Reducing Customer Wait Time And Improving Processes At Abc’S Atv Rentals, Thomas Allen Merrill Jr.

Industrial and Manufacturing Engineering

This project serves to explore the system bottlenecks of a small, family owned ATV rental company. The main objective is to reduce the average time a customer spends in the system, focusing on customer wait time as well as other areas that can be improved. This was done by collecting time studies and inputting the values into simulation software, which was run to represent the current system as well as various other possible scenarios encountered by rental companies. While creating the simulation, adaptive techniques were incorporated into the simulation. These techniques aim to increase the durability and reusability of the …

Evaluation And Redesign Of Potting Shed For The Non-Profit Organization, Growing Grounds Farms, Adya Sinha, Julianna Levy

Industrial and Manufacturing Engineering

Growing Grounds, a local nonprofit organization, operates as a fully functioning nursery in San Luis Obispo. Their planting facility is outdated and the process is inefficient. They have new funding available and need to determine if they should automate certain processes or improve existing methods. This report details the current process and presents two possible ergonomic solutions and the accompanying layouts and improvements. An analysis is conducted to determine which new layout is recommended for Growing Grounds based on their current production and revenue, and future recommendations are given.

Human Powered Helicopter: Spars, Jason Addy, Sterling Fuentes, Graham Garvin, Kenneth Girardin, Lipski Timonthy, Daniel Logue

Industrial and Manufacturing Engineering

Abstract

Neal Saiki, a Cal Poly alumnus, donated a human powered helicopter to the Cal Poly Aircraft Design and Construction Club in Fall Quarter 2012. To achieve the requirements of the Igor Sikorsky Human Powered Helicopter Competition, this senior project was tasked with reducing the weight of the load-bearing spars without changing geometry.

The aluminum spars were replaced with carbon fiber. The spars were designed to maintain the bending and torsional stiffnesses. Twelve sections of carbon fiber tubes ranging from 8 to 12 ft in length and 2" to 3" in inner diameter were made using pre-preg carbon fiber wrapped …

S&G Metal Fab Battery Tray, Matthew Nartatez

Industrial and Manufacturing Engineering

This report was written for the design of a battery tray and manufacturing process for S&G Metal Fab. The manufacturing steps of how to process the sheet metal to create the product are defined and documented in this report. This project began with constraints given by S&G and were all accomplished using coursework knowledge obtained as a manufacturing engineer student at Cal Poly San Luis Obispo. This report mainly covers parameters regarding the cutting, bending and, deforming of sheet metal to acquire the desired shapes and sizes. It also analyzes the costs that are associated with these processes and material. …

Reliability Analysis Of Low-Silver Bga Spheres Comparing Failure Detection Criteria, Briana Fredericks

Industrial and Manufacturing Engineering

One of the challenges of solder joint reliability tests is estimating the time of failure of the solder joint. Failure criteria should be able to detect solder joint failure as early as possible, while minimizing the probability of false detection. The failure mechanism under study is cracks due to thermal fatigue. The most common method to estimate failure due to cracks is to monitor the resistance during testing, because solder imaging and cross-sectioning methods are destructive. Current industry failure criteria do not adequately demonstrate the relationship between the size of the crack and the resulting change in resistance. This project …

Application Of Assignment Problem Theory To Cal Poly's Week Of Welcome Program Presentation Schedule, Kevin T. Aban

Industrial and Manufacturing Engineering

The Week of Welcome (WOW) is a part of Cal Poly’s Orientation Programs. One of the main objectives of WOW is to provide content to new students on a variety of different topics in the form of Awareness Presentations. The problem being addressed in this paper is that of assigning the orientation groups of incoming students to these Awareness Presentations so that they have a schedule that meets all of the necessary criteria. The most important of those requirements is schedule balance and flexibility for future use. This scheduling problem is solved through the use of operations research and binary …

Gyroscope Assembly Process Improvement Analysis, Ian Douglass, Juan Ulises Saucedo

Industrial and Manufacturing Engineering

The gyro is a fundamental portion of many assemblies that Company S, a directional drilling company, manufactures. The gyro assembly is a highly sensitive and complex process, and it was paramount to establish efficiency and quality guidelines to base management decisions. The first guideline succeeded by increasing throughput by means of a simulation using ProModel. Next, non-value and value added activities were identified through a value stream map. Lastly, a database was developed in order to capture high integrity quality control data, or key performance indicators, such as, throughput, first-pass inspection yields at every test performed, and defects found. This …

Implementation Of A Sustainable Project Management Methodology For Cal Poly Sae Baja, Theo Graziadei

Industrial and Manufacturing Engineering

A lack of project organization manifested through unclear team goals, rush deliveries of materials, lost tools and materials, half days of effort due to improper planning, wasted design time, missed submission dates, lack of clear job positions at competition, and low competition scores. A process was created to properly manage the team and it was implemented through the use of various templates, examples, and calculation programs. Each deliverable received feedback from this project’s stakeholders and changes were reflected in the final process. The results were as follows:

Table 1: Summary of Results

Implement a sustainable project management methodology

Each step …

The Design, Testing, And Manufacturing Of A Pin Fin Extrusion Heat Sink, Arash Michael Mira

Industrial and Manufacturing Engineering

My senior project focuses on the design, testing, and manufacturing of pin fin extrusion heat sinks that are you used to cool simple electronic applications across a multitude of markets. Without the modern day heat sink, electronics that we have become familiar with throughout our everyday lives will cease to exist. I will design these heat sinks using Solid Works 3D CAD. I will then test the heat sinks using ICEPAK CFD software, where I will model the heat sink against a 5 watt application, inside of a cabinet that models the chassis of a computer. After receiving these results, …

Evaluation And Design Of Potting Production Process Improvements For The Non-Profit Organization, Growing Grounds Farm, Maiya Avalon Bourland, Precilla Tang

Industrial and Manufacturing Engineering

This report focuses on the potting production process for the non-profit organization (NPO) Growing Grounds Farm (GGF), and aims to promote a standardized workflow system to enhance the working experience for Transitions‐Mental Health Association employees and volunteers. This project takes careful consideration into the process improvements proposed so to support the double bottom line of economic and social objectives. To address the equally important objectives, the Human Centered Design toolkit created by IDEO, specifically for third sector organizations, was integrated with the traditional Industrial Engineering design process methodology. Feasible alternatives were developed and evaluated based on the objectives. The selected …

Design Of An Automated Employee Scheduling System, Matthew Cameron, Yuriy Goldman

Industrial and Manufacturing Engineering

Many retail stores, as well as other organizations that employ a multitude of part-time employees, rely on developing schedules frequently, since the availabilities of the employees as well as the needs of the business change often. This process is often performed on a weekly basis, and is complex and time-consuming. The schedule must typically satisfy numerous requirements, including business needs, legal restrictions, and employee availability constraints. As a result, errors are common, and employee time that could have been spent on improving sales or operations is instead consumed by the scheduling task.

This project explores two solution methods for this …

Atk's Radial Airframe Forming Process Assessment, Andres Martinez

Industrial and Manufacturing Engineering

The purpose of this project was to provide ATK with a solution to increase efficiency in the R-02 radial forming center so that it could meet the increase in demand projected for the next 5 years. In addition, give ATK projected dates of when new machines would need to be implemented to be able to keep up with the demand. The system was analyzed through time studies to identify areas of possible improvement and eliminate any non-value added activities. Cycle times of each activity were used to simulate the current state of the system using ProModel software. Changes in operations …

Restaurant Design: An Industrial Engineering Perspective, Joseph Travis Spanu

Industrial and Manufacturing Engineering

The objective of this paper is to design a health food restaurant using current industrial engineering tools and practices. This includes creating a menu, determining the average gross profit per customer, determining the location, designing a 3-d layout, simulating service, and analyzing local food supply chains. Using a simplified menu and pricing quotes from a food distributor, the average gross profit per customer is estimated to be $3.50. Location is determined by comparing the predicted number of customers and the cost to rent at two different areas. A downtown location is determined to gross approximately $5,200 per month over a …

Women's High Heel Discomfort Analysis And Prototype Solution, Kevin Blakley, Annamarie Kepple

Industrial and Manufacturing Engineering

ABSTRACT

WOMEN’S HIGH HEEL DISCOMFORT ANALYSIS AND SOLUTION

Kevin Blakley and Annamarie Kepple

Women love high heeled shoes, but this love comes at the cost of comfort. Wearing high heels causes a lot of pain and, in the long term, health complications. This project tries to overcome the problem by ultimately making high heels more comfortable. In order to do this, one must first understand the reasons that high heels are uncomfortable, such as arch angle, heel height, and the changes in walking motion. Once there is a true understanding of the factors that contribute to high heel discomfort, the …

Strider: Manufacturing Processes, Michael Warren-Angelucci

Industrial and Manufacturing Engineering

The goal of the Strider Project is to create a mobility device that can support a person with weakened leg strength and enable them to be supported and maintain a standing position. A prototype of the Strider was created by three Mechanical Engineering students as their senior project. The topic of this senior project was to analyze and create a manufacturing process for the manufacture of the Strider that will be ergonomic and cost effective.

There were many things that needed to be accomplished in order to create the manufacturing process. The first step was to verify that the prototype …

Process Improvements For Establishing Cmmi Certification At Company Xyz, Megan Farrell

Industrial and Manufacturing Engineering

CMMI stands for Capability Maturity Model Integration and is an enterprise-wide Process-Improvement model that provides a set of best practices that addresses productivity, performance, costs, and stakeholder satisfaction. This improvement model is generally used in computer software companied and not only does it improve their processes, but many contracts will only be awarded with those companies who are CMMI certified, so it is very important for Company XYZ. This goal of this project was to help improve the CMMI efforts at Company XYZ in 4 of the 20 distinct processes areas to attain a CMMI Maturity Level of 3. Improvement …

Design And Manufacture Of Natural Composite Canoe, Derek Baptista

Industrial and Manufacturing Engineering

Abstract

This report looks into the application and feasibility of manufacturing natural composite canoes. The main fabrics that were analyzed are flax, hemp, and jute. These were then compared to carbon fiber and fiberglass to see the difference in mechanical properties. It was found that the natural fibers have lower mechanical properties but that this could be overcome by designing a balsa wood core with ribs running up the walls. After manufacturing a hemp canoe, many lesson were learned and areas of interest were further explored. With the use of different natural fibers, these canoes can greatly reduce the carbon …

Chsr Clothing: How To Start A Small Business Clothing Line To Be Run Efficiently With Minimum Capital And Maximum Profit, Kayvon Banisalam

Industrial and Manufacturing Engineering

Executive Summary

Many clothing brands have failed because they did not design marketable products with a suitable business plan. Often times, clothing brand owners do not use the capital they possess in efficient ways. They can get caught off guard with unexpected costs and are not running the business in the most resourceful and professional way.

The goal of this project is to create a clothing brand that portrays distinctive designs to go along with an effective business model. This includes implementing decision analysis at several points of the planning phase, along with quality and cost controls. Creating quality products …

Facilities Planning For An Aerospace Manufacturing Company, William Petrossi

Industrial and Manufacturing Engineering

Absolute Technologies Inc. (ATI) has been growing for years, and is running out of space at their current manufacturing facility in Yorba Linda, CA. ATI will be moving to a much larger facility this winter. They are looking for an efficient way to utilize this space. The machine positions were taken as fixed, seeing as a lean expert was brought in to give advice on placement. With the machines fixed, the scope was narrowed to other areas.

A systematic approach to facilities design is utilized. First, a goal needs to be defined. The goal is to reduce the time wasted …

Consolidation Of Company Abc, Estelle Sillari-Owen

Industrial and Manufacturing Engineering

This project aims to solve Company ABC’s issues in order to keep the company afloat and to keep the company profitable. This was done by reducing Company ABC’s organizational and inventory build-up issues. The project aims to reduce the company’s dependence on outside storage, with plans of consistent inventory reduction over the next year. An implementation plan was created to ensure the company keeps on track to increase profits and prevent against increasing inventory costs.

Work In Progress: Outreach Assessment: Measuring Engagement, Lizabeth Schlemer, John Oliver, Katherine Chen, Sophia Rodriguez Mata, Eric Kim

Industrial and Manufacturing Engineering

The Learn By Doing Lab (LBDL) at Cal Poly, San Luis Obispo is an on-campus laboratory where 5th through 8th grade students are taught by undergraduates who may be planning a careers in teaching. The two populations - elementary students and undergraduates - are equally important in the process. Since 2008, the lab has seen over 4000 elementary and junior high students and over 100 undergrads have participated. In most outreach assessment the number of individuals participating is an important metric, but this last Spring we experimented with a more in depth measure of effectiveness. As in any learning experience …

Warehouse Redesign, Cristine Carmel Dewar

Industrial and Manufacturing Engineering

A young, growing biomedical company is expanding its warehouse space to keep up with the increasing production. This project’s goals were to recommend a layout and improve a process that would minimize the distance traveled by the material handlers, increase the safety of the warehouse by implementing visual controls, implement ergonomics to reduce chance of injury, and save money for the company. To achieve this first I familiarized myself with their current processes and department and the space required for their current and future production levels. Next I created two alternative layouts, the first (Layout A) to minimize distance and …

Integrating Courses Through Project Based Learning, Lizabeth Schlemer, Sema E. Alptekin, Karen R. Bangs

Industrial and Manufacturing Engineering

Integrating three courses (one sophomore level, two senior level) through Project Based Learning (PBL) within the Industrial Engineering curriculum at the California Polytechnic State University, San Luis Obispo is presented. Three courses (IME 443 Facilities Planning and Design - senior level; IME 420 Simulation - senior level; and IME 223 Process Improvement Fundamentals - sophomore level) were linked by various mechanisms: Common industry projects, common students in two of the three courses; senior students having access to sophomores in their teams to carry out time consuming tasks such as time studies, and sophomores having access to seniors as team members, …

Effect Of Gold Content On The Microstructural Evolution Of Sac305 Solder Joints Under Isothermal Aging, Mike Powers, Jianbiao Pan, Julie Silk, Patrick Hyland

Industrial and Manufacturing Engineering

Au over Ni on Cu is a widely used printed circuit board (PCB) surface finish, under bump metallization (UBM), and component lead metallization. It is generally accepted that less than 3 wt.% Au in Sn-Pb solder joints inhibits formation of detrimental intermetallic compounds (IMC). However, the critical limit for Au content in Pb-free solder joints is not well established. Three surface-mount package platforms, one with a matte Sn surface finish and the others with Ni/Au finish, were soldered to Ni/Au-finished PCB using Sn-3.0Ag- 0.5Cu (SAC305) solder, in a realistic manufacturing setting. The assembled boards were divided into three groups: one …

The Morphology Evolution And Voiding Of Solder Joints On Qfn Central Pads With A Ni/Au Finish, Julie Silk, Jianbiao Pan, Mike Powers

Industrial and Manufacturing Engineering

In this paper, we report on a comprehensive study regarding the morphology evolution and voiding of SnAgCu solder joints on the central pad of two different packages – QFN and an Agilent package called TOPS – on PCBs with a Ni/Au surface finish. Samples were isothermally aged at the equivalent of 0, 2, 7 and 14 years service life. Representative solder joints were cross-sectioned and analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) in order to investigate the evolution of the solder joint morphology as a function of Au content and isothermal aging. IMC thickness was …

A Study Of Solder Joint Failure Criteria, Jianbiao Pan, Julie Silk

Industrial and Manufacturing Engineering

One of the challenges in an experimental study of solder joint reliability is to determine when cracks occur in a solder joint or when a solder joint fails. Cracks in a real solder joint are difficult to identify using an X-Ray system. Cross-sectioning and scanning electron microscopy (SEM) is a destructive method. A common non-destructive test method is to monitor resistance increase in a solder joint or a daisy-chain. However, no scientific research has been done in establishing the relationship between the crack area of an interconnection and the change in resistance of the interconnection. This paper proposes a method …

Effect Of Gold Content On The Reliability Of Snagcu Solder Joints, Jianbiao Pan, J. Silk, M. Powers, P. Hyland

Industrial and Manufacturing Engineering

Electroplated Ni/Au over Cu is a popular metallization for printed circuit board finish as well as for component leads, especially wire-bondable high-frequency packages, where the gold thickness requirement for wire bonding is high. The general understanding is that less than 3 wt% of Au is acceptable in SnPb solder joints. However, little is known about the effect of Au content on the reliability of SnAgCu solder joints. The purpose of this paper is to determine the acceptable level of Au in SAC305 solder joints. Three different package platforms with different Au thicknesses were assembled on boards with two different Au …

The Inside-Out Classroom: A Win-Win Strategy For Teaching With Technology, Daniel J. Waldorf, Lizabeth Schlemer

Industrial and Manufacturing Engineering

As costs of higher education soar and many universities face uncertain funding models, institutional pressures have increased to improve instructor efficiency. At the same time, U.S. industry leaders and leading educators have called for improvements in engineering education based on more interactive, hands-on student learning experiences. Although many efforts have been made to take advantage of technology to either improve student learning or to maintain student learning while increasing instructor efficiency, few approaches have been shown to improve both learning and efficiency. A teaching method is proposed to improve student learning and increase student satisfaction while also addressing the instructors’ …

Evolving A Summer Engineering Camp Through Assessment, Katherine Chen, Lizabeth Schlemer, Heather Scott Smith, Teana Fredeen

Industrial and Manufacturing Engineering

EPIC (Engineering Possibilities in College) is a one-week summer program for high school students (entering 9th-12th grades) to learn about engineering and experience hands-on labs in a university atmosphere. It's an opportunity for students to explore the different types of engineering available at many universities. The aim of EPIC is to expand the College of Engineering mission to K-12 students: "To educate students for careers of service, leadership and distinction in engineering or other fields by using a participatory, learn by doing, ‘hands-on’ approach".

Design Projects With Out-Of-Town Companies, Lizabeth Schlemer

Industrial and Manufacturing Engineering

The capstone design class in the industrial engineering department at California Polytechnic State University, San Luis Obispo (Cal Poly) includes projects with companies. The projects are large ambiguous facilities design problems that allow students to incorporate many aspects of the IE curriculum. For the past 15 years students have been participating in these projects with local companies. Over the past several years, companies from out of town (200 miles to the north in Mountain View or 200 miles to the south in Oxnard) have participated. These out of town companies have presented certain logistical issues, but they have proven to …