Industrial Engineering Commons^™

Warehouse Reconfiguration With Ats Lab, Ed Cantor, Dana Pazhouhesh, Mathew Oshinski, Samantha Sanchez

Senior Design Project For Engineers

The ATS Lab Warehouse Reconfiguration project is a collaborative effort between Kennesaw State University’s Department of Industrial and Systems Engineering and ATS Lab, located in Marietta, GA. The goal of this project is to redesign the current warehouse layout to enhance operational efficiency, reduce travel time, and implement sustainable inventory management practices, including 5S and Kanban. Aaron Roob, ATS Operations Manager, and Franklin Hungerford, Continuous Improvement Manager, led this initiative. Our team, “Sick Sigma’s,” is composed of Ed Cantor, our Project Manager, who is working as an intern at ATS during this process; Dana Pazhouhesh (Process Engineer); Matthew Oshinski (Quality …

Workstation Redesign, Mclean Dowell, Anna Seville, Luz Corral Parra, Farah Talib

Senior Design Project For Engineers

Tellerex is a leading ATM refurbishing and repair company operating from Atlanta, Georgia. Due to its rapid growth, the company is facing challenges pertaining to their parts repair and refurbishing lab. Tellerex aims to fulfill orders by 4:00 pm on the day they are placed, guaranteeing their clients same-day shipping. Orders often build up throughout the day, causing lab technicians to stress, rush through orders, and lose organization.

Tellerex has requested our help regarding one of their repair/refurbishment labs. Our goal is to redesign the lab workspace through human ergonomics and Lean Six-Sigma principles. The company wants us to create …

Optimizing Xo Throughput At Imerys, Derek Beasley, Brennan Chandler, Baris Erarslan, Cynthia Grogin

Senior Design Project For Engineers

This project is conducted in collaboration with Imerys to optimize the performance of the VSI (Vertical Shaft Impactor) system at their Plant 4 facility, focusing on improving the production of XO, a fine material used in products such as textured coatings, acid neutralization, and water filtration systems. The VSI operates continuously, producing several materials at the Marble Hill, Georgia location, including #1 Chip, #2 Chip, OZ, XO, Z, and 30–50. The main focus of this project is to increase the throughput of XO, as it requires both throughput improvement and product quality consistency to meet growing market demand. Imerys’ quality …

Exploring The Link Between Emotional States And Coding Task Quality: A Pilot Study, Aquib Reshad, Valentina Nino, Maria Valero, Adriane Randolph, Yang Shi

Faculty Articles

Emotions play a crucial role in shaping cognitive performance, yet their influence on programing remains understudied. This pilot study investigates the relationship between emotional states and coding task quality. Ten participants completed a programing task while their brain activity was recorded using electroencephalography (EEG), with frontal alpha asymmetry (FAI) applied as a neural marker of emotional valence. Emotional self-reports were collected using the Scale of Positive and Negative Experience (SPANE), and coding quality was evaluated through a structured rubric. Preliminary findings indicate a potential association between FAI and coding performance, whereas self-reported affect showed weaker or inconsistent patterns. Given the …

Bridging The Gap: Care Team’S Perspectives On Technology And Ai Integration In Healthcare, Sarah Fernandes, Pranathi Boyina, Awatef Ergai Dr., Wellstar Health System, Mohammad Yousef Mousa Naser, Sylvia Bhattacharya Dr.

Symposium of Student Scholars

As healthcare systems increasingly integrate digital solutions, understanding the perspectives of frontline healthcare workers on technology adoption is critical. This study explores how Registered Nurses (RNs), Licensed Practical Nurses (LPNs), and Certified Nursing Assistants (CNAs), collectively referred to as the Care Team, interact with existing and emerging healthcare technologies, including artificial intelligence (AI). Given the growing reliance on digital tools for clinical and administrative tasks, this research examines the challenges and benefits perceived by healthcare professionals when incorporating AI-driven solutions into their workflows.

A cross-sectional research design was employed, involving 30 semi-structured interviews with Care Team members from an Intensive …

Kennesaw State University Student Managed Investment Fund Sector Sensitivity Analysis, John Kiersznowski, Joe Johnson, Kyler Howell, Geranger Lewis

Senior Design Project For Engineers

The Kennesaw State University Student Managed Investment Fund (SMIF) Sector Sensitivity Analysis focuses on improving the fund’s decision-making and performance through data science. The SMIF is a diversified index fund designed to outperform indices like the S&P 500. This project investigates how macroeconomic variables—such as GDP growth, inflation, interest rates, and commodity prices—impact sector performance. By structuring data, developing a sustainable data pipeline, and leveraging advanced statistical techniques and predictive modeling, our team was able to provide the framework and proof of actionable insights that enhance the fund's ability to manage risks and optimize returns.

Digital Twin And Cybersecurity In Additive Manufacturing, Lidong Wang

Journal of Cybersecurity Education, Research and Practice

Additive manufacturing (AM) has been applied to automotive, aerospace, medical sectors, etc., but there are still challenges such as parts’ porosity, cracks, surface roughness, intrinsic anisotropy, and residual stress because of the high level of thermal gradient. It is significant to conduct the modeling and simulation of the AM process and achieve quality products. Digital Twin (DT) can help AM with forecasting defects/errors through simulation and real-time process monitoring. DT is a concept of Industry 4.0, and its digital structure reflects the real-time behaviors of a cyber-physical or physical system. This paper introduces the progress of DT applications in AM, …

Processing Cost Analysis For Great South Metals, Evan Briggs, Madisen Laskos, Jared Perrin

Senior Design Project For Engineers

Great south Metals (GSM), a steel processing company based in Acworth, GA, has partnered with the Kennesaw State University (KSU) Industrial and System Engineering (ISYE) department to optimize its costing model. Currently, GSM uses a flat pricing structure for GSM-owned materials and estimates costs for toll processing. However, this approach has led to inaccuracies in pricing and challenges in tracking profitability. GSM seeks to transition to a more systematic and data-driven costing model that will improve both internal and external quoting while ensuring competitiveness in the market.

To address these challenges, the project focused on developing separate costing matrices for …

Evaluating The Health Benefits And Cost-Effectiveness Of Dental Sealant Reapplication Among Children And Adolescents, Pritam Deb, Jayden Ayash, Christina Scherrer

Symposium of Student Scholars

Dental caries, commonly known as cavities, persist as a prevalent chronic disease among children. Dental sealants, which are transparent coatings applied to the molars, have been proven to prevent over 80% of caries in these teeth. However, the effectiveness of sealants diminishes over time, primarily due to their potential to detach shortly after application due to inadequate bonding, or else gradually over time. Notably, dental insurance coverage for resealing teeth after the initial sealant has been lost varies widely, with many policies only covering the cost of the initial application. This study employs a Markov model-based discrete event simulation to …

Great South Metals: Slitter Head Building Process, Nabhan Karim, Evan Swierski, Raven Morin, Patrick Kelsey, Michael Williams

Senior Design Project For Engineers

Great South Metals (GSM) operates two steel slitter machines, which take large coils of flat rolled steel and cut them into smaller strips for use in customers’ applications. Setting up the working components of each machine, called the slitter head, is a precise and arduous task. This system relies on several manually performed calculations and acute attention to detail; and thus, is prone to human error. The management at GSM commissioned our team to simplify the slitter head assembly process by creating an automated computer program and make additional recommendations to improve their operations.

The program we created is a …

Mathematical Modeling For Dental Decay Prevention In Children And Adolescents, Mahdiyeh Soltaninejad

Dissertations

The high prevalence of dental caries among children and adolescents, especially those from lower socio-economic backgrounds, is a significant nationwide health concern. Early prevention, such as dental sealants and fluoride varnish (FV), is essential, but access to this care remains limited and disparate. In this research, a national dataset is utilized to assess sealants' reach and effectiveness in preventing tooth decay, particularly focusing on 2nd molars that emerge during early adolescence, a current gap in the knowledge base. FV is recommended to be delivered during medical well-child visits to children who are not seeing a dentist. Challenges and facilitators in …

Imerys: Tube Mill Optimization Project, Ryan Waltman, Dalton Beasley, Dyson Beasley, Tristan Mcmichael

Senior Design Project For Engineers

The Tube Mill Optimization Project is in partnership with Imerys for Tube Mill 81 at their Marble Hill site in Georgia. Tube Mill 81 is a dry ball mill that operates 24/7 and makes an intermediary product for Plant 3. Tube Mill 81 needs quality improvement and a production rate increase to meet demand. Imerys’s quality specification is between a particle size of 12-18 microns and an acceptable production rate of 5 tons per hour. This project focuses on the development and implementation of three solutions: increase the amps on the separator to increase production, replace missing classifier blades in …

Kwad - Ksu All Weather Autonomous Drone, Nick Farinacci, Sebastian Gomez, Stewart Baker, Ed Sheridan

Symposium of Student Scholars

"KWAD" or "KSU all-Weather Autonomous Drone" project was sponsored by Ultool, LLC to the KSU Research and Service Foundation to create a lightweight drone capable of capturing HD video during all-weather operations. The conditions of all-weather operation include rainfall of one inch per hour and wind speeds of up to twenty miles per hour. In addition, a global minimum structural safety factor of two is required to ensure the system's integrity in extreme weather conditions. Potential mission profiles include autonomous aerial delivery, topological mapping in high moisture areas, security surveillance, search and rescue operations, emergency transportation of medical supplies, and …

Human Factors Engineering, Robert S. Keyser

KSU Distinguished Course Repository

Human Factors Engineering is a comprehensive survey of human factors theory, research, and applications which are of particular relevance to Quality and Engineering Management. Emphasis will be placed on operator constraints in the design of work processes, workplaces, and instrumentation.

The Effect Of Mental Demand On Body Postures, Rodrick Adams, Valentina Niño

Symposium of Student Scholars

How we perceive our work has a profound relationship with how our body reacts to help facilitate the performance of our tasks. This is an observational study of the experiment in which participants performed tasks under four different conditions (baseline, interruptions, time, and alarm) and used NASA-TLX (NASA- Task Load Index) scores to assess their mental workload for each condition across six dimensions: mental demand, physical demand, temporal demand, effort, performance, and frustration level. We juxtaposed their NASA-TLX score with corresponding REBA (Rapid Entire Body Assessment) scores while standing and RULA (Rapid Upper Limb Assessment) scores while sitting to determine …

Reducing Restaurant Inventory Costs Through Sales Forecasting, Tyler Mason, Chris Schoen, Trevor Gilbert, Jonathan Enriquez

Senior Design Project For Engineers

Family Restaurant is a local restaurant in the greater Atlanta area that serves a variety of dishes that include an assortment of 19 different proteins. Currently, Family Restaurant places protein orders based on business intuition, and tends to over-stock and sometimes under-stock. To minimize inventory costs by reducing over-stocking and preventing under-stocking of proteins, we applied Facebook Prophet (FB Prophet), ARIMA, and XG Boost machine learning models to predict protein demand and then fed these results into a Fixed Time Period inventory model to make an overall order suggestion based on the specified time period. We trained our models on …

Hansen Technologies: Mvp Kaizen Event, Kyle Kraus, Ethan Mahon, Erick Hohler, Alexander Knowles

Senior Design Project For Engineers

Hansen Technologies, based in Commerce GA, is a global leader in the production of industrial refrigeration. One of their most profitable product assembly cells, the Multivalve Platform cell, is not currently producing enough to meet increasing demand. The MVP team focused on analyzing and designing a system using Kaizen to improve the throughput of the MVP cell. After conducting a root cause analysis through Gemba and video analysis, key areas were noted for improvement. Small inconsistencies, such as losing grip on the heavy MVP and searching for materials can take a lot of time away from achieving higher throughput levels. …

Student Success And Evaluation Metrics, Ricky L. Singletary Jr, Andrew I. Morgan, Elena S. Van Zanten

Senior Design Project For Engineers

In so many instances, students drift through high school and are unaware of what types of job opportunities are out there for them. It is easy to see that a student can get overwhelmed by the number of career options, or they may not know what they want to do at all. The Blue Barred has generated a solution that allows students to see their options much more clearly through the analysis of six factors and their contribution to success: Engagement, Value Added Learning, Network-ability, Literacy, Numeracy, and Graduation Rates. Through the usage of tools such as literary research, surveys, …

Manufacturing & Service Systems, Robert S. Keyser

KSU Distinguished Course Repository

An analysis of decision making in the current production environment and the tools and optimization models needed for finding solutions to problems relating to production planning and scheduling, inventory, and warehouse design.

Size And Cost Reduction Of The Antenna 3000, Mario Mignott, Austin Deaver, Josh Madaris

Senior Design Project For Engineers

For our senior design project, we have partnered with Compass Technology Group to improve its Antenna 3000 manufacturing process. The Antenna we are working on is not actually called this, but due to NDA regulations, we will disguise it as the Antenna 3000. This will include finding a way to minimize material costs and labor hours involved to assemble this product together. Our minimum success criteria will be to reduce both the manufacturing time and materials' cost by 20%. Our primary approach to solving this problem will be to implement Lean Six Sigma practices such as the DMAIC principle.

Using …

Aerial Screw Vtol Rotorcraft, Macale Rielly, Alexa Culp, Thomas Osteen, Adeline Perry

Senior Design Project For Engineers

Known as the “Renaissance Man,” DaVinci’s impressive knowledge of mechanics and inventive prowess would influence engineers and innovators hundreds of years later to make human flight a reality. However, due to the limited capacity of engineering and manufacturing at the time, his invention had been shallowly investigated in a production setting. This project strove to properly acknowledge DaVinci’s invention by thorough examination and critical analysis of his concept with the hopes of gaining a better understanding of why it is considered the “foundation of vertical flight”.

An iterative design approach was employed, utilizing faculty and university resources, team knowledge from …

Kennesaw State University - Maintenance Optimization And Cost Analysis, Mary E. Ogidigben, David T. Murphy, William L. Fowler

Senior Design Project For Engineers

The Department of Housing and Residence Life was looking for ways to improve the quality of their work while saving costs at the same time. The department allowed the team to look over their work orders where the team noticed over 50% of the work orders were related to room turnover. After this discovery, the team focused all efforts on room turnover and went over the process in detail with management. The team asked to see the standard operating procedure for room turnover and learned that most of the staff did not know they had one.

The team wanted to …

Mazak Laser Optimization, Maylon Ellington, Terrilian E. Agbor Oji, William N. Palm

Senior Design Project For Engineers

Starflex Fabrication is a manufacturing company that thrives to provide custom, precision fabricated parts, and assemblies to their customers.The Mazak laser is Starflex Fabrication’s primary cutting machine and is critical to the overall process for each order. Team Flex will look to optimize the laser’s process and improve overall shop throughput.

Space Optimization And Process Improvement, Harith Alshareef

Senior Design Project For Engineers

Siemens Energy warehouse located in Suwanee, GA runs out of space in the Precision Lab due to rapid growth, seasonal peaks, and poor space utilization. The objective of the project is to redesign the Precision Lab layout and improve the tool assessment process to increase efficiency, productivity, and profitability.

The first solution is to add shelves in the Precision lab as well as the Torque lab and reduce the honeycombing effect on the shelves, which results in a 120%-150% increase in the storage space. We propose adding Tablets that include barcode scanner features to reduce the time spent on the …

Extreme Altitude Search And Rescue Helicopter, Matthew J. De Sieno, Anthony Chavarria, David Stuver, Zach Boss

Senior Design Project For Engineers

The goal of this design was to develop an extreme altitude rescue helicopter capable of retrieving hikers stranded on top of Mount Everest. Using the Eurocopter AS350 as a baseline, a conceptual model was produced that is fully capable of hovering and delivering forward flight at the desired altitude of 8,848 meters. Combined blade element momentum theory, proper airfoil selection, and forward flight calculations were utilized in order to optimize the rotor for the given flight conditions on top of Mount Everest. Conceptual fluid dynamics and CAD modeling aided in the process of visually designing the fuselage and rotor. Not …

Optimization Of The Retention Rates Of Ready Mix Usa Drivers, Pruthvi Hira, Jaime Harmon, Kenneth Correa, Destiny Sessums

Senior Design Project For Engineers

Ready Mix USA, a CEMEX company, is a giant in the building materials industry, servicing the Southeastern region of the United States through various commercial and residential projects. The Atlanta Division of RMUSA currently consists of 15 operational plants in the state of Georgia with its headquarters located in Woodstock. From the years 2015 to 2018, managers at Ready Mix USA noticed a drastic increase in turnover rates of ready mix truck drivers and did not have an answer for the increasing percentages. The Continuous Improvement at RMUSA tasked the student project team from the Industrial and Systems Engineering department …

Smart Flow Facility Analysis, Chantal Ann George, Pete Suktankar, Eric Wilson, Matthew Geiger

Senior Design Project For Engineers

The SMART Flow Design Team has been tasked in providing a physical layout for a single building facility used to consolidate three separate business units. The objective for the new facility will be to manufacture, receive, ship, and store the company's finished products. When designing the physical layout, the team must take into consideration stable and seasonal business volumes, current and future volume demand growth, designated inbound, outbound, and storage areas, and product turn rates. All specifications must be met while determining an efficient flow of goods. The team has designed indoor and outdoor layouts using Microsoft Visio, performed various …

90 Day Kit Assessment, Sarah Abdullah, Karim Daoudi, Jennifer Rutledge

Senior Design Project For Engineers

Field Service Products (FSPA) in Atlanta, GA provides Siemens Energy, Inc., with tool sets and systems used to work on Power Generation Equipment. When the FSPA receives the tool systems back from the customer, there is a window of 90 days in which the FSPA must verify that the tool systems were returned complete and operational. If the verification process happens within the 90-day window and something is missing from the system, the FSPA can bill the customer for the missing or damaged items. If the tool system is verified outside of the 90-day window, the FSPA must replace any …

Foster Care Support Foundation Volunteer And Capital Outreach Analysis, Abeer Bhatti, Alexandro Martinez, Sunny Patel, Desmond Vail

Senior Design Project For Engineers

Care Support Foundation (FCSF) provides free goods to children in Georgia. Annually, 11,000 volunteers are needed to deal with the massive influx of donations and fundraising events. Through our analyses, we aim to make recommendations to the FCSF, which can help raise funds and implement mitigating strategies that would increase funds and improve the foundation.

Supply Chain Network Analysis For Outboard Motors At Motor Boaters Usa, Seyedalireza (Ali) Ghiasi, Chase Griffith, Djanene Manuel, Yesenia Pérez, Alvand Rafiee

Senior Design Project For Engineers

Motor Boaters USA found themselves possibly spending too much on their current network distribution of small and large outboard motors and requested new distribution alternatives for the U.S. Through past network distribution data analysis, the team devised 3 scenarios it believed would provide one or more cost effective distribution networks applicable to the request. Through what-if analysis, the teams' calculations produced solid results, which were then presented to Motor Boaters USA for reflection and possible implementation.