As the problem solvers for the manufacturing and service industries, our industrial engineers design factories, production systems, and service systems. They are also involved in reengineering existing factories and systems to use resources effectively and increase productivity in fields such as quality engineering, ergonomics, production planning and control, facilities management and project planning. Manufacturing engineers design the methods by which products are manufactured. This program focuses on materials and processes, product engineering and assembly, and manufacturing quality and productivity.

Virtual Factory Model of Spirit's Plant II with Major Assets

MEMBERS: Travillion Denno; Benjamin Heide; Cade Heikes

ADVISOR: Dr. Cindi Mason

TABLE: 233

The facilities team at Spirit AeroSystems needed to effectively manage and understand assets and their states in order to support operations activities impacted by key equipment. As it was, critical information on assets, particularly cranes, was not readily available in a user-friendly system. If one needed specs on a crane, they would need to walk great distances to acquire proper measurements. Furthermore, managers had no way of simulating the impacts of moving machinery or changing processes around large equipment, leaving projects of that nature carrying burdensome risks. The countermeasure devised was a virtual factory. The team utilized 2D layout drawings of Spirit’s Plant II to create a 3D replica in the Autodesk software package Navisworks. 3D models of cranes and critical assets, some provided and some generated by the team, were integrated into this virtual plant in their appropriate absolute coordinates per Spirit standards. Data not implicit to the asset models was collected and displayed in windowpanes that could be accessed by an end user through simple point and click interfacing. The final deliverable was a simulation ready file that would allow users to maneuver through Plant II virtually and interact with key assets and their relevant information.

Ascension Hand Hygiene

MEMBERS: Ghuzlan Aldhufairi; Joseph Holthusen; Cynthia Morin; Mahfuzur Rahman

ADVISOR: Dr. Cindi Mason

TABLE: 232

The simplest and most effective measure for preventing healthcare-associated infections is hand hygiene. Overall hand hygiene compliance amongst healthcare workers in the hospital settings falls under fifty percent across the nation. Hand hygiene compliance is associated with healthcare workers perception and knowledge. Using a modified version of the Perception Survey for Health-Care Workers created by the World Health Organization (WHO), a study was conducted on health care workers at three Ascension Via Christi Hospitals in Wichita, KS. The goal of the study is to focus on healthcare perceptions of hand hygiene from behavioral, cultural, environmental, educational and knowledge standpoints. Based on the results, both interventions and recommendations to help increase hand hygiene compliance at each Ascension Via Christi Hospital will be available, hopefully helping to reach their target compliance rate of ninety percent each month.

737 Max Pylon Line Balancing

MEMBERS: Natalie Dreher; Allen Hommertzheim; Channing Kimble

ADVISOR: Dr. Cindi Mason

TABLE: 231

Spirit AeroSystems is preparing for a potential change in demand for the 737 Max. This project involves improving the efficiency of the production line for the pylon. The team will improve efficiency by utilizing line balancing to reduce downtime and bottlenecks. The team will design 3 different production lines based on takt times necessary to achieve 3 different production rates.

Spirit Aerosystems' Rack-within-a-Rack

MEMBERS: Zachary Carman; Anh Kieu; Luke Winter

ADVISOR: Dr. Cindi Mason

TABLE: 230

At Spirit AeroSystems, we were tasked with proposing ways to decrease the footprint of non-value-added areas in the Chemical Finishing Center. Our project required us to analyze the current layout and process flow of the chemical milling area to determine where space could be created. This space would be used by parallel projects to increase flow through the process. Our team used Facilities Planning and LEAN concepts to rearrange the process flow and redesign support equipment to allow for Parallel Processing and reduction of WIP inventory and footprint.

Pemier Food Services Preventive Maintenance Program

MEMBERS: Kawther Alawami; Talal Alrashidi; Abdulaziz Alzeed; Unchenna Ukwu-Nwoga

ADVISOR: Dr. Krishna Krishnan

TABLE: 229

The purpose of this project is to create a preventive maintenance (PM) schedule for the coffee machines managed by Premier Food Services (PFS). The PFS reactive maintenance program leads to increased maintenance, which causes the company to waste a lot of money, prevents them from serving accordingly, and thus, lose customers. The PFS reactive maintenance program will be replaced with the PMs in order to ensure standard maintenance, reduce cost, and improve customer morale.

Western Industries Plastics Products: Warehouse Layout & Flow Optimization

MEMBERS: Ahmad Alali; Nicolette Blasgen; Gracie Delisi; Adam Scott

ADVISOR: Dr. Cindi Mason

TABLE: 200

Western Industries Plastic Products LLC specializes in manufacturing plastic blow mold products. The company is rapidly expanding and needs IE skillsets implemented in their everyday operations to help organize and manage their current warehouse inventory. Our goal is to reduce material movement distances, handling cost of materials, and inventory costs. Our scope includes the west warehouse where a production line and a steady number of SKUs is stored. After information is collected, the team will work to research and create a solution for a new warehouse layout. Our team plans to supplement these goals by utilizing facilities planning and lean techniques, such as 5S, Kanban, and continuous improvement. Upon completion of this project, we will deliver a solution for implementation to management, the operations team, and the receiving/shipping teams. Western Industries can use our solution for proper product storage and product movement within the warehouses. We hope to provide a long-term, flexible solution that Western Industries can continue to utilize with their increasing and dynamic demand.

Boeing 767 Value Stream Mapping at Spirit Aerosystems

MEMBERS: Salem Al-Mansor; Brighton Brown; Christelle Nassif

ADVISOR: Dr. Cindi Mason

TABLE: 202

The following is an in-depth look at value stream mapping at Spirit Aerosystems on the Boeing 767. The group has identified starbursts and problem areas in the “current state” map and addressed bottleneck issues with a variety of solutions. Using data, discussion and interviews with shop floor workers, and a combination of Industrial Engineering tools, the team has worked to develop solutions to eliminate waste in the problematic areas on the 767 line, specifically on the side panels and lower lobe. These changes are reflected in the “future state” map, along with measurements to quantify how the changes have improved the process. The team has systematically identified bottlenecks by choosing the most obstructive, fixing it, and moving to the new problem area of the operation, with the aim of refining it to have as little waste as is possible.

Predictive Analytics Model - PFS

MEMBERS: Alwaleed Adwan; Ahmed Aljedeed; Diego Fretes Pereira; Krishi Panchal

ADVISOR: Dr. Krishna Krishnan

TABLE: 203

The scope of work for the project is to create a predictive analysis model to improve customer sales projections. Consistently identifying KPIs to predict the future sales of certain products.

Western Industries Plastics Products: Tufway Process Layout Improvement

MEMBERS: Shamlan Aljamal; Munthir Alkhattaf; Houng Bui; Scarlet Mitchell

ADVISOR: Dr. Cindi Mason

TABLE: 201

The Tufway Process Layout Improvement project goes in depth on the Tufway pack-out satellite line at Western Industries Plastic Products. Western Industries has been supplying blow-molded plastic products for years and continues to seek improvement and expansion. The company has emphasized the dissatisfaction of the efficiency of their Tufway line and has looked to this project for possible improvement measures.  This project uses data collected from the process using work systems methods including time studies and process mapping. With this data, we designed alternative layouts to compare with the current layout to determine the optimal flow of material and operators with the limited amount of floor space. We also used lean manufacturing concepts, incorporating 5S principles to the workstations to allow greater organization within the work cell. This reduces the time for operators to find necessary items from searching and walking, reducing cycle times and movement waste. Both of these efforts targeted our main objective of increasing efficiency, while also reducing space usage and lowering ergonomic risks.

Certification Tracking for 3rd Party Aerospace Materials

MEMBERS: Edwin Gitau; Seth Hilger; Kylie Meier; Katherine Moore

ADVISOR: Dr. Cindi Mason

TABLE: 204

Spirit AeroSystems has seen significant time delays due to waste in the certification tracking process. Certification tracking is a transactional system that follows raw materials from the mill onto a finished aircraft to establish an identifier for each part produced in the Aerospace industry. Our goal is to increase the availability of the floor manager and improve the certification tracking process by eliminating Type II Muda including motion, excess processing, and wait time. Our group proposes a new information system that ties physical materials to a certification database through barcode scanning to automate the most strenuous portions of the current process.