MSE Project Topics

  • Ensuring Reliability in Low-Volume Manufacturing

Volvo Construction Equipment (VCE) bought the Road Machinery Division from the IR Corporation with the intention of immediately, and fully, integrating the acquisition into VCE. Reliability growth testing is a concept introduced by Volvo to ensure successful product development launches. This paper examines the reliability methodology and the challenges facing the Road Machinery business as they attempt to implement reliability growth testing in a low-volume manufacturing environment.
         
The reliability growth testing process was developed for businesses with much higher volume and more resources in their design and test groups. In addition to a lack of resources, the problem facing Road Machinery is that the statistical underpinning for the process assumes that both high volumes of prototypes and large amounts of time will be readily available. In the case of Road Machinery these assumptions do not make economic sense due to the low-volume nature of the business. This paper explains the proposed modifications to the original Volvo Reliability Growth Testing process.

  • The Progression towards Paperless Systems

Interviews, literature predictions, and research of subjects related to manufacturing transformations and the office of the future is the basis of research that explores the transition to paperless digital systems in manufacturing and office operations.
         
Results indicate that paper will continue to occupy a vital position in the office but a less strategic position in the manufacturing world. The use of paper is directly connected to the type of work functions performed by individuals within the organization. Use of paper could even be considered an addiction or human support element based on the need of some workers to have a physical medium present in order to perform daily tasks (i.e. thinking, creating, editing, etc.), looking busy, appearing important, or seeming to be productive.  The research suggests a slow conversion to paperless digital systems, as new technology comes on-line and new generations of workers, proficient with digital technology, take their place in the workforce. In a properly configured work or manufacturing environment, paperless digital systems can be an improvement through the application of Lean Technology. With proper planning, the conversion to digital paperless systems can continue to expand into and improve the business environment.

  • CNH Supplier Guide - Welding SAE 1045 Steel to ASTM A36 Steel

    Case New Holland (CNH) utilizes an extensive array of materials when designing construction and agricultural equipment. An incredible array of various steels are used in almost all CNH equipment. Due to material complexity, many unique welded joints must be designed into the products each needing a specific and proven Welding Procedure Specification (WPS). Each WPS must be followed to avoid a failure of the welded joint in the field. The main goal of the project is to develop supporting information on the CNH welding standards for use by outside suppliers of weldments. Actual examples, in addition to written documents and specifications, will assist a supplier’s understanding of the process of welding these types of joints. By educating outside suppliers on the importance of using correct preheats when welding 1045 steels to A36 steels or other mild carbon steels, we expect to achieve a reduction of field failures rates.

The objective is to develop a supplier guide to welding 1045 steel to A36 steel plate while maintaining acceptable HAZ hardness levels to help suppliers understand the acceptable practice to weld 1045 steels to low carbon steels such as A36 plate. The guide references all applicable CNH specifications and guidelines for welding such materials to reduce the potential for suppliers to overlook necessary requirements. Process suggestions and Gas Metal Arc Welding (GMAW) typical settings to successfully weld the materials are provided along with actual weldment examples of 1045 steel shafts to A36 steel plates. Data includes weldment cut and etched samples with microhardness readings that are from various preheat temperatures and thicknesses of 1045 shafts to A36 steel plates. Various preheat temperatures result in both good and bad microhardness readings. These results will aid suppliers in the understanding of the effects of preheat temperatures and what hardness levels result within these ranges. Samples, fabricated with both 1” and 3” diameter 1045 steel shafts, show the effects of heat sinking characteristics of larger sections over smaller sections and how shaft diameter affects resulting micro-hardness.  

  •  Anodizing Line at Pulse Technologies, Inc.

    Titanium Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of titanium components, with minimal dimensional change. Titanium anodizing is classified in four types; the focus of this project is Titanium Anodizing Type III, which offers a perceived spectrum of surface colors on titanium components without offering anti-galling or wear resistivity. In the medical industry this process is widely used in orthopedic components such as bone screws and plates, to ease the identification of the component to be implanted, by using specific colors according to the size, without having to use measuring devices during surgery.
    The purpose of this report is to document the evolution of this process implementation at Pulse Technologies, Inc., from the installation of the equipment to the present day, exposing some of the problems encountered in the development of the project and the executed solutions.

  • Kryptonite Needle Project

    This project was started as part of an existing relationship between Ethicon and Bihler of America, Inc. BOA is a contract manufacturer that produces surgical needles for Ethicon. Ethicon tapped BOA to manufacture a new type of needle with improved characteristics over current needle offerings.
    Ethicon’s plan is to introduce a superior needle which will retain current customers and win back any customers that have moved to a competitor’s product. BOA’s overall goal for the project is to manufacture a needle that meets or exceeds Ethicon’s expectations.The goal of this portion of the project is to develop the necessary documentation to move the project forward. The project has gone through many Quality and Management aspects of the coursework involved in the MSE program. BOA will be moving forward as anticipated. The plan for the next steps in the process entails proceeding with Development and Qualification of the needles and manufacturing equipment.

    • Availability Provider and General Contractor: Business Models to Achieve Sustainment Growth for Lockheed Martin Aeronautics
      Global Sustainment has been given the objective of increasing projected 2015 sustainment revenues by 10%. Two large market segments that require sustainment services for their aircraft are Readiness Buyers and Basic Needs Buyers. To succeed in both of these business models seven projects will be executed to meet commitments in terms of revenue growth, and perhaps more importantly meet commitments to keep customers’ aircraft at peek performance. These projects include the following: brand LM as a committed provider of sustainment, create the internal IT architecture, align the solution invention process, improve field operations reporting, align supply chain management organizations, institutionalize lifecycle product management, improve cost competitiveness.

    • Postmortem Analysis of Initial Production Phase

    Multiple aspects from the initial request for quotation (RQD) to contract close will be reviewed in a postmortem analysis. It examines personnel changes, engineering and material costs and quoted versus actual time to determine how each phase affects both the successes and failures of the overall project.

    • Establishing A Cycle Count Process in a Biological Pilot Plant

    This research project examines the development and implementation of a cycle counting process in a pilot plant facility in a pharmaceutical company.  The pilot plant primarily manufactures vaccines and other bio-molecules for Phase I & II clinical trials and uses a vast array of chemicals in their production. The project focuses on the development of the current state through the formalization of the cycle count procedure.  It addresses the obstacles that were faced by the project manager by offering data-driven solutions, identifying the critical success factors, and explaining the lessons learned during the process.  A future strategy is offered by identifying five key areas where the process could be incorporated.

    • Push-Button Line 3 Validation

    The project objectives are to validate an additional automated assembly line and to upgrade the existing equipment with improvements. The line assembles a safety medical device in various configurations. This device helps to protect healthcare workers who are at risk from the hazards of accidental needle sticks during routine blood draw procedures.
             
    During the installation, qualification procedures and line readiness were verified. The operational qualification challenged the machine at process parameter extremes to verify that quality product could be made within specifications.
             
    Without a strong project champion and also a lack of dedicated resources impacted progress. Nevertheless project deliverables were met ahead of schedule.

    • Liquid Dispensing Technology: An Innovative Pharmaceutical Manufacturing Platform for the 21st Century

    The System known as Liquid Dispensing Technology has revolutionized the way highly potent / low dose drug products are developed and manufactured at GlaxoSmithKline (GSK). This paper examines the platform technology’s basic operation and features (such as continuous processing, modular flexibility, process analytical technology and the potential for real-time product release), its functional performance compared to traditional pharmaceutical unit operations, and a cost comparison to traditional processes, as well as some of the technological challenges.

    • Ultra High Molecular Weight Polyethylene (UHMWPE) Study for Use in the Material Handling Industry

    The scope of the research undertaken for Garvey is to find a suitable replacement material that can be used in clean room applications, and also find a material that is more easily machined and can handle tighter tolerances needed on accumulators and conveyors.

    • Optimizing Human Input to a Manufacturing System by Utilizing the Measurement and Prediction of Human Performance (thesis)

    Although human input has been recognized to have a significant impact on the system, optimization of human input has not had much academic attention or significant attention in industry. This study examines the case for including operator assessment during the hiring process using pre-employment assessment testing. It presents the methodology behind the science of human performance predictors and connects this science of psychometric testing with current pragmatic assessment testing service offerings that are steadily growing internationally. The current state of the assessment testing industry and market are presented along with trends seen in industry.

    • Construction Jobsite 4-D Real-Time Modeling Data and Methods for Standardized Crane Motion Simulation and Study

    An original 4-D model was created to represent crane motion on a construction jobsite. It comprised positional data in terms of a standardized X, Y, Z coordinate frame-of-reference, and also a standardized time-frame for the crane kinematic behavior. The time-frame is expected to be consistent with computations for construction operations simulation models. One test application of the model and a CSX file utilized a CAD system to produce crane motions and a CSX file; another used crane lifting parameters as input to a computer program which automatically generates potential lifting motions and a CSX file. The CSX file was used to demonstrate an animation of the crane operation and indicated that the 4-D model data and methods are valid for various crane operations on construction jobsites and can now be included in simulation and operational improvement programs.

    • Dedicated Flow and Level Production of Hot Tamales at Just Born, Inc.

    Hot Tamales manufacturing and scheduling processes were examined at Just Born, Inc. Data from the production process was mapped graphically along with problems and issues associated with current processes. Utilizing a series of lean elements, opportunities were identified to solve the current problems and improve the Hot Tamales processes. Actionable items were recommended and deadlines established. Metrics were developed to ensure the project stays on schedule and improvement align with corporate objectives.

    • Effects of a Hybrid Six Sigma/Systems Engineering Approach to Overtime Reduction or Output Increase Related to the Hourly Union Workforce at Merck and Company

    Extension of Six Sigma processes aimed at reducing overtime expenditures and increasing the amount of testing done by the union workforce in order to increase efficiency or optimize environmental sampling utilizing six sigma tools and also automation and supply/logistical principles. Bottom line efficiency increases will serve as a quantitative indicator of success along with qualitative outcomes related to union workforce reaction.

    • Market Assessment, Entry, and Product Strategy in the Nuclear Arena from Chemical Processing and Aerospace and Defense Industries.

    In the past five years, the commercial nuclear industry is experiencing a resurgence worldwide and a renewed interest in nuclear power as a suitable substitute to fossil fuels in the U.S. Due to the nearly thirty years of inactivity after the Three Mile Island incident, new participants are entering into the nuclear market from adjacent markets such as chemical processing and aerospace and defense. This paper follows a company’s market assessment and entry strategy, including the development of a product strategy and implementation of the strategy.

    • Merck & Company’s Operational Database Used for Varicella Process Improvements and Robot Reliability

    Automated systems manipulate, control and monitor the Varicella manufacturing process. Robots manipulate roller bottles that contain the cells and virus. A tracking system for processing delays was implemented in January 2010. The operability database tracks and trends delay details in processing. Reoccurring issues become opportunities as a priority project for process improvements and robot reliability. These specialized projects drive down process issues and ensure a higher quality product.