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

investment costs andgreen values for each technology option, and there is a hierarchy to the innovation optionsavailable for each turn. The students work within their team and budget (and within ten rounds ofthe game) to try to create the most profitable and green supply chain. Students compete withother supply chain teams. Successful game strategy requires both cooperation and competitionfor players to succeed.1. BackgroundThis work is based upon development of a board game, entitled Shortfall (previously reported[1-3]), which simulates a simplified supply chain for automobile production. The goal andchallenge of playing Shortfall is to learn to maximize profit while minimizing environmentalimpact. The auto industry manufacturing supply chain

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

” and “Six Sigma” technical articles published in the Societyof Manufacturing Engineering Technical Articles section, Six Sigma was primarily identified asa quality program with a focus on reducing process variation and Lean as a program focused oneliminating waste and improving flow using problem solving and statistical tools.1 Many of thearticles simply focused on the Lean and Six Sigma tool kits.In a recent article, the author advocated an integrated approach to process improvement usinglean manufacturing and Six Sigma principles.2 Another article which focused on Lean, arguedthat “successful execution of the corporate strategy is the ultimate goal not merely becomingLean” and offered Profit Mapping as a methodology for tying Lean to the

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

certain activities such as the follow:From “Value Stream Management” (Don Tapping)1The process of Value Stream Mapping can be reduced to 6 general steps: 1. Determine the appropriate process to improve. 2. Create the current state map of the process. 3. Determine the appropriate metric for improvement. 4. Create the future state map of the process. 5. Determine improvement methods to go from the current state to the future state that achieve the correct metric. 6. Initiate the improvements. Step 1: Determine the appropriate process to improve. In any normal manufacturing environment there can exist many individual processes. Many individual products contain multiple processes, of which each process is further

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

engineers tocome up with the most efficient plant layout. However, there is not a set methodology that can berepetitively applied to all plant layout exercises so that they turn out as the most efficient plantlayout. In this sense, creating of plant layouts is more of an art than a science1,2,3. Page 13.386.2To aid in coming up with the best layout, one needs to search for alternative solutions whichshould push one to become creative in coming up with a solution that is most efficient. Kirck3, 4has summed up these efforts in a worthy to repeat manner, which have been elaborated below:1) Exert the necessary effort to come up with an optimized

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

,funding and support from industry, professional societies, and state and federal agencies will bediscussed.Background A recently completed study by the Indiana Department of Workforce Development (DWD)1presents the results of research to identify and analyze the root causes of occupational and skillsshortages across Indiana’s 11 economic growth regions. Given the importance of manufacturingto Indiana’s economy (Figures 1 and 2) it is not surprising that manufacturing was included asone of the industries most affected in all of the identified root cause areas.Figure 1: 2006 Indiana Gross State Product Figure 2: 2006 Indiana World Exports (x $106)(Source: Bureau of Economic Analysis) (Source: Office of Trade and

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

, where larger tools maydemonstrate cooling issues. Using the smaller tool, greater clearance is available for chipevacuation and cutting fluid access. This method of cutting results in an increased tool life. Figure 1 Traditional toolpath (left) versus trochordial toolpath (right)6Since the focus is on using existing, conventional machine tools to achieve HPM, it is Page 13.665.3worthwhile to review the factors in a CNC machine that play a role in determining the HPMcapability of the machine. This information helps manufacturing engineers judge the suitabilityof their machine (or a new

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

Electrical Engineering and Chair of the Department of Electrical and Computer Engineering at the University of Kentucky. He was former Director of the University of Kentucky Center for Manufacturing. Dr. Holloway was an original member of the University of Kentucky Lean Manufacturing program, and has taught students and industry personnel in lean manufacturing since 1994. Page 13.208.1© American Society for Engineering Education, 2008 Application of Lean Concepts to the Teaching of Lean Manufacturing 1. IntroductionLean manufacturing organizations, such as Toyota

Conference Session

Technology Integration in the Classroom

Collection

2008 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University

Tagged Divisions

Manufacturing

experience, and one engineer from at an airconditioning manufacturing company with two years of experience. The four applicationengineers all have 15 or more years of system integration experience and are considered to beexperts by their peers. The latter two engineers work with automated manufacturing systems, buthave little system design experience; we consider them to be novices for the purposes of thisinvestigation.Procedure. The interviews were conducted as follows. The interviewer would:1. Introduce himself and describe the purpose of the interview (to gain a better understanding of system integration)2. Show the engineer a cell phone assembly consisting of eight parts (see Figure 1).3. Ask the engineer to think aloud about

Conference Session

Pedagogical Issues in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Eric Roe, Hillsborough Community College; Richard Gilbert, University of South Florida; Marilyn Barger, University of South Florida; Bradley Jenkins, St. Petersburg College

Tagged Divisions

Manufacturing

Applied Science (A.A.S.) degreesassociated with manufacturing and related technologies. This reform has resulted in a statewidedegree in Engineering Technology with a common technology core, based on a nationalcertification, and five specialization tracks to meet local needs.There are a number of benefits to this change or consolidation of Engineering Technology 2-yearprograms in Florida. These include: 1) A degree program that meets manufacturers’ skills andknowledge competencies related to foundational skills in engineering technology. 2) AllCommunity Colleges in the State can market jointly to students and industry employers with acommon degree program and certification; 3) Completion of the common technology corecreates a portable completion

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Atin Sinha, Albany State University

Tagged Divisions

Manufacturing

. Page 13.991.7 Figure 1. Object on a turntable being scanned by E-Scan 3D scannerFigure 1. shows the set up to scan objects by E-Scan 3D scanner which is connected to the laptopcomputer with a USB cable. Results of the successful projects, with original objects and theprototype made in 3D printer are shown in the figures 2 and 3. Figure 2. Original clay idol and prototype made in 3D Printer Page 13.991.8 Figure 3. Original hammer and prototype inside the build chamber of 3D Printer (Note: small columns of support material to facilitate building process)Lessons Learned and Future ChallengesCurrently the

Conference Session

Innovations in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Jianbiao Pan, California Polytechnic State University; James Harris, California Polytechnic State University; Albert Liddicoat, California Polytechnic State University; Dominic Dalbello, Allan Hancock College

Tagged Divisions

Manufacturing

only 24ABET (Accreditation Board for Engineering and Technology)-accredited manufacturingengineering programs, and only a few of these programs offer electronics manufacturing relatedcurricula. Based on a review of the curricula of ABET-accredited manufacturing engineeringprograms, only Boston University,1 Oregon State University,2 and Cal Poly San Luis Obispohave electronics manufacturing courses. Recently, the newly established manufacturingengineering program (not yet ABET-accredited) at Washington State University Vancouverbegan to offer a microelectronics emphasis area.3It should be noted that electronics manufacturing is a multidisciplinary topic because it isrelevant to the fields of materials engineering, mechanical engineering

Conference Session

Pedagogical Issues in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Sean Falkowski, University of Dayton

Tagged Divisions

Manufacturing

requirements for a manufacturing engineering technology curriculum. Thefocus of this paper is on a baccalaureate degree program in the United States for manufacturingengineering technology. First what are the requirements of a program in manufacturingengineering technology? According to ABET each program must have published educationalobjectives. They also must have a program that includes a curriculum that enables graduates toobtain these objectives.1 There is a list of various program outcomes that must be met. Thecurriculum must “provide an integrated educational experience that develops the ability ofgraduates to apply pertinent knowledge to solving problems in the engineering technologyspecialty”1. The assumption is that a program that is

Conference Session

Technology Integration in the Classroom

Collection

2008 Annual Conference & Exposition

Authors

Yuqiu You, Morehead State University; Xiaolong Li, Morehead State University; Gabriel Alungbe, Morehead State University; Sam Mason, Morehead State University

Tagged Divisions

Manufacturing

systems.Laboratory experiences are important for technology students in the CIM courses to reinforcetheories and concepts presented in class lectures. Therefore, the ability to offer hands-on labexperiences to both traditional students and online students is vital to effective learning [1]. Thedevelopment of an online laboratory will enable participation in laboratory experiences bydistance students. It is also motivated by the fact that presently, as never before, the demand foraccess to the laboratory facilities is growing rapidly in engineering and technology programs.Being able to make the laboratory infrastructure accessible as virtual laboratories, available 24hours a day and 7 days a week, goes far in addressing these challenges, and would

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

Page 13.866.2Engineering Technology. This baseline of manufacturing industry exposure, and the productionlaboratory facility itself, are essential resources for subsequent upper-division technical courses,which purposefully use the students’ shared Enterprise knowledge and applied experiences.“Big Picture” Enterprise InsightA key benefit of the Manufacturing Enterprise course is that it provides a clear understanding ofhow the various engineering, technology, and business functions comprising a typical productiondepartment relate to each other and to the seven other functional components of the totalcompany (Figure 1). EXTERNAL CUSTOMER The Manufacturing Enterprise

Conference Session

Technology Integration in the Classroom

Collection

2008 Annual Conference & Exposition

Authors

Yuqiu You, Morehead State University

Tagged Divisions

Manufacturing

interfacing and application development [1]. Most students in the IET department canbetter understand the topics if they can see how they work. Therefore, instead of pure coding forinterfacing, a graphic programming language, LabVIEW, is introduced to the class to implementrobotics interfacing and develop Human-machine interface (HMI).LabVIEW, developed by National Instruments, is a graphic programming language to buildvirtual instruments (VIs) for control systems. The VI developed in LabVIEW environmentprovides an interface between a user and a control process, such as a robotic system. The mainconcept of such an interface is to provide a general view of the process and facilitate full controlof the operations [2]. In the LabVIEW environment

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

integratedactivities, the program has been brought back to 183 students. Figure 1 depicts the enrollmentdata for the manufacturing engineering program. It clearly shows a precipitous decline after theinitial startup spike and highlights a period of growth as a result of the recruiting strategies used.Since there has been a steady enrollment increase since 2004, it is unclear whether a true steady-state enrollment has been found. At the time of writing, the Fall 2007 applications are exceedingany prior year application rates. Historically, the manufacturing engineering program has aaccepted application fall show rate of roughly 70 percent, thus indicating Stout’s program is afirst choice program for students. This show rate is significantly higher than most

Conference Session

Multidisciplinary and Capstone Experiences in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

James Ejiwale, Jackson State University

Tagged Divisions

Manufacturing

, Page 13.1148.2Engineering and Technology (CSET) where research has currently begun. This approach willhelp prepare and put our graduates at the forefront of employment in the new industrialrevolution.Knowledge sharing and management among departmental scholarsSince nanotechnology is highly interdisciplinary, relevant activities on this new industrialrevolution at JSU has synergized many disciplines such as physics, chemistry, biology,mathematics, technology and engineering with focus on the strength of the participants. This hasled to the development and implementation of research clusters across science, technology,engineering, and mathematics (STEM) or simply the STEM fields. The research clusters listed infigure 1 with their subgroups

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Somnath Chattopadhyay, Pennsylvania State University

Tagged Divisions

Manufacturing

commanded input,the velocities of the individual tables go through different velocities including zero. Sucha variation in velocities leads to a variation of friction forces in a nonlinear fashion. Theinclusion of these nonlinear effects into the dynamics of the X-Y tables leads to a coupledsystem of nonlinear differential equations. Numerical solutions to the equations ofmotion would yield responses typical of a nonlinear dynamical system and has beenexplored in this study.ANALYTICAL MODELFigure 1 illustrates a typical 3-axis CNC machine with its mathematical idealization. Thetwo tables moving in the X and Y directions are connected to the individual lead screwsthat provide them with the required motions as programmed in the controller. For each

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

Innovations in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

for quick reference at the end of this section.Production Engineering (Junior Year Fall Term): This course presents the techniques of Page 13.904.2production engineering and fundamental manufacturing process concepts, at an introductorylevel. Methods of production are introduced, and productivity improvement methods areexplored with an emphasis on quality, efficiency, and product cost. Basic metrology principlesare also introduced. Applicable ABET Outcomes are: 1, 3, 5, 7 and 8. Applicable Track-SpecificABET Outcomes are: M2 and M4.Fundamentals of Manufacturing Engineering (Junior Year Spring Term): This course is anintroduction to the

Conference Session

Multidisciplinary and Capstone Experiences in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Robert Creese, West Virginia University; Deepak Gupta, Southeast Missouri State University

Tagged Divisions

Manufacturing

the strength ofmaterials and basic materials courses for the industrial engineering students and the only courseemphasizing costs for the mechanical engineering students. There is no specific productdesign/development course in either program, but the mechanical engineers do have a seniordesign course consisting of several sections which focus on a specific project for each section.The manufacturing course does discuss the predominant methods for making the structuralshapes such as extrusion and roll forming and relates these to the project.Project Description and Instructions The project for the fall semester was the ladder design problem and the projectassignment sheet is presented in Appendix 1. The ladder is the most difficult of

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 2

Collection

2008 Annual Conference & Exposition

Authors

Joseph Chen, Iowa State University; Ronald Cox, Iowa State University

Tagged Divisions

Manufacturing

manufacturing sectors.This three-credit lean course, which is comprised of a weekly two-hour lecture and two-hour lab(considering holidays and exam days), will be restructured into two major sessions: (1) 32 hours of lecture and lab activities for learning lean tools and principles, such as visual management, 5S, standardized work, quick changeover, pull system using kanban and poyayoke, and how to cost justify a lean project. (2) 22 hours working as a lean team at a local manufacturing company located less than 50 miles of campus, thus enabling students to conduct onsite a full- or half-day project.The final result is a lean presentation from the team to industrial mentors at the end of the semester. Itis

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

airplanes. The production goal was to make 108paper airplanes in a half-hour period – a takt time of 16.7 seconds. Three styles of airplaneswere manufactured in each session: 60 of model “A”; 30 of “B”, and; 18 of “C” (Figure 1).These designs were selected for aesthetics; none were very good flyers. Four airplanes of anymodel fit on a single sheet of 8-½”×11” paper. Each airplane followed the same basicmanufacturing process: 1. TRACE. A three-axis CNC knee mill marked the outlines and fold lines for four airplanes of one type on a sheet of paper taped to the bed. A marker was held in the machine’s tool holder. 2. CUT. The outline was cut with scissors. 3. FOLD. The airplane was folded along the marked lines. 4. TAPE. A short

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

professional development and related outreach services.The merger of the two resource centers was supported by their joint National Visiting Committee(NVC), which met in August 2007. The NVC representatives present at the meeting included:• Abi Aghayere, Rochester Institute of Technology• Walter Buchannan, Texas A & M University• William Clark, Bell South Corporation• Beverly Davis, Purdue University• Winston Erevelles, Robert Morris University• Mark Stratton, Society of Manufacturing EngineersThe Need for MERC and Benefits for MERC UsersThe need for MERC is evident and perhaps even urgent. Manufacturing accounts for two-thirdsof all US research and development expenditures and 90% of all US patents (Molnar, 2005)1.Manufacturers require

Conference Session

CAD/CAM in Manufacturing Education

Collection

2008 Annual Conference & Exposition

Authors

Paul Nutter, Ohio Northern University

Tagged Divisions

Manufacturing

. Page 13.437.2Time and expense have been reduced by reducing the number of physical prototypes that must becreated in order to validate a product design in the physical world.” 3Simulation is one of the growing applications within the DM realm. The Society ofManufacturing Engineers (SME) has created a technical group to provide reference informationand networking opportunities within this field. This group has designated four areas of simulationrelated to manufacturing operations: 4 1. Virtual product design 2. Physical prototype validation 3. Production/operations analysis 4. Enterprise analysisThe principle applications used in our curriculum fall within the production/operations domain.Curriculum Background at Ohio Northern

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

-- analysis, supervising design, specifications faculty sophomores: basic analysis; laboratory testing freshmen: data gathering; testing support Figure 1: Initial Concept for a Vertically-integrated Scholar TeamAcademic Integration and Growth of Learning through Innovation: During this period oftime, interest in innovation and collaboration was growing across the entire campus

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

department’s industrial advisory board, and employers.The following will present additional detail about each of the two courses in this capstonesequence. Each course has three distinct, but highly connected areas of content includinglectures, manufacturing documentation (known as the manufacturing plan) and activity basedlearning (known as lab). Each of these areas will be discussed for each course. Capstone Course #1, Contemporary Integrated Manufacturing (4 credit hours with 6 contact hours per week).Lecture ContentThe lecture content includes formal lectures (via PowerPoint), class discussions, teampresentations, etc. The lecture content is described below: • Introduction to Manufacturing operations including: historical

Conference Session

Lean Manufacturing and Six Sigma in Manufacturing Education 2

Collection

2008 Annual Conference & Exposition

Authors

Susana Lai-Yuen, University of South Florida

Tagged Divisions

Manufacturing

through the virtual assembly of LEGO blocks. Thesecond laboratory experiment uses LEGO Mindstorms NXT systems to provide students withhands-on team projects to design and build an automated system while applying concepts learnedin the classroom. Data from students’ projects and surveys is presented to evaluate the efficacyof the designed laboratory experiments on student engagement and conceptual understanding.1. IntroductionConcepts in manufacturing can be very challenging for engineering students to understand inclassroom lectures alone. This paper focuses on two particular areas of manufacturing:micromanufacturing and industrial automation. In micromanufacturing, the layer-by-layermanufacturing process for microdevices becomes a challenge for