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 …

Effects Of Machining Parameters And Cooling Strategies On Cutting Forces And Surface Integrity In High-Speed Slot End-Milling Of Titanium Alloy, Emenike Chukwuma

Masters Theses

“Paper 1 presents the results of the investigations of the effects of cooling strategies [Emulsion cooling, Minimum Quantity Lubrication (MQL) and Liquid Nitrogen (LN₂)] and machining parameters (feed rate and spindle speed) on cutting force components, cutting temperature and tool wear during slot end-milling of titanium Ti-6Al-4V workpiece. All machining experiments were conducted using four-flute 0.5 inch diameter uncoated solid carbide end-mill on Cincinnati Milacron, Sabre 750 vertical machining center equipped with Acramatic 2100 controller. Cutting force components were acquired and tool wear was indirectly measured from maximum cutting force variation per slot from the first pass to …

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 …

Sustainability For Die Manufacturing: Comparative Study Of Wedm And Milling, Matthew S. Kalus

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

Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society. Concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries are the most well known industries that machine harder materials using mills and WEDM. The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute to …

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.

Droplet Spray Behavior Of An Atomization-Based Cutting Fluid (Acf) System For Machining Of Titanium Alloys, Chandra Nath, Shiv G. Kapoor, Anil K. Srivastava, Jon Iverson

Manufacturing & Industrial Engineering Faculty Publications

The aim of this research is to study droplet spray characteristics of an atomization-based cutting fluid (ACF) spray system including droplet entrainment angle and flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. The flow development behavior is studied by modeling the droplets entrainment mechanism, and the density and distribution of the droplets across the jet flare. Machining experiments are also performed in order to understand the effect of the droplet spray behavior on the machining performances, viz., tool life/wear, …

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 …

Development And Validation Of A Model For Granular Material Volume Measurements, Pourya Fasounaki

Department of Industrial and Management Systems Engineering: Dissertations, Theses, and Student Research

Keeping inventory record of packed grains in silos poses challenges since the bulk material’s different segments do not discharge uniformly, leading to formation of random peaks and valleys on the surface. To facilitate obtaining accurate volume measurement of the grains by taking into account this non-linear behavior on the surface, laser or plumb-bob level-sensing devices are employed at different part of the surface to probe the level of material under those regions.

The main goals of this research is to study the behavior of granular material in silo while discharging downward and by doing so, differentiate certain flow patterns formed …

Improving Health Care Quality And Safety: The Development And Assessment Of Laparoscopic Surgery Instrumentation, Practices And Procedures, Bernadette Mccrory

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

Adverse events due to medical errors are a leading cause of death in the United States exceeding the mortality rates of motor vehicle accidents, breast cancer and AIDS. Improvements can and should be made to reduce the rates of preventable surgical errors since they account for nearly half of all adverse events within hospitals. Although minimally invasive surgery has proven patient benefits such as reduced postoperative pain and hospital stay, its operative environment imposes substantial physical and cognitive strain on the surgeon increasing the risk of error. In order to mitigate errors and protect patients, a multidisciplinary approach was taken …

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, …

A Unified Enterprise-Wide Cost Modeling Framework For Engineering Applications Based On Systems Engineering Principles, Yousuf S. Mohammed

Mechanical & Aerospace Engineering Theses & Dissertations

In the present research the problem of enterprise-wide cost modeling is approached from a systems engineering standpoint. What this does is to use each stage of product life cycle to obtain useful information that helps in estimating the cost of the system. Once a generic framework is developed for estimating the core cost, layers of other factors that affect the cost are applied to the core cost, such as risk and uncertainty, maintainability, supply-chain and socioeconomic conditions. The cost model is expanded to accommodate a product domain ranging from a simple object to a system in the following hierarchy: System, …

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 …

Network-Based Data Collection For A Project-Based Freshman Class, Samuel Bogan Daniels, Cheryl Q. Li, David Harding

Mechanical and Industrial Engineering Faculty Publications

The hands-on experience for engineering students is often lacking with class sizes increasing and classroom resources under constant pressure. Even with smaller class sizes and studio classrooms there is only so much equipment and technical support to run experiments and allow for student interaction. Network-based data collection and control may alleviate some of these issues and allow for more hands-on experiences, although remote, in the classroom. This paper discusses the interesting problems and not so obvious pitfalls of setting up some simple network-based data acquisition systems for a multidisciplinary freshman level engineering course. The course as currently taught includes some …