Industrial Technology Commons^™

Digital Lean Transformation Through Mes–Scada Intergration: Reducing Transactional And Cognitive Waste In High-Volume Electronics Manufacturing, Kamal Alalul

Graduate Dissertations and Theses

This research addresses inefficiencies in Manufacturing Execution System (MES)-driven workflows, where excessive user interactions and fragmented access to work instructions introduce transactional and cognitive waste. To address these limitations, an integrated architecture was developed using Ignition as a SCADA-based operator interface connected to the MES through API-based communication. The system replaces direct MES interaction with a unified interface that embeds work instructions and automates transaction execution within the production workflow. The approach was implemented and evaluated through an industrial case study on a 15 station electronics manufacturing line. Results show a 51% reduction in total cycle time, decreasing from 2,996 …

Cross-Facility Reliable Deep Learning Based Beef Marbling Assessment Via Unsupervised Domain Adaptation Regression, Samuel Vinson

Biological and Agricultural Engineering Undergraduate Honors Theses

Inconsistent quality grading in beef production leads to inefficiencies, economic disparity, and consumer mistrust. While USDA meat grading traditionally relies on skilled visual inspectors, these human evaluations suffer from cross-facility variability and subjectivity. This paper introduces the first known application of unsupervised domain adaptation regression for cross-facility beef marbling score prediction—an innovation that improves generalization across diverse environments in the beef supply chain. Utilizing numerical scores ranging from 100-900, the research employed convolutional neural networks (CNNs), including ResNet, VGG, and AlexNet architectures. The study specifically introduced and validated a unified unsupervised domain adaptation regression method using the ResNet-50 architecture to …

Feasibility Study Of Transitioning From Thick Plates (0.250”) Mounted On 30-Point Pvc Carriers To Thinner Plate Technologies Mounted On Recyclable Foam And Pet (0.155”) For Post-Print Corrugated, Nathaniel J. Poole

All Theses

In the United States, the most common press configuration for brown-box printing is a 0.280” undercut press. These press configurations have long relied on thick 0.250” plates mounted on 0.030” PVC sheets to print onto corrugated substrates. Each year, around twenty million pounds of waste are produced by the printing industry, through paper waste, plate waste, among other materials. One large factor of that waste is flexographic plate waste, which either ends its life in a landfill or is repurposed into other products. This study establishes a comparison between traditionally used 0.250” plates on 30pt PVC versus 0.155” plates mounted …

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 …

A Capability Maturity Model For Artificial Intelligence Integration In Supply Chain Management, Lordt Becklines

Dissertations

Artificial Intelligence (AI) is transforming Supply Chain Management (SCM), yet many organizations struggle to assess their readiness for AI adoption and to understand how AI capabilities develop across maturity stages. This dissertation addresses this gap by developing a Capability Maturity Model (CMM) for AI integration in SCM, grounded in Organizational Information Processing Theory (OIPT), the Resource-Based View, and related capability frameworks. The model provides a structured approach for evaluating an organization's information-processing requirements, resource configurations, and alignment needed for effective AI-enabled supply chain operations.

Using a design science research approach, the AI-SCM CMM and its associated assessment instrument were derived …

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 …

The Design And Effect Of Continuum Robot Compliance On Locomotion, Parsa Molaei

LSU Doctoral Dissertations

Continuum robots, due to their compliant structures and ability to navigate through constrained environments, offer significant advantages in applications requiring safe physical interaction and dexterous motion. However, challenges related to limited structural stiffness, payload capacity, and precise control remain open problems in the field. This dissertation presents novel contributions aimed at addressing these limitations through two main actuation units of continuum robots: tendon-driven continuum robots (TDCRs) and concentric tube robots (CTRs). In the first part, we focus on methods to improve the stability and modify the stiffness of the TDCR. A tendon decoupling strategy is introduced for planar TDCRs. The …

Ease Of Product Disassembly Through A Systematic Structured Time-Based Design For Disassembly Methodology, Emeka S. Igwe

College of Graduate Studies: Theses & Dissertations

This research introduces a systematic time-based design for disassembly (DfD) framework aimed at optimizing product disassembly by addressing important features like liaisons between components in product, component accessibility and the overall modularity of the product. This study specifically covers electromechanical and mechatronic systems in both household and industrial setup, identifying their disassembly challenges and high value pointers for improvement. The methodology involves using a design for disassembly framework called LeanDfD in carrying out a holistic disassembly process and evaluating quantitative metrics like disassembly time and complexity and suggesting further redesign strategies to minimize disassembly time and cost. Adopting this systematic …

A Comprehensive Usability And Economic Analysis Of Heat-Related Wearable Technologies: Applications To Occupational Health, Ryan T. Cannady

Theses & Dissertations

The purpose of this research was to analyze the usability and economic considerations of real-time wearable technologies that are implemented in occupational settings to assess risk of heat stress and heat strain. The study population included current agriculture workers and Department of Energy (DOE), Environmental Management (EM) contractors. We employed a mixed-methods approach to comprehensively analyze the usability and economic considerations of heat-related technologies. Specifically, our approach assessed three distinct aspects the applications of these technologies in occupational settings to comprehensively address our research objective: (1) worker perceptions of heat-related wearable technologies, (2) field-based assessment of these heat-related wearable technologies, …

Autonomous Experimentation For Accelerated Calibration Of Fused Deposition Modeling 3d Printers, Graig S. Ganitano

Theses and Dissertations

Additive Manufacturing (AM), also known as 3D printing, has emerged as a key component of Industry 4.0, enabling reduced cost, quick production, greater sustainability, and increased design complexity compared to its traditional manufacturing counterpart. Currently, Fused Deposition Modeling (FDM) technology dominates the AM market with respect to the number of 3D printers in use. However, the FDM process is sensitive to changes in system configuration, especially the feedstock material. Utilizing a new feedstock requires a time-consuming trial-and-error process to identify optimal settings for a large number of process parameters, acting as a barrier to the technology.

To enable greater accessibility …

Dynamic Model Of An Overhead Crane, Leonard Ruesga

UNLV Theses, Dissertations, Professional Papers, and Capstones

In this thesis a novel spatial model of an overhead crane was developed. The model includes: bridge, trolley, driving and follower wheels for the bridge and trolley, drum, cable, and the payload. The model accounts for the winding/unwinding of the cable around the drum as the payload is raised/lowered. The cable and the payload were considered as rigid bodies with uniformly distributed mass. First, the kinematic equations of the model were developed by using constraint equations. Second, the dynamic equations were derived through use of Newton’s Laws. Developing the rotational dynamic equations required the determination of the angular momentum vectors …

A Screening Life Cycle Analysis Of One-Way And Reusable Crate Designs – Estimating Environmental Impacts Via Lca Software, Nicolas R. Corona

Master's Theses

A comparison analysis conducted via COMPASS life cycle analysis software has indicated that a one-way crate design, rather than a reusable crate design, is in fact the more environmentally friendly packaging system. These results can be interpreted differently, however, as the manufacturer of said crate designs must confirm what impact indicators they would like to reference as environmental goalposts. The conducted analysis provides insight into what the environmental impacts of each packaging system look like as packaging at all three system levels has been identified as a means of reducing environmental impacts globally. As such, the manufacturer of said crate …

Predicting Rheology Of Uv-Curable Nanoparticle Ink Components And Compositions For Inkjet Additive Manufacturing, Cameron D. Lutz

Master's Theses

Inkjet additive manufacturing is the next step toward ubiquitous manufacturing by enabling multi-material printing that can exhibit various mechanical, electronic, and thermal properties. These characteristics are realized in the careful formulation of the inks and their functional materials, but there are many constraints that need to be satisfied to allow optimal jetting performance and build quality when used in an inkjet 3-D printer. Previous research has addressed the desirable rheology characteristics to enable stable drop formation and how the metallic nanoparticles affect the viscosity of inks. The contending goals of increasing nanoparticle-loading to improve material deposition rates while trying to …

Waste Illuminates Worlds: Printed Modular Lamp Design Based On Brick And Clay Tile, Yechen Zhu

Masters Theses

The building industry in the New England area is often in a state of entropy, with abandoned brick buildings contributing to urban decay. The recycling rate of brick and clay tile wastes generated by construction and demolition is only 12.2%, meaning the majority is sent to landfills. The expansion of landfills can lead to significant environmental and community challenges, including increased traffic from waste transport, habitat destruction, ecosystem degradation, and contributions to climate change. Specifically, the Bethlehem landfill in New Hampshire, which is planned to undergo a 5.71-acre lateral expansion through 2026, has already encountered issues such as leachate spills …

Cyber Attacks Against Industrial Control Systems, Adam Kardorff

LSU Master's Theses

Industrial Control Systems (ICS) are the foundation of our critical infrastructure, and allow for the manufacturing of the products we need. These systems monitor and control power plants, water treatment plants, manufacturing plants, and much more. The security of these systems is crucial to our everyday lives and to the safety of those working with ICS. In this thesis we examined how an attacker can take control of these systems using a power plant simulator in the Applied Cybersecurity Lab at LSU. Running experiments on a live environment can be costly and dangerous, so using a simulated environment is the …

Containerization Of Seafarers In The International Shipping Industry: Contemporary Seamanship, Maritime Social Infrastructures, And Mobility Politics Of Global Logistics, Liang Wu

Dissertations, Theses, and Capstone Projects

This dissertation discusses the mobility politics of container shipping and argues that technological development, political-economic order, and social infrastructure co-produce one another. Containerization, the use of standardized containers to carry cargo across modes of transportation that is said to have revolutionized and globalized international trade since the late 1950s, has served to expand and extend the power of international coalitions of states and corporations to control the movements of commodities (shipments) and labor (seafarers). The advent and development of containerization was driven by a sociotechnical imaginary and international social contract of seamless shipping and cargo flows. In practice, this liberal, …

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 …

Reliability Modeling And Improvement Of Critical Infrastructures: Theory, Simulation, And Computational Methods, José Carlos Hernández Azucena

Graduate Theses and Dissertations

This dissertation presents a framework for developing data-driven tools to model and improve the performance of Interconnected Critical Infrastructures (ICIs) in multiple contexts. The importance of ICIs for daily human activities and the large volumes of data in continuous generation in modern industries grant relevance to research efforts in this direction. Chapter 2 focuses on the impact of disruptions in Multimodal Transportation Networks, which I explored from an application perspective. The outlined research directions propose exploring the combination of simulation for decision-making with data-driven optimization paradigms to create tools that may provide stakeholders with optimal policies for a wide array …

An Examination Of The Role Of Industry 4.0 In Supply Chain Management: Critical Success Factors And A Roadmap, Alper Senol

Electronic Theses and Dissertations, 2020-2023

Global supply chain management aims to enhance efficiency and profitability for suppliers, manufacturers, logistics providers, and warehouses. It faces challenges due to the complexity involved. To stay competitive, organizations in the industry are leveraging Industry 4.0 technologies, but some struggle with implementation due to limited expertise. The primary challenge of Global Supply Chain Management now is to integrate Industry 4.0 tools and technologies to maintain high-quality standards and optimized processes. This study focused on identifying the key factors that directly affect the success of integrating Industry 4.0 into the supply chain. It examined both tangible and intangible business resources and …

Ai Methods For Identifying Process Defects In Advanced Manufacturing With Rare Labeled Data, Ayantha Umesh Senanayaka Mudiyanselage

Theses and Dissertations

This dissertation aims to provide efficient process defect identification methods for advanced manufacturing environments using AI tools/algorithms with limited labeled data availability. Asset and equipment quality become highly sensitive in sustaining virtuous performance and safety in various manufacturing domains. Internally generated process imperfections degrade finished products' optimum performance and mechanical attributes. The evolution of big data and intelligent sensing systems leverage data-driven defect identification in advanced manufacturing environments. Widely adopted data-driven process anomaly detection methods assume that the training (source) and testing (target) data follow the same distribution and that labeled data are available in both source and target domains. …

Fungi In Flux | Designing Regenerative Materials And Products With Mycelium, Arvind Bhallamudi

Masters Theses

As the world grapples with the escalating crisis of climate threats and environmental degradation, this research delves into the synergistic potential of design and biology, developing safe and sustainable materials for applications in prototyping, furniture and interior design. Harnessing the power of a unique organism - fungi, the study proposes an accessible, efficient, and resilient material resource system. It utilizes local waste streams and mycelium (the vegetative part of fungi) to grow functional structures. An experimental and small-scale protocol is modeled by testing bio-fabrication and bio-printing methods. The composites' performance qualities and characteristics are evaluated through mechanical testing and a …

Cybersecurity In Industrial Automation Lab Design For Ee 435, Jules Khalil Emile Hajjar, Emily Zhou

Electrical Engineering

This project involves the creation of an instructional laboratory aimed at teaching cybersecurity for industrial automation applications. Specifically tailored for Electrical Engineering students at Cal Poly, the experiment focuses on configuring the Modicon M580, a PLC from Schneider Electric, and serves to introduce students to relevant cybersecurity protocols and techniques. This project will be implemented into the EE435 (Industrial Power Control and Automation) course curriculum upon Cal Poly’s transition to the semester system.

Developing Systems Engineering And Machine Learning Frameworks For The Improvement Of Aviation Maintenance, Fatine Elakramine

Theses and Dissertations

This dissertation develops systems engineering and machine learning models for aviation maintenance support. With the constant increase in demand for air travel, aviation organizations compete to maintain airworthy aircraft to ensure the safety of passengers. Given the importance of aircraft safety, the aviation sector constantly needs technologies to enhance the maintenance experience, ensure system safety, and limit aircraft downtime. Based on the current literature, the aviation maintenance sector still relies on outdated technologies to maintain aircraft maintenance documentation, including paper-based technical orders. Aviation maintenance documentation contains a mixture of structured and unstructured technical text, mainly inputted by operators, making them …

Automation Of Life Cycle Assessment, Jacob Hickman

Graduate Theses and Dissertations

An automation program, named Jacob LCA, was created to help perform life cycle assessment (LCA). The program uses a template file to perform controlled and consistently ordered actions with the LCA program, SimaPro, and effectively removes the need for manual user input. It can be set to run using data from one or more life cycle inventory (LCI) files, which allows for rapid iteration and testing of data. It also partially addresses some of the limitations of LCA by establishing a procedure through which temporal and spatial variations in data can be integrated into LCI files and then passed to …

Efficient Routing For Disaster Scenarios In Uncertain Networks: A Computational Study Of Adaptive Algorithms For The Stochastic Canadian Traveler Problem With Multiple Agents And Destinations, Neel Chanchad

Graduate Theses and Dissertations

The primary objective of this research is to develop adaptive online algorithms for solving the Canadian Traveler Problem (CTP), which is a well-studied problem in the literature that has important applications in disaster scenarios. To this end, we propose two novel approaches, namely Maximum Likely Node (MLN) and Maximum Likely Path (MLP), to address the single-agent single-destination variant of the CTP. Our computational experiments demonstrate that the MLN and MLP algorithms together achieve new best-known solutions for 10,715 instances. In the context of disaster scenarios, the CTP can be extended to the multiple-agent multiple-destination variant, which we refer to as …

Development Of Detection And Tracking Systems For Autonomous Vehicles Using Machine Learning, Tyler Ward

Morehead State Theses and Dissertations

A thesis presented to the faculty of the Elmer R. Smith College of Business and Technology at Morehead State University in partial fulfillment of the requirements for the degree of Master of Science by Tyler Ward April 25, 2023.

Fast And Accurate 3d Object Reconstruction For Cargo Load Planning, Adam R. Nasi

Theses and Dissertations

Cargo load planning involves efficiently packing objects into aircraft subject to constraints such as space and weight distribution. Currently, this is performed manually by loadmasters. The United States Air Force is investigating ways to automate this process in order to improve airlift operational readiness while saving money. The first step in such a process would be generating 3D reconstructions of cargo objects to be used by a load planning algorithm. To that end, this thesis presents a novel method for fast, scaled, and accurate 3D reconstruction of cargo objects. This method can scan a 2.5m×3m×2m object in less than 10 …

Automated Registration Of Titanium Metal Imaging Of Aircraft Components Using Deep Learning Techniques, Nathan A. Johnston

Theses and Dissertations

Studies have shown a connection between early catastrophic engine failures with microtexture regions (MTRs) of a specific size and orientation on the titanium metal engine components. The MTRs can be identified through the use of Electron Backscatter Diffraction (EBSD) however doing so is costly and requires destruction of the metal component being tested. A new methodology of characterizing MTRs is needed to properly evaluate the reliability of engine components on live aircraft. The Air Force Research Lab Materials Directorate (AFRL/RX) proposed a solution of supplementing EBSD with two non-destructive modalities, Eddy Current Testing (ECT) and Scanning Acoustic Microscopy (SAM). Doing …

Generalizable And Adaptable Data-Driven Methods For Overcoming Barriers To Practical Industrial Condition Monitoring, Matthew B. Russell

Theses and Dissertations--Electrical and Computer Engineering

The future of smart manufacturing relies on predictive maintenance systems that intelligently minimize expensive downtime through timely assessment of machine condition. Deep Learning (DL) has achieved excellent performance in industrial condition monitoring experiments, but the constraints of the manufacturing environment prevent many algorithms from being practically deployed on the factory floor. Ubiquitous sensing from online machines generates high velocity data streams that require new techniques for efficient transmission and storage. Despite these ever-increasing data lakes, many applications still lack the data needed for training DL fault diagnosis and wear tracking models since most data is unlabeled and only from nominal …

Evaluating Electrification Of Fossil Fuel-Fired Boilers For Decarbonization Using Discrete Event Simulation, Nahian Ismail Chowdhury

Graduate Theses, Dissertations, and Problem Reports (ETD)

Decarbonizing fossil fuel usage is crucial in mitigating the impacts of climate change. CO2, which comprises the major portion of greenhouse gas, is emitted from burning fossil fuels. One of the significant sources of fossil fuel user is industrial process heating, and most of the heating in industrial processes is achieved through boilers. Electrification is a promising solution for decarbonizing these boilers, as it enables renewable energy sources to generate electricity, which can then be used to power the electric boilers. The electrification of boilers can reduce greenhouse gas emissions, improve air quality, and increase energy efficiency. However, it requires …