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An Innovative Approach to an Integrated Design and Manufacturing Multi-site “Cloud-based” Capstone Project

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Conference

2012 ASEE International Forum

Location

San Antonio, Texas

Publication Date

June 9, 2012

Start Date

June 9, 2012

End Date

June 10, 2012

Conference Session

Track 1 - Student Development

Tagged Topic

Track 1 - Student Development

Page Count

22

Page Numbers

17.6.1 - 17.6.22

Permanent URL

https://peer.asee.org/17028

Download Count

32

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Paper Authors

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Michael Richey The Boeing Company

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Michael Richey is an Associate Technical Fellow currently assigned to support technology and innovation research at the Boeing Company. Michael is responsible for leading a team conducting research projects to improve the learning experience for engineers and technicians. His research encompasses, Complex Adaptive Systems, Learning Curves, Learning Sciences and Engineering Education Research focusing on understanding the interplay between knowledge spillovers, innovation, wealth creation, and economies of scale as they are manifested in questions of growth, evolvability, adaptability and sustainability. Additional responsibilities include providing business leadership for engineering technical and professional educational programs. This includes development of engineering programs in advanced aircraft construction, composites structures and product lifecycle management. Michael is responsible for leading cross-organizational teams from academic, government focusing on how engineering education must acknowledge and incorporate this new information and knowledge to build new methodologies and paradigms that engage these developments in practice.
Michael holds a PhD in Strategy, Programme and Project Management, with a focus on Engineering Education Research from Skema Business School, and a Stanford Certified Project Manager (SCPM) certificate from Stanford Center for Professional Development. Michael often represents Boeing internationally and domestically as a speaker - presenter and has authored multiple patents on Computer-Aided Design and Computer-Aided Manufacturing and has published a book on nano science and multiple papers in lead journals addressing topics in large scale system integration and learning sciences.

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Fabian Zender Georgia Institute of Technology

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Fabian Zender obtained his Undergraduate degree in Aerospace Engineering from the Georgia Institute of Technology in May of 2012. He is currently working towards completing the requirements for a PhD in Aerospace Engineering which he hopes to complete by 2015. Fabian has been working in the Integrated Product Lifecycle Engineering (IPLE) Laboratory and has been involved in a variety of research as an undergraduate. Some of his research includes leading a team of undergraduate students from three universities, testing multi-user CAx tools developed under a NSF grant. Fabian has also been involved in the MENTOR project funded by DARPA which is designed to engage and interest high school students in the STEM areas. Fabians research interests include fixed-wing and rotorcraft design as well as the inclusion of Computer Aided Engineering (CAE) tools in the systems engineering process. He is also studying the impact of global collaboration on design.

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Daniel P. Schrage Georgia Institute of Technology

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Dr. Schrage is a professor in the School of Aerospace Engineering and Director of the U.S. Army Vertical Lift Research Center of Excellence (VLRCOE), a position he has held since 1986. Prior to coming to Georgia Tech in 1984, Dr. Schrage served as an Army aviator, engineer, manager and senior executive servant with the U.S. Army Aviation Systems Command (AVSCOM) for ten years. As a dynamics, vibrations and aeroelasticity engineer he served as the Army’s expert in these areas during the design and development of all the Army’s major aviation systems, including the UH-60 Black Hawk, the AH-64 Apache, the CH-47D Chinook, and the OH-58D Kiowa Warrior helicopters, as well as major upgrades to Army Aviation fixed wing aircraft, such as the RU-21D, and OV-1D Mohawk. In addition, he served as the dynamics evaluator and technical area chief on Army Aviation major Source Selection Evaluation Boards (SSEBs), that led to the development of these systems. As the Chief of the Structures and Aeromechanics Division, AVSCOM Dr. Schrage oversaw the airworthiness qualification and engineering development efforts for all new and upgraded Army aviation systems and provided engineering support to the program managers for these systems. As the Director for Advanced Systems and the Associate Technical Director at SES Level 3, Dr. Schrage oversaw the Command’s Science and Technology program, a joint program with NASA which was the largest in the Army, and also led the concept development for new systems, such as the LHX, which led to the development of the RAH-66 Comanche helicopter. Dr. Schrage also served on a temporary assignment as the Chief Scientist for the Army’s Combined Arms Center (CAC) and was an active duty Army aviator/commander and field artillery battery commander with combat experience in Southeast Asia.
Also, during the 1980s and 1990s, Dr. Schrage served as a consultant for the Army (Army Science Board twice), Air Force (Air Force Studies Board), the Institute for Defense Analysis (IDA), NASA and industry. As a member of the National Center for Advanced Technologies (NCAT) Executive Committee in the 1990s, Dr. Schrage defined the Integrated Product/Process Development (IPPD) methodology that was taught by NCAT through short courses and video based instruction for the Army, Navy and industry as part of the DoD acquisition reform effort.
Dr Schrage has written a number of book chapters and has over 100 refereed publications and is a Fellow of both the AHS and AIAA.

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Greg Jensen NSF Center for e-Design –BYU Site

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C. Greg Jensen joined the faculty at BYU in 1983. He received both his BS and MS at BYU. In 1993 he completed his dissertation, “Analysis and Synthesis of Multi-axis Sculptured Surface Machining” at Purdue University. He is currently the BYU site director of the NSF IUCRC Center for e-Design that is focused on the development of next generation multiuser collaborative cloud-based CAx tools and methods. Dr. Jensen was chosen as the first Fulton College Professorship of Global Engineering, a position he held from 2007 -2009. Under the direction of Dr. Jensen, BYU’s mechanical engineering students have participated in six PACE global collaborative design projects. From 2006-2010 he directed a PACE Project that spanned 19 time zones and involved 26 national and international schools in the modeling, analysis and manufacturing of four working Formula-1 type racecar. Dr. Jensen has also conducted research in Engineering Design and Modeling found in the specific areas of Computer Aided Geometric Design, Parametric CAx Modeling, and Multi-discipline CAD-centric Design Optimization. He is currently involved in the development next generation CAx tools, curvature matched machining methods, parametrics and customization of CAx tools for industries like Boeing, GM, Pratt & Whitney, ATK, Ford, Belcan, etc.

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Barry McPherson The Boeing Company

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James Fehr The Boeing Company

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James Fehr is currently the Learning, Training and Development (LTD) Senior Manager responsible for Engineering Learning support across The Boeing Company Enterprise. He started his career in aviation in the United States Air Force and in 1988 joined the Boeing team. After holding various production positions supporting Boeing Commercial Airplanes, James joined the Boeing Training and Development Team as an Employee Development Specialist. Expanding on this experience, James accepted a position with Boeing Commercial Aviation Services (CAS) in 1997 where he was responsible for developing technical publications and learning courseware for Boeing Customer Airlines.
James accepted management responsibility for the Boeing 737 maintenance training group in 1998 where he assisted in establishing the global maintenance training network to support Customer Airlines worldwide. In 2004, James rejoined the Boeing Learning, Training and Development team to help launch the new Boeing 787 program. In 2010, James led the LTD team in providing preparatory support and learning strategies that led to Boeing’s success in capturing and launching the KC-46 Tanker program. James is now the Learning, Training and Development (LTD) Senior Manager responsible for engineering learning support to the Boeing Enterprise.
James has a Masters in Business Administration and a Masters Certificate in Project Management from the Keller Graduate School of Management, and a Bachelors of Science degree in Technical Management from DeVry University.

James has a wonderful wife Angela and three great kids, Krista (18), Monica (16) and Anthony (14). As a family, they enjoy road trips in the RV, quad & dirt bike riding and water sports. James and family currently live in Granite Falls, Washington.

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Matthew M. Symmonds The Boeing Company

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David E French The Boeing Company

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Biography – David French,

David French is an engineer and learning science researcher at the Boeing Company in Everett, Washington, where he is currently working with a team conducting research projects to improve the learning experience for Boeing engineers. His current research focus is directed at studying the integration of social networking tools to improve online education and training courses, and examining the communication behaviors of informal groups of learners. He has 25 years experience teaching engineering courses in the workplace, designing assessment tools, and developing courseware and curricula used in training engineers in the commercial and defense product lines. Dave is also committed to helping improve Science, Technology, Engineering, and Math education for K-12 students to grow the supply pipeline of our future technical workforce. Recent projects include development of engineering programs in advanced aircraft design and construction, composites structures and product lifecycle management. He works in the Technology and Innovation group within the Boeing Learning, Training, and Development organization.

Mr. French holds a BS degree in Mechanical Engineering and has completed extensive coursework in adult and industrial education. He has co-authored several research papers pertaining to education in the workplace and product lifecycle management.

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Abstract

An Innovative Approach to an Integrated Design and Manufacturing Multi-site “Cloud-based” Capstone Project C. Greg Jensen Joshua D. Winn Michael Richey David French Barry McPhersonThe Boeing model for design and manufacture of the new airplane program is among the most advancedaircraft programs in existence. The approach includes a complex database of physical and functionalcharacteristics, sub-system design/build plans, and other shared information that supports the broaderproject. In the same way that a new design criterion affects the mechanical properties and engineeringknowledge domains for aircraft structures i.e., metals to composites, suppose university programsadopted courses that required emerging, interdependent relationships between physical productconstraints and multidisciplinary, multicultural globally dispersed members of a design team? Couldgeographically dispersed teams of students complete a design assignment, with subgroups leveragingdistributive expertise independently contributing and collectively impacting the design plan? What if thedesign-build teams partnering with industry, were enrolled in courses across multiple universities, timezones, and functional disciplines university departments?This project details a cyber infrastructure platform (from the cloud) and distributive expertise within thestudents, faculty and industry advisory board members where learning was coordinated across multiplecontexts within a immersive graphical environment and dispersed geographically, all work together tooptimize multidisciplinary aerospace problem within a dynamical complex learning ecology. Thisacademic – industry learning model is not a trivial task to achieve in a cooperative environment andparticularly where grades are an important factor to consider. This concept, when overlaid againstpersonal agency and social structure specifically, the user community, models and rules, could serve asan effective guide for constructing a framework for managing and capturing complex patterns of socialbehavior, closing the industry/university “knowing … doing” gap that persists in undergraduateengineering education.This paper will detail a innovative engineering capstone collaboration between students at BrighamYoung University (BYU), Georgia Tech (GT) and University of Puerto Rico – Mayagüez Campus (UPRM)with industry mentors and learning requirements provided by The Boeing Company. While this is not thefirst multi-university capstone engineering, design and prototyping effort undertaken, it is the first multi-site effort to employ CAx tools that have been modified to allow more than one designer, engineer ormanufacturing personnel to concurrently access the same part or assembly cloud-based model file.Single-user CAx applications of the past three decades are not being modernized by implementingMassive Multiplayer Online Role-playing Games techniques, methods and servers to bring dispersedteam members together to more rapidly model, analyze and prototype the most challenging designs. thDesigns that heretofore have taken an engineer weeks to model can now be modeled in ~1/n using ateam of n designers that have been trained to work collaboratively in a cloud-based CAD model. This isanalogous to one gamer taking on a WoW (World of Warcraft) battle verses a team of gamers winning thesame battle in a fraction of the time it would have taken the single gamer, assuming the single gamercould even complete the complex battle/task.Allowing more engineers, a global digital-brain paradigm, to simultaneously enter the cloud-based CADmodel has also shown improved designs, i.e. more innovative solutions than a single designer wouldgenerate. It also leads to more reliable and reuseable contextual geometry, topology and constraints fordownstream analyses and manufacturing. The modification of these traditional engineering tools issuggesting a major restructuring of undergraduate laboratories, curriculum changes to design,engineering and manufacturing classes and in particular the existing approaches to capstone usingantiquated CAx tools couched in single-user architectures.To examine the viability and readiness of the BYU multi-user CAx tools and leverage GT’s world-classIntegrated Design and Manufacturing (IDM) curriculum, and UPR-Ms’ analysis capabilities, Boeing fundedand mentored a six month capstone project to redesign the F-86 Sabre Jet metal wing with a monolithiccomposite wing. This paper discusses the IDM, composite and multi-user curriculum and multi-user codedevelopment efforts leading up to the launch of the BYU/GT/UPRM project. Next the paper discusses theselection and organization of the team; from choosing Boeing Advisory Board mentors and specialists , tograduate student aids to selecting and assigning of (four) BYU, (three) GT and (three) UPR-Mundergrads. The paper highlights the Phase One student lectures and the Phase two design andanalysis work accomplished as well as lessons learned from using cloud-based CAx tools to bringdispersed team members together. It also discusses how the mentoring from industry experts andspecialists helped to direct and accelerated the team learning. The paper concludes with an engagementblueprint for modernizing and making capstone projects “real-world and experiential” in their exposure tothe IDM processes of the sponsoring company.

Richey, M., & Zender, F., & Schrage, D. P., & Jensen, G., & McPherson, B., & Fehr, J., & Symmonds, M. M., & French, D. E. (2012, June), An Innovative Approach to an Integrated Design and Manufacturing Multi-site “Cloud-based” Capstone Project Paper presented at 2012 ASEE International Forum, San Antonio, Texas. https://peer.asee.org/17028

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