Sized And Medium‐Sized Trucks And Automobiles, Vanee Chonhenchob, Sher Paul Singh, Jay Jagjit Singh, Joseph Stallings, Gary Grewal

Industrial Technology and Packaging

In distribution, packaged products are subjected to the variation in vibration levels from transport vehicles that vary in frequency and acceleration while moving to their destinations. This vibration may negatively affect the product or packaging. This study measured and analysed vibration levels in vehicles commonly used to transport packages in the last leg of the package delivery service that is used by single‐parcel carriers. Using data recorders, we monitored vertical, lateral and longitudinal vibrations over 75 h of travel time in five different types of small and medium package delivery vehicles. The study presents these data as power density (PD) …

Review Of Package Warning Labels And Their Effect On Consumer Behaviour With Insights To Future Anticounterfeit Strategy Of Label And Communication Systems, John Spink, Jay Singh, S. Paul Singh

Industrial Technology and Packaging

This paper investigates and reviews literature regarding a range of topics important to the research question – the themes apply across all the topics. The topics include label and package warnings, including tamperevident features, to review their effect on the consumer behaviour of changing usage or purchase decisions. This information was then applied to gain insight into anticounterfeit product/package efforts. Based on this research, it appears that there is value for brand marketers to enhance their anticounterfeit efforts and consumer confidence by utilizing warning labels and information labels on their labels or packages. Currently, consumer perception of a domestic counterfeit …

Effect Of Processing, Packaging And Vibration Treatment On The Sensory Quality Of Fresh-Cut Apple Slices, M. Siddiq, J. B. Harte, S. P. Singh, A. A. Khan, K. D. Dolan, Koushik Saha

Industrial Technology and Packaging

Fresh-cut fruit industry has seen tremendous growth in recent years. The present study was designed with the objective of studying the sensory quality of fresh-cut apple slices that were treated with different antibrowning agents, packed in three types of packaging materials and subjected to vibration treatment to simulate commercial transportation. The slices were treated with two commercial antibrowning agents [NatureSeal (Mantrose-Haeuser Co., Inc., Westport, CT, USA) and Ever-Fresh (Kraft Foods, Inc., Rye Brook, NY, USA)] at 5% (w/v) application rate. The treated slices were packaged in 5 oz polystyrene rigid container, 2 lb polyethylene bag or 2 oz polyethylene bag. …

Effect Of Palletized Box Offset On Compression Strength Of Unitized And Stacked Empty Corrugated Fiberboard Boxes, S. Paul Singh, Jay Singh, Koushik Saha

Industrial Technology and Packaging

The purpose of this study was to evaluate the effect of pallet type, tie-sheet and stack configuration on compression strength of a palletized load of boxes. Four boxes made from similar board grade and different dimensions were selected for this study. The column stack configuration which represented the control was compared with the 3 stack configurations either on a CHEP® or GMA pallet. The unitized load either had a tie-sheet in between layers or no tie-sheet between layers of boxes on the respective pallets, for compression strength comparison with the control unitized load represented by a column stack configuration. This …

Effect Of Horizontal Offset On Vertical Compression Strength Of Stacked Corrugated Fiberboard Boxes, Jay Singh, S. Paul Singh, Koushik Saha

Industrial Technology and Packaging

The purpose of this study was to evaluate the effect of horizontal offset on the compression strength of stacked box configurations. Four different boxes of varying sizes and similar board combinations, made from similar flute but different manufacturers were studied. The single box compression strength for each type of box was determined to represent as the control for this study. The compression strength of control boxes were compared to overall strength of a three-high stack and in three different offset configurations. In addition a set of perfectly aligned boxes were compared to overall strength of a three-high stack and in …

A System Model For Green Manufacturing, Ahmed M. Deif

Industrial Technology and Packaging

Manufacturing systems evolution is afunction in multiple external and internal factors. With today’s global awareness of environmental risks as well as the pressing needs to compete through efficiency, manufacturing systems are evolving into a new paradigm. This paper presents a system model for the new green manufacturing paradigm. The model captures various planning activities to migrate from a less green into a greener and more eco-efficient manufacturing. The various planning stages are accompanied by the required control metrics as well as various green tools in an open mixed architecture. The system model is demonstrated by an industrial case study. The …

Evaluation Of An Innovative System For Improving Readability Of Passive Uhf Rfid Tags Attached To Reusable Plastic Containers, Jay A. Singh, S. Roy, B. Roesner

Industrial Technology and Packaging

Radio frequency identification (RFID) is a contactless identification technology that has proven to work well in conjunction with reusable plastic containers (RPCs). The impact of this technology on returnable containers has been explored by several past studies. This study evaluates an innovative system for improving readability of passive UHF RFID tags in conjunction with RPCs. The system involves an energy transfer device (ETD), which when attached to the RPCs, passively transfers radio frequency signals to interior regions of a unitized load thereby improving the readability of all RFID tags attached to the RPCs. This study included an evaluation of the …

Material Weight Station Optimization Senior Project, Douglas Peters, Michael Eng

Industrial Technology and Packaging

The main principle of all industry is that “time is money”. This senior project focuses on reducing operation times for Specialty Silicone Fabricators (SSFab) materials weighing station. Currently SSFab is set up so that multiple operators check the weights of materials. This is done to guarantee the accuracy of the readings and maintain tight quality control. This project will focus on eliminating the need of multiple weight checkers as a way to save time and ultimately save money.

Through detailed research and studies it has been determined that the most appropriate solution to this problem is a weight checking software …

Gauge Repeatability And Reproducibility Study For A Bulge Test Fixture For Corrugated Boxes, Anthony J. Hall

Industrial Technology and Packaging

This senior project evaluates the measurement variation within a corrugated container bulge tester by utilizing a gauge repeatability and reproducibility study. Bulge is a type of deformation containers experience when subject to compressive forces such as stacking or internal forces due to under- and over-packaging. Both compressive and internal forces can accelerate the failure of a container by causing panels to flex and flutes to buckle, compromising structural integrity. Additionally, variable environmental conditions such as temperature and humidity can magnify the effect bulge has on a container, speeding up the failure rate of a container.

The Fresh Express Lean Changeover Project, Mario Borbas

Industrial Technology and Packaging

In the current economic turmoil, industry leaders across the globe are resorting to means of increasing efficiency without having a large initial investment.  Lean manufacturing principles have been adopted by companies because of its ability to increase throughput, lower overhead, reduce waste, and increase the overall quality of products.  The value of lean manufacturing solutions has been increasing in the past decade and continues to increase into 2011.

This project is centered on a current situation regarding a changeover process that has recently been made more efficient. The goal is to create new ways to make this same process even …

An Exploratory Model For Predicting Post-Consumer Recycled Pet Content In Pet Sheets, Dong Ho Kang, Rafael Auras, Keith Vorst, Jay Singh

Industrial Technology and Packaging

An exploratory model for determining post-consumer recycled polyethylene terephthalate (PET) content in PET sheets for one specific stream of mechanically recycled PET (RPET) was developed. Six kinds of PET sheets with varying percent of virgin (V) and recycled (R) PET contents (i.e., 100V, 80V20R, 60V40R, 40V60R, 20V80R, and 100R PET) were commercially extruded. The optical, thermal, physicomechanical and barrier properties of the PET sheets were evaluated as function of RPET content. Differences were found between the sheets for UV and visible light absorption in the regions 200–350 nm and 670–700 nm, respectively. Intrinsic viscosities of 100V and 100R PET sheets …

Life Cycle Inventory Of Hdpe Bottle-Based Liquid Milk Packaging Systems, Jay Singh, Aric Krasowski, S. Paul Singh

Industrial Technology and Packaging

This study aims at providing a relatively straightforward methodology to serve as a decision-making tool when more than one packaging solution could be available to a user. It involves a life cycle inventory (LCI) analysis and comparison of three currently available 3.79 l (1 gallon) packaging systems for liquid milk. Two of the primary container types studied use reusable plastic crates (RPCs) for stacking and shipping,
while the third type is a heavier duty container that does not require secondary shipping containers. The three primary containers studied are identified as original, cube and stackable throughout this paper. The study shows …

A Multiple Performance Analysis Of Market-Capacity Integration Policies, Ahmed M. Deif, Hoda A. Elmaraghy

Industrial Technology and Packaging

A model that uses simulation augmented with Design of Experiments (DOE) is presented to analyse the performance of a Make-to-Order (MTO) reconfigurable manufacturing system with scalable capacity. Unlike the classical capacity scaling policies, the proposed hybrid capacity scaling policy is determined using multiple performance measures that reflect cost, internal stability and responsiveness. The impact of both tactical capacity and marketing policies and their interaction on the overall performance was analysed using DOE techniques and real case data. In addition to the different insights about the trade-offs involved in capacity planning decisions, the presented results challenged the conventional capacity planning wisdoms …

A Dynamic Approach To Determine The Product Flow Nature In Apparel Supply Chain Network, Mohammed Marufuzzaman, Ahmed M. Deif

Industrial Technology and Packaging

This paper presents a novel metric, product flow number, to determine the product flow nature across the supply chain of apparel industries. The metric is based on mapping the dynamics of fluid flow across a pipe to product flow across a supply chain. Numerical analysis is conducted to examine the impact of the different metric parameters on the product flow. Results showed that smooth dynamics can be achieved through scaling production and extending delivery times, while undesirable dynamics are tied to complex product designs and increasing number of suppliers. Finally, the paper demonstrated how the new metric can be used …

Evaluation Of The Stress-Energy Methodology To Predict Transmitted Shock Through Expanded Foam Cushions, J. Singh, L. Ignatova, E. Olsen, P. Singh

Industrial Technology and Packaging

Mechanical stresses experienced by packages in the distribution environment include shock and vibration amongst several others. The destructive effects of these hazards can typically be restricted by using cushioning materials to help protect fragile goods during distribution. ASTM D1596 is the conventional standard used to determine shock absorbing performance of a cushioning material for a given combination of static loading, thickness, and drop height. This industry-accepted standard, however, requires significant amounts of transmitted shock data and can be expensive with respect to costs associated with testing and materials amongst others. Alternate stress-energy-based methodologies, developed in the past decade, recommending a …