Operations Research, Systems Engineering and Industrial Engineering Commons^™

Crystal Engineering Manufacturing Facility Analysis, Maximiliano Cortes, Eric Dustin Kornrumpf, Sthefano Alvarado

Industrial and Manufacturing Engineering

This report will encompass a two-quarter long senior project effort to provide a recommendation for the client, Crystal Engineering. Crystal Engineering is currently in the process of introducing three new products, one now and two within the next six months. However, their existing lines already occupy the available production space and as a result, they are unable to determine how to effectively incorporate new production lines within the facility. Therefore, the main objectives of this project were to deliver several facility redesign layouts backed by a holistic justification for each. The formulation of the facility redesign layouts incorporated several industrial …

Design The Capacity Of Onsite Generation System With Renewable Sources For Manufacturing Plant, Xiao Zhong, Md Monirul Islam, Haoyi Xiong, Zeyi Sun

Computer Science Faculty Research & Creative Works

The utilization of onsite generation system with renewable sources in manufacturing plants plays a critical role in improving the resilience, enhancing the sustainability, and bettering the cost effectiveness for manufacturers. When designing the capacity of onsite generation system, the manufacturing energy load needs to be met and the cost for building and operating such onsite system with renewable sources are two critical factors need to be carefully quantified. Due to the randomness of machine failures and the variation of local weather, it is challenging to determine the energy load and onsite generation supply at different time periods. In this paper, …

Life Cycle Sustainability Analysis (Lcsa) Of Polymer-Based Piping For Plumbing Applications, Andy J. Rivas Bolivar

Senior Honors Projects, 2010-2019

Water conveyance systems play a critical role in modern developed areas. Polymer pipes have been used for about a century, and their convenient physical properties have positioned polymers as the leading material in the piping industry. Having such influence in the market means that changes in current material selection and manufacturing could lead to significant reductions in the footprint associated with their products. Currently, there are no comparative lifecycle assessments that evaluate the different polymer selections commercially available, which makes it hard to determine what products have the least impact on the environment. Understanding how such impacts are relative to …

A Study Into The Production Efficiency Of Cal Poly Chocolates, Fernando Calderon

Industrial and Manufacturing Engineering

The project objective was to: identify ways to reduce the production cost of Cal Poly Chocolates. The project was executed through the DMAIC approach, a data driven improvement cycle. Using several industrial engineering tools, six improvement opportunities were found. Three project deliverables were created and three process changes were recommended. The total annual savings, if recommendations are implemented, sum to $1700.

Best Matching Processes In Distributed Systems, Mohsen Moghaddam

Open Access Dissertations

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common …

Design For Manufacturability: Off-Road Toyota Bumper, Drew Donlon

Industrial and Manufacturing Engineering

The purpose of this project is to design a new off-road bumper that is improved from the stock form of a 1996-2002 Toyota 4Runner and a 1996-2004 Toyota Tacoma. The current state of the component is too weak to endure to off-road endeavors, and a kit bumper market is virtually untapped for these vehicles. The objectives of this project were met by redesigning the stock front bumper, conducting a finite element analysis on the model to test for strength, prototyping the bumper with CNC cut cardboard, and conducting a full cost analysis including the costs for waterjet and laser cutting …

The Agricultural Growth And Malting Production Of Barley Grains In Northeast Tennessee And Southwest Virginia, Mark Evans Patton Mr.

Electronic Theses and Dissertations

The purpose of this study is to explore the history and production processes of beer and examines the components that contribute to its brewing. The narrative will provide a timeline of the processes that are required to create the product of beer beginning with the agricultural products and following the brewing processes that result in beer as the finished product. I will also examine the business of agriculture and grain processing and will provide some historical perspectives of grain, beer, and malting. I will also consider whether the growing, processing, and malting of grains in the East Tennessee and Southwest …

Optimization Of Rfid System Coverage In A Manufacturing Environment, Scott D. Malatesta

Master's Theses

This paper compiles existing ideas, theories, and experiments across multiple disciplines to provide guidance for a company looking to implement an optimal RFID system in their production facility. The desire is to maximize the information received by the system while minimizing the cost. Four potential layouts of RFID antennas, two with overlapping antenna coverage and two with non-overlapping layouts, are first analyzed to understand the special coverage and the number of antennas required. The value of information is then quantified to determine whether higher coverage layouts are worth the additional costs associated with the higher number of antennas required. It …

Knowledge Reuse Through Electronic Knowledge Repositories: An Empirical Study And Ontological Improvement Effort For The Manufacturing Industry, Peter Panha Chhim

Wayne State University Dissertations

Knowledge management adoption is growing, and will continue to grow in no small part because of its recent inclusion into the ISO 9001 quality standard. As organizations look towards ways in which to manage their knowledge, the codification of explicit knowledge through Knowledge Management Systems (KMS) and Electronic Knowledge Repositories (EKRs) will undoubtedly gain more interest.

An EKR is a form of KMS that emphasizes the codification and storage of organizational expertise for the purposes of Knowledge Reuse (KRU). Unfortunately, the factors surrounding KRU are not well understood. While previous studies have viewed EKR usage from a narrow perspective, a …

Improving Machine Changeover/Setup Times By Increasing U.S. Manufacturers' Knowledge Of 5s, Nicole Schra-Martin

Walden Dissertations and Doctoral Studies

The 5S process is one of the techniques born out of Japanese manufacturing. Ohno, the developer of 5S, found that when manufacturing waste is eliminated, costs are reduced and profits increase. This is the bases of 5S and this research. The cost of U.S. manufactured products is higher compared to the cost of products from other global manufacturers that use 5S. This study was conducted to determine if implementing 5S in U.S. manufacturing could change U.S. manufacturing cost and if using 5S could impact U.S. manufacturing. The research questions focused on the relationship between 5S and changeover/setup times on production …

The Application Of Gage R&R Analysis In S Six Sigma Case Of Improving And Optimizing An Automotive Die Casting Product’S Measurement System, Qizheng Ren

Masters Theses & Specialist Projects

With the rapid development of automation technology in automotive manufacturing processes, massive and efficient production is a current trend. Therefore, measurement systems with accurate and automated measuring instruments are sought by automotive companies and suppliers. However, the problematic measuring instruments with unreliable accuracy and stability lead to erroneous measurements and wrong quality decisions that cause manufacturers huge profit losses. An effective method called “measurement system analysis” can be applied to define and eliminate erroneous measurements to ensure adequate reliability. An automotive transmission die casting parts supplier called company T was suffering a serious profit loss due to the erroneous measurements …

Wasco Environmental Chamber System Manifold, Steve Mark Yatco

Industrial and Manufacturing Engineering

This report details the process of designing and producing a manifold that connects ultra-high purity (UHP) pressure and vacuum switches to an air supply so that the parts may be tested in an environmental chamber. Using the DMAIC (define, measure, analyze, improve, and control) methodology of problem solving, progress on the project includes thorough research about the problem, preliminary design solutions, iterative prototyping, and testing specific functionalities. Manufacturing engineering topics of tooling, fixturing, metrology, quality, and machining with manual and computer numerical control (CNC) varieties of both mills and lathes are applied during the course of the project. The report …

The Programmatic Generation Of Discrete-Event Simulation Models From Production Tracking Data, Christopher Rand Smith

Theses and Dissertations

Discrete-event simulation can be a useful tool in analyzing complex system dynamics in various industries. However, it is difficult for entry-level users of discrete-event simulation software to both collect the appropriate data to create a model and to actually generate the base-case simulation model. These difficulties decrease the usefulness of simulation software and limit its application in areas in which it could be potentially useful. This research proposes and evaluates a data collection and analysis methodology that would allow for the programmatic generation of simulation models using production tracking data. It uses data collected from a GPS device that follows …

Size Effects In Human Visual Inspection For Micro/Meso Scale Parts, Sri Harsha Kavuri

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Visual inspection has been a major method of quality control in conventional manufacturing processes for the last fifty years. Utilizing trained human inspectors to perform this visual inspection has been the most effective means of maintaining quality control. Extensive research has been performed to understand the factors that influence the human inspection process.

In the recent years, there has been a significant emphasis on manufacturing at the smaller end of the size-spectrum such as Micro and Meso scale manufacturing. Quality control at becomes a challenging task due to the extremely small sizes. Several automated visual inspection techniques have been proposed …

Design Of A Custom Software Application To Monitor And Communicate Cnc Machining Process Information To Aid In Chatter Identification, Valerie Pezzullo

All Theses

In any manufacturing environment, it is important to be able to monitor the Computer Numerical Control (CNC) machining process so that high quality parts can be produced in the least amount of time in order to be profitable. This involves acquiring the proper parameters needed from the machine's controller, which can prove to be difficult with proprietary machine tools that tend to limit access to the internal data collected by the controller. This closed approach to controller design also means that many technological advances that have recently become prevalent in society are not being adopted in the manufacturing industry, preventing …

A Framework For The Development Of A Model For Successful, Sustained Lean Implementation And Improvement, Julie Sisson

Electronic Theses and Dissertations

Lean is a business philosophy focused on shortening lead times by removing waste and concentrating on value-added processes. When implemented successfully, it not only allows for cost reduction while improving quality, but it can also position a company to achieve tremendous growth. The problem is that though many companies are attempting to implement lean, it is estimated that only 2-3% are achieving the desired level of success. The purpose of this research is to identify the key interrelated components of successful lean transformation. To this end, a thorough literature review was conducted and the findings indicate six key constructs that …

A Heuristic For The Analysis Of Truncated Standard Normal Distribution Assemblies, John Walter Ralls, Cesar Ariel Pinto, Shannon R. Bowling, Resit Unal, Charles B. Daniels, S. Long (Ed.), E.H. Ng (Ed.), C. Downing (Ed.)

Engineering Management & Systems Engineering Faculty Publications

The analysis of data sets and process conditions commonly assume the use of standard normal distributions and truncated standard normal distributions (TSND). The use of these distributions has application to various engineering disciplines along with numerous other industries (e.g., financial industries, medical fields, management, etc.). For engineering managers, the use of truncated standard normal distributions has particular relevance when evaluating process conditions commonly associated with assembly tolerances, manufacturing, and associated measures of quality. This article summarizes a heuristic approach for the analysis of assembly-level truncated standard normal distributions and associated research from a recent dissertation (Ralls, 2014). This article provides …

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. …

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, …

Manufacturing Strategy & Operations: Reflections On Key Current Issues: Challenges And Associated Human Resource Implications, Lorraine Mcgrath

Books/Book chapters

This chapter evaluates the current issues and challenges in defining a company’s manufacturing strategy and its production operations in consideration of the contemporary shift to low cost manufacturing locations. Competitive priorities of cost, quality, delivery and flexibility are reviewed. The structural and infrastructure elements of a manufacturing strategy are outlined. Mitigating risks in a global arena are reviewed. Collaborative efforts, including the cultural and personality issues of being human are included in the discussion of managing diversity in such a highly competitive and challenging enterprise resource planning environment.

High Speed Turning Of Compacted Graphite Iron (Cgi) Using Controlled Modulation, Tyler Paul Stalbaum

Open Access Theses

Compacted graphite iron (CGI) is a material which emerged as a candidate material to replace cast iron (CI) in the automotive industry for engine block castings. Its thermal and mechanical properties allow the CGI-based engines to operate at higher cylinder pressures and temperatures than CI-based engines, allowing for lower fuel emissions and increased fuel economy. However, these same properties together with the thermomechanical wear mode in the CGI-CBN system result in poor machinability and inhibit CGI from seeing wide spread use in the automotive industry.

In industry, machining of CGI is done only at low speeds, less than V = …

Factors Impacting Technology Transfer: The Maquiladora Industry In Yucatan, Mexico, Ana Maria Canto, Carlos Blanco, Pilar Pazos

Engineering Management & Systems Engineering Faculty Publications

Technology transfer and knowledge transfer are the building blocks for innovation, efficiency and increased competitiveness. The topic of technology transfer in the context of multinational companies has been the focus of technology management researchers for well over two decades. Developing countries housing twin plans have been exposed to technology transfer from very diverse countries with different approaches to the technology transfer process and different levels of success. This cultural and national diversity adds an additional level of complexity to the technology transfer domain that has been largely unexplored. This paper will explore critical factors that had an impact in successful …

Identification Of Rework Station Location To Enhance Reworkability Using Design For Disassembly, Juan Alejandro Saavedra

Open Access Theses & Dissertations

Rework stations are commonly established as part of each assembly stations causing the material flow of the process to be constantly interrupted. Another option is to place the rework station at the end of the production, but this is not cost effective. This breakeven point between reworkability and cost methodology has been proposed in this thesis to identify the location of a single rework station in an assembly line in order to enhance reworkability using the Design for Disassembly (DfD) principles. The methodology uses the 17 guidelines of DfD in a manufacturing scenario in order to propose a reworkability index …

Extending Origami Technique To Fold Forming Of Sheet Metal Products, Ala Qattawi

All Dissertations

This dissertation presents a scientific based approach for the analysis of folded sheet metal products. Such analysis initializes the examination in terms of topological exploration using set of graph modeling and traversal algorithms. The geometrical validity and optimization are followed by utilizing boundary representation and overlapping detection during a geometrical analysis stage, in this phase the optimization metrics are established to evaluate the unfolded sheet metal design in terms of its manufacturability and cost parameters, such as nesting efficiency, total welding cost, bend lines orientation, and maximum part extent, which aides in handling purposes. The proposed approach evaluates the design …

Emergency Response Manufacturing: Lead Time Minimization And Human Factors For Ozone Water Filter Assembly And Kitting Process, Travis Gary

Industrial and Manufacturing Engineering

In the unfortunate event of a natural disaster affecting San Luis Obispo, response from national entities cannot be relied upon for a timely or efficient response. Local disaster recovery is superior because it minimizes response time, the need for costly stockpiling and creates a solution that is uniquely suited to the community that empowers local people in their most troubled times. Extensive planning is required for local disaster recovery and this project aims to provide the research and recovery system design required to implement an effective recovery plan.

Potable water is the primary need for people in the disaster situations …

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 …

Analysis Of Part Consolidation Techniques For Automotive Body In White Panels Based On Advanced Sheet Metal Forming Technologies, Harish Thiruvengadam

All Theses

The automotive industry is looking to move from mass production to mass customization in order to manufacture and sell a variety of products in different markets on a global scale. This requires a robust and cost effective manufacturing system which would help design new products in the shortest possible lead time. This thesis tries to investigate the current sheet metal forming process for body in white, identify the limitations and propose an alternative which would help the industry cut down product lead time and costs. Decision making tools are used to identify the technical requirements of a BIW manufacturing system …

Design For Manufacturing Of Sports Equipment, Cedrick Bit, Christopher L. Head

Industrial and Manufacturing Engineering

The purpose of this project was to validate industrial designs for a product in its conceptual stage and suggest/implement design changes that suit the contracting company’s needs while assuring the product maintains its basic functional requirements. Techniques and methods used to validate the design include 3‐D solid modeling, physical product application using rapid prototyping to produce the product. Methods of design for manufacturing were analyzed in the design. Processes used in the validation and verification of the design include solid modeling design, methods of measurements, fixture design and manufacturing processes. Full design specifications and solid model files were finalized and …

Automated Fixture Design For A Rapid Machining Process, Wutthigrai Boonsuk, Matthew C. Frank

Faculty Research & Creative Activity

Rapid prototyping techniques for CNC machining have been developed in an effort to produce functional prototypes in appropriate materials. One of the major challenges for rapid machining is to develop an automatic fixturing system for securing the part during the machining process. The method proposed in this paper is the use of sacrificial fixturing, similar to the support structures in existing rapid processes like Stereolithography. During the machining process, sacrificial supports emerge incrementally and, at the end of the process, are the only entities connecting the part to the stock material. This paper presents methodologies for the design of sacrificial …

Automated Fixture Design For A Rapid Machining Process, Wutthigrai Boonsuk, Matthew Frank

Faculty Research & Creative Activity

Rapid prototyping techniques for CNC machining have been developed in an effort to produce functional prototypes in appropriate materials. One of the major challenges for rapid machining is to develop an automatic fixturing system for securing the part during the machining process. The method proposed in this paper is the use of sacrificial fixturing, similar to the support structures in existing rapid processes like Stereolithography. During the machining process, sacrificial supports emerge incrementally and, at the end of the process, are the only entities connecting the part to the stock material. This paper presents methodologies for the design of sacrificial …