Conference Session

Multidisciplinary and Capstone Experiences in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Todd Myers, Ohio University; Peter Klein, Ohio University

Tagged Divisions

Manufacturing

project reviews are presented during thecapstone sequence. Page 13.865.2It must be emphasized that this is not a simulation exercise, it is real manufacturing. Studentdecisions have real consequences and their design and plan must work. For example, designinga product assembly fixture is not simply a CAD activity. The fixture is designed, built, tested foraccuracy, reliability, capacity, repeatability of set-up, etc. and must be robust enough to handlethe abuse in a production environment. The fixture must also be capable of withstanding theinevitable variability of the raw materials and parts for which it will be used. The average teamwill

Conference Session

Innovations in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

David Wells, North Dakota State University; Daniel Ewert, North Dakota State University

Tagged Divisions

Manufacturing

Page 13.1329.3office chair. The role of the business students was and is to devise a business plan for the team. By Autumn semester 2006, active college-to-college collaboration in scholar teams was well-established. Two new MBA students joined each of two scholar teams -- one working indevelopment of a test platform for biomedical devices and the other working on design of aninstrumented space suit. Again, the role of the business students was in creating businessplanning for commercialization of the new products and eventual launch of new companies.Throughout this entire period, the atmosphere across the State of North Dakota became more andmore favorable to innovation, invention and the commercialization of research. Among theseveral

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 2

Collection

2008 Annual Conference & Exposition

Authors

Phil Waldrop, Georgia Southern University

Tagged Divisions

Manufacturing

until pricing is established; • Pricing is defined through use of a financial break-even analysis that cannot be performed without input of direct and indirect expenses. • None of this can occur without Production Planning and Control input that depends on Product Engineering specifications and subsequent Purchasing research on materials and part costs.MotivationThe pragmatic “learning by doing” educational philosophy of John Dewey (1859-1952)continues to be highly relevant today. One is not as motivated or as able to learn a sport or careerskills through books and lecture alone. The merits of simulation are presented in numerouspapers presented at recent ASEE conferences. In one such paper4, the authors quote ABET 2000

Conference Session

Innovations in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

discipline of Manufacturing Engineering. The role and function of themanufacturing engineer are introduced in the context of the production, inspection, qualitycontrol, and enterprise environments. Manufacturing engineering methods, techniques andalgorithms are introduced, and engineering ethics issues are also discussed. Applicable ABETOutcomes are: 1, 2, 3, 4, 5, 7, 8, 9, and 11. Applicable Track-Specific ABET Outcomes are: M1,M2, M3, and M4.Product and Tool Design (Junior Year Spring Term): This course provides an introduction toproduct design issues including design for manufacturing and assembly, the producibility index,process planning and tolerance selection. The course also covers the design and engineering ofjigs, fixtures, and tooling used

Conference Session

Pedagogical Issues in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Jahangir Ansari, Virginia State University; Amir Javaheri, Virginia State University; Stephen S. Tompkins, Virgina State University; Keith Williamson, Virginia State University

Tagged Divisions

Manufacturing

ABET criteria for continuous improvementrequirements. The assessment process and evaluation of the program outcomes are discussedalong with the results as well.IntroductionAlthough there are several papers published in the field of engineering program outcomeassessment 1, 2, 3, there are very few that discuss assessment process of manufacturingengineering programs. Most of these assessment plans revolve around certain aspects of theprogram such as courses, capstone courses, or engineering labs. This paper presents anassessment procedure which considers all program outcomes assessment processes.The Manufacturing Engineering (MANE) program at Virginia State University developed acurriculum that provides students with balanced coverage of ABET

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 1

Collection

2008 Annual Conference & Exposition

Authors

Jacqueline Isaacs, Northeastern University; Jay Laird, Metaversal Studios; Seth Sivak, Carnegie Mellon University; Mark Sivak, Northeastern University

Tagged Divisions

Manufacturing

, work sheets,innovation cards and current event cards. It was necessary to streamline and simplify the game Page 13.654.2play elements as much as possible, while not oversimplifying any element in order to maintainacademic merit.With the addition of computers to handle all the calculations rather than the players, additionalrounds for the game became a reality. The new ten-round game allowed for more flexibility incontent and play styles, with long-term planning and goals becoming possible. Strategicplanning for technological innovation became possible with the increased number of rounds.This also gave students more exposure to current events

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Paul Nutter, Ohio Northern University

Tagged Divisions

Manufacturing

manufacturers (OEMs) and suppliers, along with amajor defense-industry company. This paper and presentation includes examples of simulationsand the results of the students’ analysis of the operations.The simulation applications used in these industrial projects include robotic workcell processing,assembly sequencing, ergonomics analysis, and discrete event materials/process flow studies.This curriculum has also provided an opportunity for integration of several technologies andmanufacturing management aspects into application-based environments, including 3-D CADmodelling, robotics, and production system design. Students gain skills and experience inteamwork, project planning, problem solving, and formal multi-media presentations in

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 2

Collection

2008 Annual Conference & Exposition

Authors

Arlie Hall, University of Kentucky; Lawrence Holloway, University of Kentucky

Tagged Divisions

Manufacturing

Page 13.208.2 1further argued that these three steps constitute a “dynamic scientific process for acquiringknowledge”2.Dr. W. Edwards Deming, a colleague of Dr. Shewhart, made a significant addition to Shewhart’sthree step learning cycle by adding a vital fourth step, his “Act” step. Deming argued that hisfourth step in a given cycle of improvement should lead to a new operating standard3. TheShewhart and Deming well-known learning cycles, Plan-Do-Check (PDC) and Plan-Do-Check-Act (PDCA), respectively4, were developed and utilized as means to continuously improve thequality of military hardware during World Ward II. Dr. W. Edwards Deming introduced

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 1

Collection

2008 Annual Conference & Exposition

Authors

Alan Leduc, Ball State University

Tagged Divisions

Manufacturing

provides project planning skills and development of a Six Sigma Project Charter (contract) in cooperation with the community partner. The student will begin the project in the second portion of the course. • 400 Level Course: Design of Experiments – This course provides training in DOE and Design for Six Sigma, including robust design. This course is an existing course in the MfgET curriculum. • 400 Level Course: Six Sigma Project II – This course is for completion of the Six Sigma Project and writing of a formal report. The formal report must be written from the position of a consultant and not simply a practitioner. This is important because the formal report is what the student will have to

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 1

Collection

2008 Annual Conference & Exposition

Authors

Michael Lobaugh, Pennsylvania State University-Erie

Tagged Divisions

Manufacturing

the desired metric gain? If not, then the team/group must go back and reinvestigate the situation. In an industrial setting, Lean Manufacturing and Value Stream Mapping are typicallytaught on-site by a consultant or at seminars, typically lasting two to five days. These aredesigned to give a detailed explanation of the technique and often include simulation examplesand workshops using actual on-site manufacturing examples. For a company planning to trainmany employees, a seminar given by a consultant is a good method, although very expensive. Ifa company involved in lean manufacturing or planning to implement VSM, an engineeringgraduate possessing that information and experience would be very valuable and highly soughtafter.The value

Conference Session

Our Future in Manufacturing

Collection

2008 Annual Conference & Exposition

Authors

Bradley Harriger, Purdue University; Mike Aikens, Butler County Community College; Mark French, Purdue University; Steve Shade, Purdue University

Tagged Divisions

Manufacturing

nation. The traditional recruitment approach of static websites and brochures fail to attractthe interest of potential students. This approach must be adjusted to include the evolving interestsof each new incoming generation of students; if it’s not animated, colorful, virtual, “cool” andmost importantly part of their current world, capturing student interest is difficult at best. This paper will address a planned summer workshop for high school students that will usethe guitar to introduce the “fun” side of engineering and specifically manufacturing. Theworkshops build on experience from semester classes in stringed instrument manufacturing andfrom an adult summer workshop on guitar making. Additionally, details of the guitar workshop

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Somnath Chattopadhyay, Pennsylvania State University

Tagged Divisions

Manufacturing

path is referred as the contouring error. A typicaltest that is used is a circular test in which the machine is programmed to travel along acircle, and the difference between the programmed path and the measured actual path iscompared. The purpose of this study is to identify the various contributors to thiscontouring error, and in particular estimate the error due to stick slip motion usinganalytical techniques. It is planned to measure the errors experimentally making use ofcapacitance probes. The study is intended to develop an appreciation for the sources ofdifferent errors produced in a machine tool and as such forms a module in a typicalsemester long class devoted to manufacturing processes.INTRODUCTIONComputer controlled machine tools

Conference Session

Our Future in Manufacturing

Collection

2008 Annual Conference & Exposition

Authors

Gilah Pomeranz, Sinclair Community College; Robert Mott, University of Dayton; Steve Wendel, Sinclair Community College; Shep Anderson, Sinclair Community College; Sean Falkowski, University of Dayton; Robert Wolff, University of Dayton; Jack Waintraub, Middlesex County College

Tagged Divisions

Manufacturing

AC 2008-630: CONSOLIDATING TWO NSF ONLINE MATERIALS ANDINFORMATION RESOURCE CENTERS FOR MANUFACTURING ANDENGINEERING TECHNOLOGY EDUCATIONGilah Pomeranz, Sinclair Community CollegeRobert Mott, University of DaytonSteve Wendel, Sinclair Community CollegeShep Anderson, Sinclair Community CollegeSean Falkowski, University of DaytonRobert Wolff, University of DaytonJack Waintraub, Middlesex County College Page 13.327.1© American Society for Engineering Education, 2008Consolidating Two NSF Online Materials and Information Resource Centers for Manufacturing and Engineering Technology EducationAbstractThis presentation describes the plan for the future of the Manufacturing and

Conference Session

Technology Integration in the Classroom

Collection

2008 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University

Tagged Divisions

Manufacturing

compare designs for a virtual assembly line. The AALD environment isdescribed in detail in the Activities section of this report and will be evaluated in the next year ofthis project, both by students for instructional effectiveness and by expert system integrationengineers for fidelity and accuracy.Future DirectionsPossible future directions include: • Continued analysis of the interview and think-aloud data that we have collected thus far. Although the data collection conditions were less than ideal, the interview data are very detailed and provide a rich source of information about the system integration industry. We plan to analyze data from the airline passenger seat and truck frame assembly line design exercises to

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 2

Collection

2008 Annual Conference & Exposition

Authors

M. Brian Thomas, Cleveland State University

Tagged Divisions

Manufacturing

time frames between ninety minutes5, 10-12 and one day1, 13.Regardless of the time frame, all authors cited here employ repetition as a tool to highlight thedifference between non-Lean production and Lean production. The shorter time frames allowfor just two or three rounds to be used as a basis of comparison. For example, the exercisedescribed by Billington6 uses three rounds (push, pull with lot size = 3, pull with single-pieceflow) to demonstrate to students how Lean can reduce work-in-process (WIP). An advantage formultiple sessions, though, is that it provides the students with time to reflect on the events of aprevious exercise and plan for the next. The added time permits a less-structured exercise, asstudents are able to develop their

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Adrian Teo, Arizona State University; Scott Danielson, Arizona State University; Trian Georgeou, Arizona State University

Tagged Divisions

Manufacturing

gathered for all the tools used in the process plan for the target parts.During the evaluation phase, several programming pitfalls were found. These included severalpoorly designed toolpaths, poor contour surface finishes and cutting parameters that did notutilize the full capability of the machine. In the redesign step, the information gathered from theprocess analysis, as well as the machine cutting baseline tables, a new manufacturing processplan and “draft” CNC program were generated. For example, optimizing the face-millingoperation by increasing the depth of cut while maintaining a high federate, increasing the peakspindle load to over 140% (projected), provided a significant gain. This change reduced the sub-operation time to about five

Conference Session

Our Future in Manufacturing

Collection

2008 Annual Conference & Exposition

Authors

Danny Bee, University of Wisconsin-Stout; Richard Rothaupt, University of Wisconsin-Stout; Linards Stradins, University of Wisconsin-Stout

Tagged Divisions

Manufacturing

roboticdesign challenge along with a related research project. Students gain valuable experience havingfun designing and building a LEGO robot, but they also research a current and relevantengineering problem and present that to a panel of judges during a sporting event stylecompetition. University of Wisconsin-Stout currently hosts a regional tournament in the state ofWisconsin and is putting plans in place to be the primary host of the State FLL tournament.Another example would be the Science, Technology, and Engineering Preview Summer Campfor Girls (STEP for Girls).3 This seventh grade (girls are entering seventh grade) experience

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 1

Collection

2008 Annual Conference & Exposition

Authors

Merwan Mehta, East Carolina University

Tagged Divisions

Manufacturing

plant layout engineer still needs to be incorporated into the layoutto make it flow optimally, but it can go a long way in ensuring that the holistic flow is optimizedfrom the point raw materials enters a company till the point it leaves the company as a finishedproduct. This should give the right start in implementing lean manufacturing and theory of Page 13.386.11constraint principles for any company.Bibliography1. Meyers and Stephens, Manufacturing Facilities Design and Material Handling, Third Edition, Pearson Prentice Hall, 2005.2. Tompkins, Et Al, Facilities Planning, Third Edition, John Wiley & Sons, Inc., New York, 2003.3