Industrial Engineering Commons^™

Development Of A Putting Green Manufacturing Process, Jose Andres Cepeda Santiago

Honors Theses

Our Capstone project investigates the end-to-end design, development, and production of a 6‑foot long portable putting green marketed for individuals seeking a high quality, competitively priced golf product for home or office use. The capstone project examines the full lifecycle of product creation applying manufacturing principles learned through the center of manufacturing’s coursework. From the initial concept through engineering design, market research, prototyping, manufacturing optimization, and final production the project emphasizes cross‑functional collaboration across engineering, business, and accountancy majors. Methods used to gather data included marketing surveys, CAD drawings, time studies during production runs, value stream mapping, and controlled documentation …

Enhancing Control Charting Schemes And Exploring New Assessment Metrics To Advance Quality Control And Cyber-Attack Detection In Manufacturing, Ahmad Al Majali

Dissertations

The increasing integration of digital technologies and industrial control systems in modern manufacturing has introduced new cybersecurity vulnerabilities within cyber–physical production environments. Malicious actors can exploit these vulnerabilities to induce subtle process deviations that degrade product quality while remaining undetected by conventional statistical monitoring tools. Such attacks can be deliberately engineered to manipulate process behavior through transient shifts that vary in magnitude, duration, and frequency. Despite extensive research on transient shifts caused by assignable causes in Statistical Process Control (SPC), limited attention has been given to intelligently designed cyber–physical attacks that exploit the structural characteristics and limitations of control charting …

Project Management Practices In Manufacturing: An Analytical Case Study, Margaret Randle, Robert Reynolds

Honors Capstones

Global industries are undergoing significant transitions in organizational models, technological innovation, and non-economic indicators of product quality, including sustainability and operational efficiency. The current workforce needs to not only develop competency of these technical skills, but also an adaptive, system-oriented approach to problem-solving as well. This case study, which highlights a manufacturing company’s project of increasing production efficiency, presents concepts learned through the textbook Project Management: Achieving Competitive Advantage by Jeffrey K. Pinto. The study thoroughly breaks down the full project lifecycle and the integration of systems of people, data, and initiatives in a framework that can be used to …

Ai-Based Porosity Detection In Babbitt Bore Turning, Kaylee Leggett, Hannah Adams Gemmell, Kaisa Shingleton

Williams Honors College, Honors Research Projects

For this project, an external company reached out to the University of Akron requesting assistance with defect detection during their vertical turning operations. As babbitt is removed in a vertical turning process, it occasionally reveals defects, mainly porosity, which can lead to costly downstream failures of the part. Current inspection techniques involve use of dye penetrant, which is time consuming, labor intensive, unergonomic, and a source of human error. The goal of the project is to create an alternative inspection method using an AI-based machine-learning model. After the turning operation, a camera is deployed to perform an in-place inspection, taking …

Leveraging Synthetic Data For Efficient Training Of Ai Models For Real-World Object Detection, Reinaldo A. Moraga

Graduate Research Theses & Dissertations

Modern computer vision (CV) systems largely depend on real-world data for training, which is costly in terms of time, materials, and resources. As industries push toward automation and Artificial Intelligence (AI) -driven solutions, the need for enabling more efficient model training is growing. The primary aim of this work is to explore a framework tailored for industrial applications that uses synthetic images generated from 3D models to train a CV model capable of real-world object detection. This approach seeks to reduce the time, cost, and resources typically required for training AI models with real-world data. This work presents a method …

Yankee Manufacturing Multi-Assembly Pvc-Gasket Assembly Mechanism, Lily Coss, Jessica Kun, Dana Chapin, Jenan Hasan

Williams Honors College, Honors Research Projects

This project focuses on designing and implementing an efficient mechanism to connect PVC and gasket pieces in the door assembly process at Yankee Manufacturing. The aim is to improve process efficiency and productivity by increasing the assembly rate from 130 to 195 assemblies per hour, a 38% improvement. The project involved research, design iterations, performance evaluations, and adherence to engineering codes and standards, particularly focused on safety, ergonomics, and sustainability. The design process includes addressing challenges from a previous attempt, redefining project scope, and incorporating new elements such as transitioning to the packaging process seamlessly. Ethical considerations include promoting operator …

Productivity And Quality Evaluation In Assembly Using Collaborative Robots, Carlos F. Manzanares Vega

Open Access Theses & Dissertations

In Industry 4.0, various technologies have been applied to achieve automation for traditional manufacturing and practices. For this reason, Smart Manufacturing (SM) environments utilize collaborative robots for process optimization by integrating the Internet of Things (IoT). Cobots are equipped with sensors and/or other devices to be able to transmit data in real-time while performing their tasks. Consequently, such SM implementations improves the decision making and business development, such as supply chain and operations, by sharing real-time data from a plant operational level. The collaborative robots are also designed to safely interact and collaborate with humans to perform tasks and optimize …

Assessing Readiness For Implementation Of Prognostics And Health Management In Small And Medium Enterprises, Sara C. Fuller

Theses and Dissertations

Prognostics and Health Management (PHM) refers to using robust sensing, monitoring, and control to detect, assess, and track system health degradation and failure modes, allowing for enhanced management and operational decisions. The need for PHM within a manufacturing facility has increased due to a variety of reasons, such as the increasing complexity of manufacturing equipment.

A lack of readiness for digital implementations is linked to failure. The literature highlights certain barriers and enablers that can signal whether a technology implementation will be successful, such as management and maintenance employees’ desire to change the existing process, an understanding and willingness to …

Center For Manufacturing Excellence Capstone Project: Sec Rivals Checkers, Ward Winstead

Honors Theses

Each year, the seniors in the Haley Barbour Center for Manufacturing Excellence complete a capstone project. A team comprised of seniors in varying disciplines work to develop a business model focused on producing a specific product. This team, SEC Rivals Checkers, chose to produce wooden checker boards where each half of a board is custom to a specific SEC school. These halves were designed to be interchangeable, so a variety of different combination could be created when utilizing the product. Through initial marketing analysis, cost estimation, prototyping, and process development, the original SEC Rivals Checkers idea was developed into a …

A Dual Perspective Towards Building Resilience In Manufacturing Organizations, Steven A. Fazio

Theses and Dissertations

Modern manufacturing organizations exist in the most complex and competitive environment the world has ever known. This environment consists of demanding customers, enabling, but resource intensive Industry 4.0 technology, dynamic regulations, geopolitical perturbations, and innovative, ever-expanding global competition. Successful manufacturing organizations must excel in this environment while facing emergent disruptions generated as biproducts of complex man-made and natural systems. The research presented in this thesis provides a novel two-sided approach to the creation of resilience in the modern manufacturing organization. First, the systems engineering method is demonstrated as the qualitative framework for building literature-derived organizational resilience factors into organizational structures …

Predicting Zero Bin In The Semiconductor Manufacturing Industry: Machine Learning Algorithms, Yazmin Montoya

Open Access Theses & Dissertations

The semiconductor industry has faced supply chain manufacturing shortages that ultimately led to a worldwide chip shortage during the COVID-19 pandemic. These chip manufacturers use sophisticated and advanced manufacturing machinery in their fabs to manufacture chips. As experienced during the pandemic, manufacturing unavailability is often due to the lack of critical manufacturing-related spare parts. This thesis evaluates the effectiveness of machine learning algorithms to identify significant factors contributing to manufacturing part outages (i.e., zero-bin) to keep manufacturing equipment running at total capacity within the organization. We propose clustering methods to segment the data and use logistic regression, logistic lasso regression, …

Fasten: An Iot Platform For Supply Chain Management In A Covid-19 Pandemic Scenario, Fernando Lemos, Thays Do Nascimento, Gustavo Dalmarco

Markets, Globalization & Development Review

This paper points out the major disruptions caused by the COVID-19 pandemic. It proposes an automated Internet-of-Things (IoT) based manufacturing and supply chain system, termed FASTEN, that can deal with such severe disruptions.

Strategies For Implementing Internet Of Things Devices In Manufacturing Environments, Todd Efrain Hernandez

Walden Dissertations and Doctoral Studies

The Internet of Things (IoT) has been exploited as a threat vector for cyberattacks in manufacturing environments. Manufacturing industry leaders are concerned with cyberattacks because of the associated costs of damages and lost production for their organizations. Grounded in the general systems theory, the purpose of this multiple case study was to explore strategies electrical controls engineers use to implement secure IoT devices in manufacturing environments. The study participants were eight electrical controls engineers working in three separate manufacturing facilities located in the Midwest region of the United States. The data were collected by semistructured interviews and 15 organizational documents. …

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 …

Product Realization Capstone: Element Proof Safety Steps For Willie Price Lab School, Catherine Thomas, Allan Heuerman, Jared Mumme

Honors Theses

The purpose of this document is to describe the process we took to complete our capstone which paired the Center for Manufacturing Excellence with the Willie Price Lab School. The goal of the capstone was to remake step stools for the students of Willie Price, as the last stools failed to withstand weather damage. However, with the COVID-19 pandemic, plans were hindered, shifting the goal from actually producing the steps to creating instructions so that a younger Center for Manufacturing class could complete the production at a later date. Standardized Work Instructions, a detailed production plan, and engineering drawings were …

Development Of An Additive Manufacturing Compression Molding Process For Low Cost In-House Prototyping, Grant Forrester Warden

Industrial and Manufacturing Engineering

Composite parts can be manufactured using various processes. Generally, a mix of resin and fiber is formed into the desired geometry using a mold and pressure. One process used by Dr. Joseph Mello in his research is known as compression molding. Compression molds are generally made from large billets of aluminum or stainless steel, are machined by a CNC mill, and are then hand-finished with polishes and mold preparation products. This process is expensive, requires large machinery and experienced operators, and introduces long lead times relative to the design cycle of the part being manufactured. The nature of Dr. Mello's …

Slm Materials Development, Justin G. Reiner, Michael T. Schembri

Industrial and Manufacturing Engineering

The purpose of this project was to create a procedure to efficiently determine a “recipe” of parameter values that create a desired set of mechanical properties. Research was conducted into the laser powder bed fusion process with focus on underdeveloped materials. A design of experiment was used with a set of density correlated parameters to establish a method of producing nearly dense parts. Our methods include SLM printing, metrology, and statistical analysis. An experimental procedure for materials development was designed, but unable to be validated during the scope of this project, due to unforeseen safety issues (exposure to Chromium 6, …

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 …

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 …

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 …

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 …

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 …

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. …