Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

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

Tagged Divisions

Manufacturing

AC 2009-118: SOFTWARE DEVELOPMENT FOR TEAM PROJECTS INMANUFACTURINGRobert Creese, West Virginia University Robert C. Creese is Professor of Industrial Engineering in the Industrial and Management Systems Engineering Department in the College of Engineering and Mineral Resources at West Virginia University in Morgantown, West Virginia. He obtained his BS, MS, and Ph.D. degrees from The Pennsylvania State University(1963), The University of California-Berkeley(1964), and The Pennsylvania State University(1972). He is a life member of ASEE, AACE-International and AFS as well as a member of ASM, AWS, AIST, ISPA, SCEA and SME.Deepak Gupta, Southeast Missouri State University Deepak Gupta is an

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Yuqiu You, Morehead State University

Tagged Divisions

Manufacturing

AC 2009-2354: A PROJECT-ORIENTED APPROACH IN TEACHING ROBOTICSAPPLICATION ENGINEERINGYuqiu You, Morehead State University Page 14.92.1© American Society for Engineering Education, 2009 A Project-oriented Approach in Teaching Robotics Application EngineeringI. IntroductionAutomated robotic systems are critical components in implementing flexible manufacturingsystems (FMS) which is the current trend for improving productivity and flexibility. Usingrobots in actual manufacturing platforms is a decision to improve flexibility and to increase theagility of the manufacturing process. To prepare students in the manufacturing

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Dave Kim, Washington State University, Vancouver; Yongha Kim, Washington State University, Vancouver

Tagged Divisions

Manufacturing

, the hands-on manufacturingexperiments was an effective project to review concepts of lean manufacturing, applylean manufacturing tools to identify wastes or ‘non-value-added’ activities in factories,and suggest how to minimize or eliminate them.1. IntroductionLean thinking has been well known as an effective strategy to provide and increase thevalue delivered to the customer. Lean is based on the Toyota Production System (TPS),which is a more flexible manufacturing system than the traditional mass-productionsystem. Lean manufacturing, developed from TPS, utilizes fewer resources and results ina larger variety of products and at the same time high levels of product quality andservice [1,2]. Lean manufacturing has been widely applied in many US

Conference Session

Technology Integration in the Classroom

Collection

2009 Annual Conference & Exposition

Authors

Susana Lai-Yuen, University of South Florida; Maria Herrera, University of South Florida

Tagged Divisions

Manufacturing

Projects into Manufacturing Education AbstractThis paper describes the integration of real-world medical device projects into manufacturingeducation to increase students’ interest and hands-on experiences in product design andmanufacturing while exposing them to real engineering challenges. Teams of undergraduatestudents in a Manufacturing Processes course worked with a medical doctor and practicingsurgeon on a project to design and create the prototype of a new medical device to improve aminimally-invasive surgical procedure. The medical device project provided students with realengineering and interdisciplinary learning experiences with clinical exposure and high societalimpact. The end goal is to prepare students with

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

David Culler, Oregon Institute of Technology; Noah Anderson, Oregon Institute of Technology; Stanley Ames, Oregon Institute of Technology

Tagged Divisions

Manufacturing

“semester project on steroids”, students at theOregon Institute of Technology set the lofty goal of designing and constructing a RapidPrototyping (RP) machine based on an international community of “Rep-Rappers” (ReplicatingRP Machines) that was started at the University of Bathe, England [1]. The idea is based onbuilding machines that can reproduce almost all of the components to make copies of themselvesusing the RP process, and through collaboration with other groups, implement improvements tothe previous generation of machines. By looking at the machine in terms of subsystems,multiple engineering strategies and tools were employed to complete the project. The studentsalso had to consult with experts from other departments, local industry and

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

Wayne Hung, Texas A&M University; Sriharsha Sundarram, Texas A&M University; Fatih Ozkeskin, University of Michigan; Mike Powers, Agilent Technologies; Juan Manriquez, Cideteq; Venkata Vasiraju, Texas A&M University

Tagged Divisions

Manufacturing

educational project. Some researchobjectives have been achieved by dividing an objective into manageable laboratory projects thatcan be completed by undergraduate students in a few weeks.The anodic dissolution µECM process effectively forms and shapes micro components from anyconductive material. Unlike classical ECM technology, the novel µECM utilizes very highfrequency pulses and proprietary electrode shapes/motions to remove materials at the micro ornano scales, and can mass-produce micro components with exceptional quality and surfaceintegrity. A theoretical model is developed which agrees with experimental data for 316Lstainless steel and copper beryllium alloy. The environmentally friendly technology showspromise as a high-resolution production

Conference Session

Multidisciplinary and Project-based Experiences in Manufacturing

Collection

2009 Annual Conference & Exposition

Authors

Janet Dong, University of Cincinnati; Janak Dave, University of Cincinnati

Tagged Divisions

Manufacturing

toward a baccalaureate degree in Mechanical Engineering Technology at theCollege of Applied Science, University of Cincinnati are required to complete a “Design, Build,and Test” senior capstone design project. In 2007/08, one of these capstone design projects wasto design and build a robot to participate in the BotsIQ National Competition. This robot wasbuilt to meet the BotsIQ 120lb weight class specifications.A BattleBot is a robot which possesses fighting capabilities and competes against otherBattleBots with the intent to disable them. The weapon is the main component of these robots.BattleBots compete one on one and the winner is determined by the amount of damage inflictedto the other using the weapon.In the 2007-2008 academic year, a team

Conference Session

Design Education in Manufacturing Programs

Collection

2009 Annual Conference & Exposition

Authors

Guanghsu Chang, Minnesota State University, Mankato; William Peterson, Minnesota State University, Mankato

Tagged Divisions

Manufacturing

AC 2009-1301: BRIDGE DESIGN PROJECT: A HANDS-ON APPROACH TOSTATICS AND STRENGTH OF MATERIALS LEARNINGGuanghsu Chang, Minnesota State University, Mankato Dr. Guanghsu A. Chang is an associate professor of the Automotive and Manufacturing Engineering Technology Department at Minnesota State University, Mankato. His research interests involve the study of robotic applications, manufacturing automation, Design for Assembly (DFA), and Case-Based Reasoning (CBR) applications. He holds both MSIE, and Ph.D. degrees from University of Texas at Arlington.William Peterson, Minnesota State University, Mankato Dr. Bill Peterson is currently an associate professor and chair of the Automotive and

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Ning Fang, Utah State University

Tagged Divisions

Manufacturing

AC 2009-284: A PROJECT-BASED ACTIVE AND COOPERATIVE LEARNINGAPPROACH TO IMPROVING MANUFACTURING ENGINEERING EDUCATIONNing Fang, Utah State University Ning Fang is an Associate Professor in the Department of Engineering and Technology Education in the College of Engineering at Utah State University. His areas of interest include computer-assisted instructional technology, curricular reform in engineering education, the modeling and optimization of manufacturing processes, and lean product design. He earned his PhD, MS, and BS degrees in Mechanical Engineering and is the author of more than 60 technical papers published in refereed international journals and conference proceedings. He is a Senior

Conference Session

Our Future in Manufacturing: STEM Outreach

Collection

2009 Annual Conference & Exposition

Authors

Terence Fagan, Central Piedmont Community College

Tagged Divisions

Manufacturing

difficult” cannot be ignored. Now is the time for those in industry andacademia to find opportunities that change this stigma and offer a more positive outlook on theengineering industry. This paper addresses a service learning project that involved first yearMechanical Engineering Technology and second year Graphic Design students collaborativelyworking on “How To” delivery systems that would engage middle and high school students.Some of the projects included comic books on “How to Modify an Xbox 360” and videos andpamphlets on “How To Build a Car Stereo,” which encourage them to work with theirhands. The novelty of the delivery systems, coupled with more age-appropriate and interestingprojects, introduce middle and high school students to the

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

James Sample, Oregon Institute of Technology; John Anderson, Oregon Institute of Technology

Tagged Divisions

Manufacturing

adapted from common appliances such as hand drillsand hot melt glue guns to emulate common industrial processes. The work cell can be easilyduplicated at low initial cost and ongoing maintenance. Undergraduate student teams wereintegrated with graduate students to design and build the system.IntroductionThis work was sponsored through the Graduate Fellowship Program of the Oregon NASA SpaceGrant Consortium. At the onset of this project the Mechanical and Manufacturing Engineering(MMET) department at the Oregon Institute of Technology had just a handful of functioningrobots, even fewer robotic work cells, and none which were fully capable of simulatingmanufacturing assembly processes. This scenario left the MMET department with few real-worldtools

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Tayte Nelson, Oregon Institute of Technology; Jialu Xie, Oregon Institute of Technology; John Anderson, Oregon Institute of Technology

Tagged Divisions

Manufacturing

industry and government funded research projects. He is currently Co PI of a National Science Foundation Grant to facilitate the pipeline of new engineers into the aerospace manufacturing industry segment. Page 14.106.1© American Society for Engineering Education, 2009 Flexible Robotic ManufacturingAbstractThe following paper describes a hardware and software system used in modeling anautomatic flexible manufacturing system. This system was designed, constructed andtested by students at the Oregon Institute of Technology to model an agile manufacturingsystem. The focus of this system is exploring

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

George Gray, Texas Tech

Tagged Divisions

Manufacturing

.” ≠ “really enjoyed the welding, machining was also very useful and interesting.” ≠ “the more focus on practical manufacturing methods, the better. ME courses already provide plenty of theory. Good practical knowledge is important for engineers.” ≠ “I only wish we had more time.”These hands-on manufacturing activities can also be very valuable as recruiting and retentiontools within the engineering disciplines, as students seem to relate better and stay focused withintheir chosen engineering fields when they are actively engaged in hands-on projects early on intheir curricula. The hands-on lab in a supportive learning environment helps to develop a senseof involvement and fun for the

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Priya Manohar, Robert Morris University

Tagged Divisions

Manufacturing

the choice ofmanufacturing processes, and finally to the insight as to why these materials are able todo the job that is required of them – this enquiry being the essential building block ofmaterials science knowledge. The remainder of the term was the supplementary bottom-up approach that followed the conventional body of knowledge sequence such as crystalstructures, phase diagrams, heat treatment principles and so on. The top-down approachincluded among other things two main teaching tools. The first tool consisted ofliterature research projects conducted by each student on a contemporary topic inmaterials engineering. The students were given research papers from current materialsscience journals as their primary resource. The students were

Conference Session

Manufacturing Division Poster Session

Collection

2009 Annual Conference & Exposition

Authors

Jeremy Li, University of Bridgeport

Tagged Divisions

Manufacturing

control plan morerealistic. FMEA seems to work best when a team documents its knowledge on cause- andeffect-relationships. In this analysis mode, the timely sequence of failure events should beworked out first, before entering results into a FMEA sheet. The students will learn howto apply this technology to improve the company’s competition in today’s market.Class projectsAll class formal projects, which are referenced from some U.S. famous and successfulcompanies, are introduced and assigned to students to help them in learning and planningthe manufacturing strategy in today’s industry. The instructor has brought his extensiveindustrial experiences in the class to help students in their project preparation andlearning process.The sampled class

Conference Session

Technology Integration in the Classroom

Collection

2009 Annual Conference & Exposition

Authors

Ann Goebel, Minnesota State University, Mankato; Harry Petersen, Minnesota State University, Mankato; William Peterson, Minnesota State University, Mankato

Tagged Divisions

Manufacturing

the delivery of onlinecurriculum and services. The Minnesota State University System consists of 33 state universities,community colleges, technical colleges and combined community and technical colleges locatedon 53 campuses. The system serves approximately 235,000 students annually in credit-basedcourses and another 130,000 in non-credit courses. A primary vehicle for the state universitysystem’s online entity support is largely demonstrated through seed grants for online course orprogram development. As pedagogically necessary, portions of the online program or coursewere able to be customized to use applied activities such as a course cohort activity. For thedepartment courses either a capstone project or a lab experience were integrated

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Kevin Devine, Illinois State University

Tagged Divisions

Manufacturing

cells. Also, costly problems with work cell layout, end ofarm tooling (EOT) and work holding devices are often not discovered until after they arephysically built and the programmer attempts to teach a program6.The exclusive use of teach pendants and on-line programming has many drawbacks ininstructional settings as well. In many, but not all cases8, there is no practical way to project theteach pendant screens and menus, presenting logistics problems during instruction. Further, dueto cost constraints, most engineering technology programs have very few industrial robotsavailable for instruction, effectively creating an instructional bottleneck when lab activities relyheavily on the use teach pendants. Further complicating matters is the fact

Conference Session

Manufacturing Curricula for the Year 2015 and Beyond

Collection

2009 Annual Conference & Exposition

Authors

Hugh Jack, Grand Valley State University; Venkitaswamy Raju, State University of New York, Farmingdale; David Wells, North Dakota State University; Robert Mott, University of Dayton

Tagged Divisions

Manufacturing

manufacturing educationWhat follows is a brief description of the state of each of these areas. These should be viewed asa work in progress that should be nearing completion in June of 2009.What Industry Needs From Our GraduatesThe discipline of manufacturing engineering is inherently tied to the current and emerging needsof the manufacturing industry. The diversity of manufacturers guarantees a large and diverse listof topics. It is widely agreed that while some of these are common to all industries, others arehighly specific to manufacturing sectors and regions. A partial list of topics that have beengenerally identified as core requirements are itemized below. ≠ Project Management ≠ Global Perspective ≠ Methods such as six sigma, lean

Conference Session

Manufacturing Curricula for the Year 2015 and Beyond

Collection

2009 Annual Conference & Exposition

Authors

Venkitaswamy Raju, State University of New York-Farmingdale

Tagged Divisions

Manufacturing

) State University of New York – Farmingdale, NY 11735Abstract:The project leading to this paper was carried out as part of SME’s efforts to prepare themanufacturing curricula for the year 2015 and beyond. In doing so, it considered the roleof manufacturing in the global economy, the factors affecting the scope of manufacturing,and the current efforts to revitalize manufacturing in the various parts of the world. Itthen reviewed the curricular models proposed to address the needs of the manufacturingindustry. As an extension of the analysis, recommendations were made on the key aspectsof a manufacturing curriculum with an emphasis on innovation and entrepreneurship.Further, the recommendations included the creation of a flexible degree program

Conference Session

Micromachining in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Clifford Mirman, Northern Illinois University; Andrew Otieno, Northern Illinois University

Tagged Divisions

Manufacturing

, especially for steels, and cutting conditions are stilluncertain and work continues to be done in these areas [2, 9, 10]. In addition to these factors, themechanics of micro-cutting is still a relatively new area, not well understood. In micro-cutting,there is no formal explanation of scaling effects (also referred to as “size effects”), for example,in the relationship between material removal rate and the specific cutting energy [5]. Thus, thereis a need for continued research in this area.Through funding provided by the U.S. Army, TACOM, Northern Illinois University (NIU)engineering and technology researchers developed a new generation low cost machine tool. Inthe same project, studies were conducted to examine material removal rates for different

Conference Session

Automation and Robotics Subjects in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Arif Sirinterlikci, Robert Morris University

Tagged Divisions

Manufacturing

-Integral-Derivative (PID) controls illustrated in Figure 44. This isassociated with a current research project on Real-Time PAC based controls. Figure 2.a NI LabView Model of a simple digital logic example .b NI ELVIS circuit for the model Page 14.1341.3 Figure 3. PLC Ladder logic for a mixer application written in RS Logix 5003Up to this point, the schedule of the course includes hard-wired controls based on ladderdiagrams and PLC systems programmed by ladder logic. The crucial role of ladder diagrams andladder logic in controls has been covered in detail with the utilization of two these areas. On

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Christopher Pung, Grand Valley State University

Tagged Divisions

Manufacturing

ExperimentsAbstractThe faculty at Grand Valley State University, a primarily undergraduateengineering school, use black boxes to teach basic design of experimentstechniques. The black boxes are literally wooden cubes painted black with fourknobs projecting from the surface for the adjustable variables. One of the knobswas a dummy and did not affect the response. The measured response is theheight of a metal rod projecting from the top of the box. Anecdotal evidencesuggests that the black boxes were an effective teaching aid.I IntroductionDesign of Experiments (DOE) is a useful tool for practicing engineers1,2,3. It canbe applied to both processes and products. DOE is a very efficient methodologyfor generating a great deal of useful data with a minimum of

Conference Session

Innovations in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Sheng-Jen Hsieh, Texas A&M University

Tagged Divisions

Manufacturing

orchestrate andsynchronize the process being automated. Development of expertise in system integrationtypically requires several years of industry experience. Needed is a deeper understanding of howengineers become experts in this area. This understanding can then be used to help students andnew engineers to develop system integration skills reliably and efficiently.For the past five years, the author has conducted interviews with engineers from 17 U.S. and 5European system integration companies. The interviews were conducted in two rounds. Thegoal of the first round was to develop a basic understanding of the work environment withinsystem integration firms, including types of projects, roles, constraints, and available tools andresources. These

Conference Session

Our Future in Manufacturing: STEM Outreach

Collection

2009 Annual Conference & Exposition

Authors

Tom Brady, Purdue University, North Central

Tagged Divisions

Manufacturing

].As technology and computers have become pervasive in manufacturing, so too has the need formanufacturing employees to be technically proficient. Many high tech firms encourage andstrongly suggest that floor-level manufacturing employees have some type of college or technicalschool training.Manufacturing is the largest sector of the economy in the state of Indiana with approximatelytwenty one percent of the workforce employed in it. Major products manufactured in the stateinclude automobiles, trucks, engines, caskets, furniture, orthopedic implants, air compressors,bearings, steel, and pharmaceuticals.As a result of dire projections of manufacturing employee shortages, the Center for WorkforceInnovations(CWI), an agency of the Indiana state

Conference Session

Manufacturing Curricula for the Year 2015 and Beyond

Collection

2009 Annual Conference & Exposition

Authors

Hugh Jack, Grand Valley State University; Venkitaswamy Raju, State University of New York, Farmingdale; David Wells, North Dakota State University; Robert Mott, University of Dayton

Tagged Divisions

Manufacturing

research in manufacturing can be quickly and effectively transferred from research projects or industry developments into manufacturing curricula. Session 3: Emerging Methods of Educational Delivery - Alternatives to lecture-based instruction; activity- based learning; project-based learning; case-study based learning; role of laboratories – projected changes, distance learning – Web based; distributed hybrid; role of cooperative education; internships; industry-based education; continuing education, etc. Session 4: Manufacturing Topics in Other Engineering Disciplines - Manufacturing immersed in other (non-manufacturing-named) engineering curricula (mechanical, industrial, electrical

Conference Session

Design Education in Manufacturing Programs

Collection

2009 Annual Conference & Exposition

Authors

Ramesh Narang, Indiana University-Purdue University, Fort Wayne; Jihad Albayyari

Tagged Divisions

Manufacturing

graphical format. It provides insight into product attributesthat are perceived as important by the user population. It is an excellent tool for helping designand quality teams to focus on product features that will set them apart from their competitors.Additionally, the model helps product developers to concentrate on simultaneous design ofproduct families rather than focusing on one product at-a-time.In the ‘Design for Manufacturing’ course, students learn the Kano analysis and some students dotheir course project using this model to a product of their interest. The paper describes the Kanomodel and how it can be used in product design. Even though the model can be used to definemultiple products simultaneously, the content of the model in this

Conference Session

Implementation of Experiments in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Benxin Wu, Illinois Institute of Technology

Tagged Divisions

Manufacturing

beenfound that many students feel that the class is a little bit boring, and one of the reasons is that theclass does not have an experimental section, and the students do not have the opportunities to seeand/or practice what they have seen in the lecture notes or textbooks. For example, during thefinal official evaluation of the class organized by the university, some students commented:• “This course is only theory based. Student can not have any practical knowledge about the different machining process.• “Student should have the opportunity to do practical manufacturing project.”It has also been found that the attendance rate became lower as the class went on, and in somecases it even dropped to below 30%, implying the lack of the

Conference Session

Manufacturing Education Curriculum

Collection

2009 Annual Conference & Exposition

Authors

Louis Reifschneider, Illinois State University

Tagged Divisions

Manufacturing

curriculums. However, the advent of lower cost rapidprototyping technology capable of making molds that can withstand the temperatures andpressures of thermoforming provides a means to teach net-shaped product design in semester-long courses. This paper provides examples of student projects that illustrate the level of designcomplexity possible with the paired use of prototyping and thermoforming. Finally, some of thecosts associated with the prototyping and forming technologies are outlined to provide a measureof the resources required to implement this strategy in a design curriculum.Why net-shaped processing mattersWhile many product design courses utilize rapid prototyping to communicate the form and fit ofdesigns1, the focus of this paper is to

Conference Session

Micromachining in Manufacturing Education

Collection

2009 Annual Conference & Exposition

Authors

Wesley Stone, Western Carolina University; John Graham, Western Carolina University

Tagged Divisions

Manufacturing

spot size adjustable between 6 and 24 microns (μm) with CNC axis resolution at 0.1 μm. This provides the capability of micron-level high- precision machining. A human hair is typically on the order of 50 to 100 μm in diameter. • Two solid-state cameras assist in precision alignment, while two additional solid-state cameras provide access to view the machining process during operation. • The PC drives three LCD monitors. A fourth LCD monitor is used to display the image projected by one of the two cameras in the workspace. • It is a completely enclosed class I system which means that when all doors and interlocks are closed, the laser is completely safe to be around. • Inside the enclosure, the

Conference Session

Technology Integration in the Classroom

Collection

2009 Annual Conference & Exposition

Authors

Hung-da Wan, University of Texas, San Antonio; Venkata Tarun Cherukuri, University of Texas, San Antonio; Saumya Tamma, University of Texas, San Antonio; Kranthi Kumar Tiyyagura, University of Texas, San Antonio

Tagged Divisions

Manufacturing

an innovative web-based application, the Interactive Roadmap,to provide an exciting learning environment for high school students, who are interested inengineering. The roadmap of a manufacturing project from Computer-Aided Design (CAD)modeling to Rapid Prototyping (RP) is developed for young students to gain knowledge andhands-on experiences in the field of manufacturing engineering. The interactive roadmap,presented as a treasure map, contains several training modules under the main topic. Themodules are cross-linked to provide various alternative pathways for the students to explore thewhole package in the way they choose. Students gain credits as they visit each stop and completethe associated quiz or assignment until they finish the