Operations Research, Systems Engineering and Industrial Engineering Commons^™

Cardiac Staging Facility Workflow Redesign, Ryan Chang

Industrial and Manufacturing Engineering

This study analyzes and proposes Cardiac Staging nurse workflow improvements along with a new Cardiac Staging facility design at French Hospital. Currently, patients spend an expected 125 minutes in Cardiac Staging. It was found that 60% of the time in Cardiac Staging was spent waiting to be transferred into the Cath Lab. The following Industrial Engineering methods were utilized to eliminate waste in staging and design a new staging area:

 Use of Lean and Six-Sigma tools to recommend new patient arrival time

 Manufacturing product scheduling to reduce patient wait time

 Use of facility redesign techniques to improve …

Effect Of Gold Content On The Reliability Of Snagcu Solder Joints, Jianbiao Pan, Julie Silk, Mike Powers, Patrick Hyland

Industrial and Manufacturing Engineering

Electroplated Ni/Au over Cu is a popular metallization for PCB finish as well as for component leads, especially wire-bondable high frequency packages, where the gold thickness requirement for wirebonding 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 study 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 thicknesses using …

Design And Implementation Of An Automated Pick And Place System For Johanson Technology, Inc., Alex M. Felker

Industrial and Manufacturing Engineering

Johanson Technology, a capacitor and microelectronic part manufacturer, located in Camarillo, CA has forecasted a 50% increase in demand for single layer capacitors for the year 2011. Johanson chose to hire an intern to design and implement a robotic pick and place system to meet this demand. A complete automated system composed of a Stäubli RS20 robotic arm, CS8C-M Controller, and Electrosort Bowl Feeder needed to be integrated into an environment where no system currently existed. A bill of materials and parts list indicated that the entire system would be a fixed cost of $50,104. This proved to be the …

Process Improvement Of Kaiser Permanente Medical Group, Connie Chou, Brett Witherall

Industrial and Manufacturing Engineering

This report seeks to improve the operations of the Kaiser Permanente’s Central Refill Pharmacy. In particular, the need for better workstations became evident when witnessing the cluttered appearance of the packing workbenches in the facility. Furthermore, one of Kaiser’s largest problem areas is the physical strain caused by the repetitive motion required of the packing job function. A redesign of the packing workstations has been developed on Microsoft Visio in order to reduce clutter, be more space efficient, and decrease eye and arm movement associated with employee strain. The most significant additions are an automated slide that transfers packages from …

Design Of Online Student Fee Committee Proposal Information System, Kenneth Cairns, Gregory (Greg) Jacobson

Industrial and Manufacturing Engineering

The purpose of this project is to overhaul the IME department’s Student Fee Committee (SFC) proposal system. A web enabled database was designed in order to improve this system. A significant amount of time was spent researching different programming languages, paradigms, and frameworks in order to determine the most logical approach to the system redesign. After a few false leads, it was determined that the most appropriate solution to the problem was to design a C# based web form application using asp.NET technology, developed in Microsoft Visual Studio. A mockup was created in Access in an attempt to determine if …

Discrete Event Simulation Manual: Manufacturing Applications, Brian T. Hughes

Industrial and Manufacturing Engineering

Simulation, specifically discrete event simulation, is a useful tool for industrial and manufacturing engineers when dealing with system analysis. Currently, manufacturing engineers are only exposed to simulation for only a few weeks of their curriculum at Cal Poly. A series of labs are directed by a teacher’s assistant on how to complete a successful simulation experiment. However, there is no text available for student use during this demanding learning period. The simulation learning process involves learning a software program called ProModel, which students with little experience are expected to code, run, and interpret data from complex systems. By creating a …

Optimization Of Screw Cap Process For E & J Gallo Winery, Robert Trent Latimer

Industrial and Manufacturing Engineering

This project takes a microscopic look at all raw material, machinery, and practices that effect the screw cap process of wine products in order to highlight and eliminate the causes of defects. The approach for this project involves the analysis of process capability for raw material to achieve its required dimensions. This project also displays methods of attaining appropriate machinery settings, and provides a basis for operating standards. Many quality engineering applications are used throughout this study, revealing the decision process for analyzing said applications.

The studies in this project found uncontrolled dimensions in the suppliers’ caps and bottles and …

Standardization For Retail Facility Layout For Patagonia, Inc., Derek King

Industrial and Manufacturing Engineering

The purpose of this project is to create a standard layout for Patagonia retail stores. Currently, Patagonia has no standard layouts to follow when they update or open a new store; this has resulted in improper layouts and not fulfilling customers’ needs. This project will develop a way for Patagonia to solve both of these problems based on statistical engineering. The outcome of this project will result in a standard way for determining the optimal layout for new or updated Patagonia retail stores while meeting the business needs of the location.

Hardy Diagnostics Facility Redesign, Jamie W. Lam

Industrial and Manufacturing Engineering

This senior project is a facilities design for the plate production room at Hardy Diagnostics. This project was completed using a systematic layout planning approach. The main reason for this redesign was to consolidate all plate line production into one room. This would ensure better visability for the managers. After the project was defined, the different departments were established and the relationships between those departments were found. The space requirements needed for those departments were then measured out to also include the aisle widths and any machinery or carts needed to complete each function. Having determined all requirements for this …

Sustainable Climate Control For Mid-Rise Office Building In The Salt Lake Valley, Philip M. Coleman

Industrial and Manufacturing Engineering

This report examines the sustainability of Trane’s EarthWiseTM climate control systems in the Salt Lake Valley (and the United States Mountain West in general). A simulation is performed to determine the best climate control system for a LEED Silver, 5-story tenant office building. This new building is a duplication of a pre-existing building. The climate control system installed at the preexisting building is used as a baseline against which three (3) alternative systems are compared. The social, ecological, and economic impact of each alternative is examined to determine which is the most sustainable. Since the baseline system is a proven …

Automation Of Pillow Speaker Button Testing To Avoid Repetitive Strain Injuries In Testing Technicians, Tyler P. Finnegan

Industrial and Manufacturing Engineering

Abstract Anacom MedTek, a medical device company, produces pillow speakers as their main product line. Pillow speakers are a healthcare communications tool that allow for hospital patients to control many entertainment and environmental components of the hospital room from one controller. These pillow speaker devices have anywhere from 3 to 27 metal dome key cap buttons based on their customization. Before they can be shipped to a customer, each button must be tested to ensure that it is functioning properly. This test is currently done manually by a testing technician. With so many buttons to be tested for each unit …

Pull Production System Training Guide, Adem Bilgutay

Industrial and Manufacturing Engineering

This book is a series of lessons designed to train operators and managers in pull manufacturing. It begins with a description of the different forms of waste that a system can help to identify and eliminate. The second section details the kanban as a system for controlling flow and as a powerful tool for identifying problems. It will describe the many different variations of kanban that exist to control flow in different production environments and the calculations that allow them to be used effectively. The final section will detail the activities that an operator should engage in when there is …

Expansion In Existing And Future Franchises, Shane Hart, Daniel Jeng

Industrial and Manufacturing Engineering

Zensho Group has recently acquired the restaurant US based chains CoCo’s and Carrows but has not been able to affirm the same growth as the company has established in its home country of Japan. In order to fulfill their need to grow, extensive market analysis and research needs to be done. An expansion eastward and the introduction of their flagship restaurant chain, Sukiya, would offer growth potential. Determining the best locations for these new stores is the goal of this project. Low cost and high market penetration potential will be used to recommend the ideal locations that will benefit the …

A Practical Approach To Computer Donation Supply Chain For Non-Profit Organizations, John Jacob Burrell, Adam Robert Carpenter

Industrial and Manufacturing Engineering

The United States today has a plethora of unused electronic equipment. This equipment comes from universities, small businesses, corporations, and many other sources. This project looks at the best way to put this equipment back to use for the remainder of its usable life by donating it to non-profit organizations in need. In order to complete this project it was necessary to research the areas of Supply Chain Management, Operations Research, and Engineering Economics. The approach for this specific project first involves analyzing the current donation process at California Polytechnic State University – San Luis Obispo, and its ability to …

Testing The Test: Validity And Reliability Of Senior Exit Exam, Lizabeth Schlemer, Daniel Waldorf

Industrial and Manufacturing Engineering

A senior exit exam is considered an excellent direct measure of student learning for ABET assessment, but the usefulness of the information gathered is related to the validity and reliability of the test itself. The Industrial and Manufacturing Engineering Department at California Polytechnic State University, San Luis Obispo has used a content exam for several years. This paper will discuss test development, administration, and the role it plays in the assessment process. In addition, the test is evaluated using the standard psychometric techniques of reliability and validity. The results of the evaluation are used to refine the test. The importance …

Lean Inventory Management System For Boeing Missile Defense, Danielle Partridge

Industrial and Manufacturing Engineering

Lean inventory management is influential for business. One of the wastes businesses aim to reduce, using lean principles, is inventory. Inventory management provides the essential tools for eliminating extra inventory and cost that is tied up in capital.

Boeing’s Ground Based Missile Defense inventory area was failing at meeting their proprietary lean manufacturing goals. There was a need for an inventory system that included: lean principles, inventory management and user-friendly capability. The goal of this project’s inventory management database process was to minimize inventory investment while still meeting functional requirements. The deliverables for this project met the needs of Boeing’s …

Ergonomic Methods To Improve Safety In The Construction Sector And Reduce Costs, Mona Barjasteh

Industrial and Manufacturing Engineering

Many small construction companies have difficulty providing a safe working environment for their employees because of their lack of resources. There is a need to provide a manual for small construction companies employing 10 or fewer workers with the best ergonomic solutions of the top most common injuries. Accidents in the construction field are very high with nearly 175,00o nonfatal injuries and 1,121 deaths in 2002. The nonfatal cases occur 7.1 times per 100 full time workers, while serious injuries occur 2.8 times per 100 full time workers. This information reveled the importance of focusing on minor injuries in order …

Statistical Quality Control In The Health Care Industry, Roberto Arce

Industrial and Manufacturing Engineering

In recognition to the increased length of stay of discharge patients, deteriorating patient care and staff satisfaction in a emergency department (ED), this project was set to improve these measures without reducing staff, adding new workers, and without increasing the number of beds. Lean methods such as value stream mapping (VSM) formed the basis of the project. This tool helped identify the patient process flow through the (ED) as well as the valued added and non-value added steps of the process. This project describes value stream map development in the emergency department at a community hospital. A current-state value stream …

An Alternative To Stretch Wrap Using Triple Bottom Line, Christian Guirola

Industrial and Manufacturing Engineering

Packaging products has always been a major sector of industries. Mass producing manufacturing companies use wooden pallets to store and transport items; these products are stacked and then secured by wrapping stretch wrap around them. The main issue with this packaging method is that millions of pounds of waste is produced. Some of the other effects include green house gas emissions during its production, limited recycling, and high packaging costs. In order to reduce the amounts of stretch wrap used by industries and distribution centers, there was a need to research and evaluate alternate methods to secure products on pallets. …

Development And Assessment Of A Pcb Layout And Manufacturong Laboratory Module In Introductory Electric Circuits For Ee And Non-Ee Majors, Albert Liddicoat, Jianbiao Pan, James G. Harris, Gary Perks, Linda Shepherd

Industrial and Manufacturing Engineering

In standard introductory electric circuits laboratories for electrical engineering (EE) majors and non-EE majors, prototype boards are typically used to construct and test electric circuits. Students typically do not learn how to design and manufacture Printed Circuit Boards (PCB) that are commonly used in more sophisticated design projects and other engineering applications. This paper will present the development and assessment of a PCB layout and manufacturing laboratory module that has been used in introductory electric circuits laboratories for EE and non-EE majors. The feasibility of integrating the new PCB layout and manufacturing module into the electric circuit course will be …

Assessing Curriculum Improvement Through Senior Projects, Jianbiao Pan, Albert Liddicoat, James G. Harris, Linda Shepherd

Industrial and Manufacturing Engineering

Senior project and/or capstone design courses are intended to provide a culminating design experience for students and to demonstrate their understanding of engineering knowledge and their ability to apply that knowledge to practical problems. It is expected that the quality and attributes of students’ senior design projects can be used as a good measure of determining how well the curriculum prepares students to engage in engineering design as well as a measure of faculty teaching and student learning. This paper reports the results of a study designed to assess whether the new computer engineering curriculum implemented at Cal Poly over …

Increasing Production Capacity At A Start Up Biomedical Company, Traci J. Otsuji

Industrial and Manufacturing Engineering

The following senior project was first introduced during a summer internship at a biomedical company called Asthmatx Inc. Asthmatx is responsible for the development and manufacturing of a catheter‐based device for moderate to severe cases of asthma. Upon the approval of FDA, Asthmatx had planned to ramp up their production capacity significantly in order to accommodate the potential growth.

The first step in the process improvement was a facility reconfiguration that involved the adjustment of process sequencing and the implementation of ergonomic catheter channels. Next, time studies were conducted to gain more accurate time standards of the production process. After …

Process Improvement For The Department Of Surgery Sierra Vista Medical Center, Jessica Paz

Industrial and Manufacturing Engineering

This report proposes and analyzes process improvement methods for the Surgical Services Department at Sierra Vista Regional Medical Center. The department currently operates with an average of 25% of elective cases starting on time. This can be attributed to a number of inefficiencies that occur throughout the hospital.

The following Industrial Engineering methods were utilized to improve patient flow:  creation of a data collection system to quantify delays  use of simulation and facility redesign techniques to determine feasibility and benefits of moving towards a surgical center model  development of a user interfaced database to record and analyze …

Police Operations Simulation, Robert Mcgee

Industrial and Manufacturing Engineering

In this report, the author explains the process of creating the Police Operations Simulation, shows step-by-step how it works, and statistically analyzes the results from SLOPD’s own proposed and current schedules. The data-gathering from the department and the simulation itself will receive the bulk of the coverage in this report, followed by sample results from SLOPD and a business plan for future sale to other departments.

Using the given numbers, it appears that the proposed schedule will result in significantly improved coverage for the city of San Luis Obispo. While any increase in the number officers on patrol tends to …

Maintenance Service Request Process Optimization For The Cliffs Resort At Shell Beach, John Birch

Industrial and Manufacturing Engineering

This process optimization project utilizes a new idea to have an Access 2007 database automatically send a text message to a given cellular telephone. The hotel’s maintenance service request process is outdated and inefficient, relying solely on paper and human memory for success. Initiation, tracking, and recording the maintenance service requests need to be automated to optimize this process. The solution is a working database which employs said automation using Access 2007 in combination with a separate program created to facilitate the automatic text messaging. Implementing this database will result in higher customer satisfaction for the hotel.

Laser Clean Room Re-Design: A Manufacturing Facility Re-Layout, Jennifer J. Siu

Industrial and Manufacturing Engineering

Alcon’s Laser Clean Room fosters inefficient production practices, is outdated for its current process, and lacking in clear process/product flow. A facility re-design is applied to bring order, efficiency, and optimize flow in the laser production lines.

Deliverables include a new layout that decreases product travel distances and increases productivity as well as an implementation plan and cost/savings analysis. Major design decisions include downsizing the clean room, sorting to find waste and establishing clear process/product flows. The design was implemented within three weeks and results yield 29% reduction of product travel distance, 10.4 hrs/day saved from eliminated gowning time and …

Cable Time Estimation Database, Joshua L. Okerman

Industrial and Manufacturing Engineering

The use of time standards are the basis for a high efficiency system in the manufacturing environment. This project will investigate the process followed to design and develop a database used to calculate accurate cable assembly time standards used for scheduling at General Atomics. This project will then justify the use of the Cable Time Estimation Database, through an economic analysis compared to the current methods applied.

Assessing Living Arrangements In Residential Halls, Romel Penaflor Auza

Industrial and Manufacturing Engineering

Hundreds of thousands of high school graduates head off to college each fall not knowing the environment they'll be living in for the next four years. The factors that predict success in the academic, social, and personal aspect of these freshmen students' lives revolves around one aspect that is often times overlooked. Freshmen students are subjected to the fast paced lifestyle of college and often times they need to feel “at home”. Their personal space becomes a matter that is important to them in relation to their success in the three aspects of academic success, social integration, and personal health. …

Using Sports Coaching Techniques To Enhance Project Based Learning Instruction, Lizabeth Schlemer, Faith Mimnaugh

Industrial and Manufacturing Engineering

As instructors attempt to apply project based learning as a preferred pedagogy for many aspects of engineering education, countless questions are raised. For instance, how do instructors assess individual performance in a team based environment? How do instructors prepare students for the culminating presentation or report? How do instructors develop the students individually? After reviewing literature on both project based learning and exceptional coaching, we have found that much can be learned from John Wooden, Phil Jackson and other coaches. This paper will organize some of the best practices in sports coaching and draw parallels that will enhance student learning …

Axle Assembly Takt Time Change, Punit Shivji

Industrial and Manufacturing Engineering

The Toyota managed New United Motor Manufacturing Inc. automotive plant is currently going through difficult economic times. To prepare for future production demands, the plant will need to decrease production output and maintain a lower volume of vehicles produced with a high level of quality and efficiency. This project will take on the reorganization of the rear axle assembly lines and the departments that are involved to ensure a cost effective, efficient, and safe approach in manufacturing Toyota's Tacomas. Toyota recommends the Toyota production system as well as any knowledge and experience obtained from previous jobs and coursework to be …