Industrial Engineering Commons^™

Frito-Lay - Supply Chain Impact Analysis, Kerri Blosch, Vincent Phua, Jeffrey Silva

Industrial and Manufacturing Engineering

The snack food company Frito-Lay relies on Route Sales Representatives (RSRs) to stock and maintain shelves of snack foods in every store. Frito-Lay currently does not have a system which can accurately predict cannibalization, or the effects of a store opening or closing on other stores of the same chain in the area. The goal is to sort through 1900 stores in a given metropolitan area to see the effects of cannibalization. In order to tackle the problem, a Microsoft Access program was created to filter stores based on location or whether the store was open for the full three-year …

Process Testing And Improvement Of Tapping Machinery At Lisi Aerospace, Michael James Hester

Industrial and Manufacturing Engineering

This report documents my senior project for California Polytechnic State University San Luis Obispo. I have chosen to do a senior project with Lisi Aerospace. Lisi would like to compare the manufacturer rated cycle count of taps versus an experimental one based on our machines in house. My goal for this project would be to run an experiment on one tapping machine and report on the achievable cycle count for the taps. I plan to do this in several ways including:

• Running extra cycle counts above tap manufacturer recommendations

• Documenting machine failure modes

• Create a process document to be repeated …

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Improving Advertisement Recognition And User Interface Of Gameofwarrealtips.Com, Chad Kihm, Alexander Meyer

Industrial and Manufacturing Engineering

The purpose of this experiment was to determine which location of advertisement would be the most recognized on the Game of War Real Tips website and to improve the website’s user interface by using both quantitative and qualitative data. To accomplish this, two experiments were created. The first experiment was designed to determine which location of advertisement would be recognized most by users. A screen would flash for 0.5 seconds and the subjects would mark where they believed they recognized an advertisement. A statistical analysis was completed to determine whether the location of the advertisement had an effect on the …

Wine Club Shipment Package Redesign, Emily E. Prescott

Industrial and Manufacturing Engineering

This report shows the design, manufacturing, and testing process for the product development of a wine club shipment package for Niner Wine Estates. Niner has two different shipment sizes, 4 bottles and 6 bottles, and wishes to improve their current package by giving it a more “high-class” feel. After the new package was designed and prototyped, it went through standardized quality testing to be cleared for commercial use. This testing is intended to simulate the distribution cycle the package will experience and subject it to potential hazards such as being dropped and vehicle vibration during transportation.

After the package passed …

Process Improvements Of Cilantro Harvesting With Ergonomic Considerations, Eric Penningroth, Branden Shimamoto

Industrial and Manufacturing Engineering

The problems presented by Talley Farms to the team were a lower than desired cilantro harvesting capacity and work health pertaining to lower back problems. The project objectives were to address and improve upon both of these objectives. To increase harvesting capacity, a simulation model was created using standard times from time studies. The simulation model helped to compare the different harvesting methods as well as the effect of the utilization of the on-site manager. The throughputs between each of the models were analyzed. To address ergonomic concerns, a work sampling study was conducted and it was determined that kneeling …

Bikeshare Business Model For Cal Poly- San Luis Obispo, Justin Benson, Andrew Neil Gatchalian

Industrial and Manufacturing Engineering

With the increasing admittance of students into colleges and universities across the nation, the need for alternate modes of transportation is becoming more pressing. College and university campuses, as well as small cities, in which there is a college or university, are being overloaded with student cars. In San Luis Obispo specifically, parking on campus as well as downtown can be extremely difficult to find. Traffic is also getting progressively worse, especially at the hour when class begins/ends and student arrive to or leave campus. Financial reasons are yet another deterrent for students at Cal Poly. Parking permits, gas, and …

Effects Of Patient Factors On Implantation Rates In In Vitro Fertilization, Heidi Richardson, Sofia Soto

Industrial and Manufacturing Engineering

The purpose of this report is to evaluate the effects of patient factors and embryo quality on the implantation rate in In Vitro Fertilization (IVF). For this report, statistical methods are used to test the significance of several patient and embryo characteristics on embryo implantation rate. This project is an analysis of data collected from over 36,000 patients.

The analysis concluded several findings. There was enough statistical evidence to conclude that age was significant in regards to implantation rate and FSH levels. As the patient ages, the amount of FSH levels found in their blood increases. A patient with high …

Redesign Of Talley Farm's "Fresh Harvest" Produce Program, Nicole Bordwell, John Rivera, Jared Toboni

Industrial and Manufacturing Engineering

Fresh Harvest, a Central Coast Community Supported Agriculture (CSA) program run by Talley Farms located in Arroyo Grande, CA, has a rapidly growing customer base. They harvest, package, and deliver boxes of fresh quality produce to almost 3000 subscribers. However, Talley Farms’ space for production and processing is limited and at times required for other aspects of business. This results in a problem where Talley Farms current processing system of produce for the Fresh Harvest program is not suitable for the forecasted growing demand. This report addresses the need to prepare for continued significant growth to the demand for Fresh …

Analysis And Improvement Of The Security Building At Pg&E Diablo Canyon Nuclear Power Plant, Alyssa Carter, Natalie Christa, Phuong Anh Pham Dinh

Industrial and Manufacturing Engineering

A new Security building was recently designed and built at the Pacific Gas and Electric (PG&E) Diablo Canyon Power Plant (DCPP).This building’s staff and equipment are responsible for performing routine inspections on all personnel entering the facility in order to prevent security-related incidents from occurring at the nuclear power plant. Similar to airport security procedures, the DCPP security building routine inspections include the use of x-ray machines, metal detectors, and explosive detectors.

The Power Plant periodically experiences pre-planned, preventive maintenance outages, that last 4-6 weeks. During an outage, a power plant reactor is shut down for maintenance, repair, and re-fueling. …

Semi-Automated Glass Mat Splice Operation For Asphalt Shingle Line, Justin Bracci, Harry Zhao, Chad Linafelter

Mechanical Engineering

The following report details the senior project sponsored by GAF Materials Corporation, Shafter, CA in regards to semi-automating a glass-mat splicing table for asphalt roofing shingle production. Herein includes details, research, design, and analysis regarding the semi-automation of the gluing processes for the splicing table. A working prototype was manufactured and tested for the future implementation onto GAF’s production line or further senior project involvement.

Methane Production By A Packed-Bed Anaerobic Digester Fed Dairy Barn Flush Water, Sean Richard Thomson

Master's Theses

Packed-bed digesters are an alternative to covered lagoon digesters for methane production and anaerobic treatment of dilute wastewaters such as dairy barn flush water. The physical media of packed-beds retain biofilms, often allowing increased treatment rates. Previous studies have evaluated several types of media for digestion of dilute wastewaters, but cost and media fouling have setback commercial development. A major operational cost has been effluent recirculation pumping.

In the present effort, a novel approach to anaerobic digestion of flush dairy water was developed at pilot-scale: broken walnut shells were used as a low-cost packed-bed medium and effluent recirculation was replaced …

A Control-Chart Based Method For Solder Joint Crack Detection, Jianbiao Pan

Industrial and Manufacturing Engineering

Many researchers have used different failure criteria in published solder joint reliability studies. Since the reported timeto-failure would be different if different failure criteria were used, it would be difficult to compare the reported reliability life of solder joints from one study to another. The purpose of this study is to evaluate the effect of failure criteria on the reported thermal fatigue life and determine which failure criterion could detect failure sooner. First, the application of the control-chart-based method in a thermal cycling reliability study is described. The reported time-to-failure data were then compared based on four different failure criteria: …

Local Buckling Behavior Of Round Steel Tubes Subjected To Compressive Loads, Joseph Moore, Ben Fell

STAR Program Research Presentations

This project will investigate the local buckling induced fracture behavior of round steel tubes subjected to axial compressive loads, representative of observed failures in buried pipelines during seismic events. Nine initial tests will be conducted across three lengths of round steel tube: 8”, 12”, and 20”. Another twelve tests will be conducted on the lengths of 12” and 20” to test varying initial compressive force upon the round steel tubes. Three D/t ratios will be considered for each length of round steel tube: 52.6, 78.9, and 121.2. To verify the material properties of the test specimens an ancillary tensile coupon …

2d Wireform Process Improvement, Katy Conlin, Carlo Ebora, Jordan Gamble

Mechanical Engineering

The body of this work has been created for Edwards Lifesciences in conjunction with senior project requirements. As such, the information produced and contained within is under a non‐disclosure agreement. As per request by sponsor, the body of the work will not be submitted to any outside parties, and the title page will serve as proof of completion.

A Set Union Based Formulation For Course Scheduling And Timetabling, Jesse Paul Bukenberger

Master's Theses

The Course Timetabling Problem is a widely studied optimization problem where a number of sections are scheduled in concert with the assignment of students to sections in order to maximize the desirability of the resulting schedule for all stakeholders. This problem is commonly solved as a linear program with variables for each student or group of students with identical schedules. In this paper we explore an alternative formulation that aggregates binary student variables into integer variables denoting the number of students enrolled in a course. Our solution method assumes decomposition of the general schedule into time blocks, and applies a …

Analysis Of Environmentally Friendly Marking Ink For Military Equipment And Electronics, Liang Li

Master's Theses

Recent advancements in corrosion-resistance coating technology has reduce the use of environmentally harmful compounds such as Hexavalent Chromium by replacing Hexavalent Chromium in primers and topcoat. However, marking inks were neglected in the process. Products such as Enthone 50 series are still widely used, which contain compounds such as lead, hexavalent chromium, bisphenol A (BPA), Cadmium Sulfide, and more. Excluding catalyst compositions in Enthone, the chemicals in the ink alone contained three reproductive toxicant and numerous carcinogens. Therefore, it was essential to search and validate the performance of potential marking ink that would meet the standards in military applications.

Eleven …

Investigating Present And Future Interactions Between Radio Frequency Identification, Additive Manufacturing And Supply Chain Management, Michael Nobuhiro Ochi

Master's Theses

A screening experiment was paired with research observing the past, present and futures of additive manufacturing (a.k.a. rapid prototyping, 3D printing), radio frequency identification, and supply chain management. The experiment tested different properties of objects created with a desktop fused deposition modelling printer to observe if any single factors or interactions affected the read range of embedded passive UHF RFID inlay. The combination of material and infill percentage had a statistically significant effect on read range, however the analysis is weak since the data could not justify the normality assumption of ANOVA. Furthermore, the size of the effect was small …

A Control-Chart Based Method For Solder Joint Crack Detection - Conference Proceeding, Jianbiao Pan

Industrial and Manufacturing Engineering

Many researchers have used different failure criteria in the published solder joint reliability studies. Since the reported time-to-failure would be different if different failure criteria were used, it would be difficult to compare the reported reliability life of solder joints from one study to another. The purpose of this study is to evaluate the effect of failure criteria on the reported thermal fatigue life and find out which failure criterion can detect failure sooner. First, the application of the control-chart based method in a thermal cycling reliability study is described. The reported time-to-failure data were then compared based on four …

Design Of Transportation Process For Band Equipment, Marissa N. Blustein, Chris M. Kaye

Industrial and Manufacturing Engineering

The following report documents the attempt to design a safe and reliable process for transporting Louder Space’s musical gear that requires minimal physical demand. Design specifications were derived from customer requirements as well as human factors principles. The transportation process was broken down into systematic process steps and standardized, making use of lean methodologies in order to reduce the number of non-value steps involved. Furthermore, a model portable storage unit for miscellaneous gear was developed to the specifications determined by the band using 3D modeling, as well as certain limiting constraints. Once the customer approved the prototype, the product was …

S1nn Gmbh & Co. Kg (Automobile Connectivity Module 1.1), Tyler Alexander Ball

Industrial and Manufacturing Engineering

The results of this report show how when diagnostics were run on the Connectivity Module 1.1, the problems discovered such as potential short-circuiting, 90-degree copper tracing angles, and components overheating/tombstoning were addressed. By using the method of “DMAIC,” which stands for Design, Measure, Analyze, Implement, Control, successful corrections were made. In the first design of the Printed Circuit Board (PCB), 1454 critical issues were found. With the newly designed PCB’s modifications being implemented, only 12 critical issues remained, which were later addressed and corrected. The results from this report are a functional Automobile Connectivity Module 1.1.

Project Management Of High School Shadow And Building An Engineer Day, Andrea M. Carroll

Industrial and Manufacturing Engineering

Building an Engineer Day and High School Shadow are semi-annual outreach events hosted by Cal Poly’s Society of Women Engineers section during fall and spring quarters. The events focus on encouraging women and minorities to take an interest in engineering. These events are the two largest outreach events hosted by The Society of Women Engineers and need to run smoothly in order to provide student attendees with a meaningful experience.

Building an Engineer Day and High School Shadow are currently un-organized and un-planned, which leads to problems with officer retention, increase in expediting process and a low attendance rate at …

Equipment Maintenance And Replacement Decision Making Processes, Michael W. Gage

Industrial and Manufacturing Engineering

This project contains recommendations for the decision making processes for support and production equipment maintenance and replacement for a large defense contractor. Recent literature has been reviewed to provide perspective on current trends in the field. A complete evaluation of their current processes and systems is included with recommendations on areas for improvement. A decision support system is also proposed to supplement their existing decision making.

Fixture For Carbon Fiber Spar Of Human Powered Helicopter, David John Ikeda, Luis Gonzalez

Industrial and Manufacturing Engineering

The following report describes our contribution to Cal Poly Human Powered Helicopter for the 2012 competition for the Sikorsky Prize offered by the American Helicopter Society. In order to win this prize the team needs to build and fly a human powered helicopter for more than 60 seconds reaching and altitude of 3 meters while staying in a 10 meter square box. Our team was created to support the integration of Carbon Fiber parts, specifically the carbon fiber spars with rotor and landing gears. Precise cutting and accurate drilling was needed and our team was tasked with creating a fixture …

Project Based Learning In Engineering Economics: Teaching Advanced Topics Using A Stock Price Prediction Model, Lizabeth Schlemer

Industrial and Manufacturing Engineering

A graduate level advanced engineering economics class taught at California Polytechnic State University, San Luis Obispo, includes a thorough review of time value of money, investment evaluation, inflation, risk and return, financing decisions, corporate investment strategies, risk analysis and decisions incorporating non-monetary considerations. Historically this course was taught using an advanced text where the topics were covered sequentially. A redesign of the course now includes the construction of a stock price prediction model for a company of the student’s choice. Through the model, the topics are covered and discussed in the context of the large model-building project. For instance, inflation …

Exploring A High-Tech Approach To Subterranean Dwelling Environments For Commercial Implementation, Matthew Richard Gordon

Industrial and Manufacturing Engineering

People are always looking to experience something interesting and unique when on vacation. What could be more unique than staying in a hotel that is completely underground? While people have always been amazed at natural caves and other subterranean structures, the idea of spending the night in one of these is a somewhat untried area, although it could be quite the selling point. This being the case, the idea of a subterranean hotel is not so farfetched, however there are a number of issues that arise with this project. These issues include construction and selecting the proper site and building …

Cal Poly Chocolates, Jason Ferrel, Taylor Fitzpatrick

Industrial and Manufacturing Engineering

Our design for this project began with building a strong understanding of the current production process. A meeting with the manager, Anna Nakayama, provided a detailed overview of the entire process and outlined some areas of concern. In addition, she provided us with access to critical data such as standard operating procedures and inventory spreadsheets. From there, time studies were conducted for each of the 8 types of chocolate. These time studies helped identify three main issues facing Cal Poly Chocolates. The first issue is in the packaging area of production. The process is entirely manual and has become a …

Qualification Of A New Glass Bottle With E&J Gallo Winery, Danielle Leanne Medeiros

Industrial and Manufacturing Engineering

This paper will further examine the procedures involved in transitioning to a new bottle type made by Glass Company B, on a specific bottling line within E&J Gallo’s bottling facility. For this project Bottling Line X will require thorough testing as well as the creation of a changeover choreography plan. The testing procedure will follow a 3 phase process utilizing project management and statistical skills to ensure quality standards are upheld with the transition. Since Bottling Line X is not familiar with transitioning between bottle types, lean manufacturing techniques will be required to create a changeover document ensuring operators are …

Application Of Data Envelopment Analysis To Identify Undervalued Equities On The Dow Jones Industrial Average, Ryan L. Kotzebue

Industrial and Manufacturing Engineering

Two factors that drive investors to and away from the stock market are reward and risk, respectively. By using a stock selection strategy that is quantitative, investors may feel more comfortable and secure with their decisions. However, there lacks a quantitative strategy that can produce increased returns with lower risk by purchasing a small number of stocks. The objective of this project was to formulate a quantitative stock trading strategy that produced exceptional returns with low risk while also fulfilling additional requirements to benefit the common investor.

By using a linear programming based operations research technique known as data envelopment …

Facility Redesign At The Systech Corporation, Jacob J. Rucker

Industrial and Manufacturing Engineering

This senior project is a redesign of Systech’s manufacturing floor as they move to their new facility to be able to support the expected increase in customer demand. As of January 2013, Systech was working near full capacity, and because of their new product release, they expect the demand to outstrip the production capabilities of the current facility. Because of this, Systech is moving their final testing operations in San Diego to a larger building. During this transition, they have expressed interest in redesigning the current floor layout in order to maximize the productivity of their employees. To accomplish this, …

Wart Eliminator Project Report, Colton Story, Kyle Shipman

Industrial and Manufacturing Engineering

The Wart Eliminator is a product based on the theory of resonant frequency and its ability to devitalize pathogens with the use of electronic pulses. Using the resonant frequency of the wart’s pathogen, the device is operated by the user with two switches for power and a probe connected by a wire to the device for applying to the affected area of the user while running three minute cycles. The product is in the beginning stages with only a prototype made. The product needed a proper ergonomic design to be easily used by the user and a cost analysis to …