Past Senior Design Projects

Past Senior Design Projects | 2022

Each semester we have the pleasure of working with local companies on projects as part of our Senior Design Program. These projects are an opportunity for companies to use student resources to have new concepts and fresh ideas injected into their real-world projects. This sponsorship is rewarding for both the project sponsor and the student team. We would like to thank all our past sponsors for their participation in the program.

Spring 2022 | Photo Gallery


Won 2nd Place

Becton, Dickinson and Company

Student Team: Keegan Bigoness, Cat Cobb, Chase del Charco

A Becton Dickinson distribution center experienced a dramatic decrease in output last year. This team diagnosed root causes intending to improve productivity by 15 boxes per man-hour. The team identified significant process impediments through time studies and stakeholder interviews and proposed relevant solutions.

Feed the Pack | The Food Pantry at NC State

Feed-the-Pack Food Pantry

Student Team: Alec Karam, Sammy Penninger, Jack Werner

The Feed-the-Pack Food Pantry is a project is centered around optimizing the inventory of the on-campus food pantry that serves the NC State Community. By recording the produce weights, this team developed an improved method to keep track of supply and demand using software called AppSheet.


Hanesbrands Inc – Canterbury Distribution Center

Student Team: Brendan Little, Stacy McDearmon, Phillip Sellers, Jeel Vachhani

Hanesbrand Inc. requested this team to determine if pulling and locating processes in their warehouse meet current Engineering Labor Standards. They created Standard Operating Procedures for these processes and conducted time studies on the current state of these processes to evaluate and update their labor efficiency standards.


Fan Favorite

Hanesbrands Inc – Cleveland Distribution Center

Student Team: Claire Carter, Flavio Leon, Sophie Minnick, Jordan Shore

Hanesbrand Inc. wanted to ensure that the Engineering Labor Standards for the Pick-to-Light process used to create shipment orders were still in line with the current process. The team gathered data by conducting several time studies to determine if the process labor standards are accurate today.

Home Chef

Home Chef

Student Team: Kyle House, Thad McInnis, Molly McLean, Anna Tavernaro

Home Chef currently struggles with produce spoilage throughout their meal delivery box transit. To reduce time and money spent on testing improved box designs, this team has created a thermal simulation in SolidWorks to use before developing and testing a new prototype box.



Student Team: Micah Perry, Joseph Pobrica, Thomas Quinn, Chris Toy

Leesona is currently absent from the carbon fiber market due to their inability to produce a carbon fiber winder. To create a competitive product that can enter the market, this design team examined competitors’ products and existing design patents to determine the right approach. They ultimately finalized designs for a new cutting and spool change process and an optimized yarn path.

SAS | Wakemed

SAS/WakeMed Milk Bank

Student Team: Joseph Barnabei, Anna Najjar, Lily Sullivan, Dayang Zheng

WakeMed Mothers’ Milk Bank requires potential donors to go through screening that currently takes two months on average to complete, causing many donors to drop out before approval. Our team created process diagrams and developed a tool to monitor potential donor progress throughout the screening process.

SEE | Sealed Air

Sealed Air

Student Team: Wes Hankinson, Jason Hohe, Saiesh Prabhu, Melissa Tennant

Sealed Air has proposed a future automated warehouse layout that will use automated vehicles and storage systems in place of their current forklifts. This team has simulated the future warehouse layout to determine the feasibility and efficiency of their design and provide Sealed Air with valuable insights and recommendations.

TapRoot - Root Cause Analysis


Student Team: Hannah Bauer, Meriem Laroussi, Jackson Law, Ean Lawrence

Undergraduate and Graduate-level engineering teams from four US universities have received virtual training from TapRooT® certified instructors and given an incident to analyze. This team investigated a hazardous waste fire incident, found root causes, implemented corrective actions, and presented findings at TapRooT’s Global Summit in Knoxville, Tennessee.

United States Army Reserve seal and the seal of the US Army 200th Military Police Command

US Army 200th Military Police Command

Student Team: Brenna Kenney, Abby Lampe, Eneko Zubizarreta

The US Army Reserve is currently looking to update its current systems for tracking and maintaining the accountability of detainees. This team is working to provide the 200th MP command with modern and reliable solutions to update and improve their current systems.

United States Army Reserve seal and the seal of the US Army 75th Innovation Command

US Army Reserve 75th Innovation Command

Student Team: Matthew Clayton, Brian Scott, Julie Talbot

The US Army Reserve struggles to maintain its ROWPU vehicles due to unavailable parts. This team is working on expanding its 3D manufacturing capabilities by providing CAD models and proof of concept for existing parts and creating a rapid manufacturing outline for future implementation and use.

Vanguard Furniture

Vanguard Furniture – Frame Build Cell

Student Team: Jonah Andrews, Kyle Browning, Axel Flores-Roman, Rachel Harris

Vanguard requested that this senior design team find areas to improve the efficiency of the frame building section. The team chose to supply the company with an MDI (Managing Daily Improvement) Dashboard with operating instructions, an alternate floorplan proposal to increase efficiency, and a proposal for a counter-balance system to improve ergonomics.

Vanguard Furniture

Vanguard Furniture – Upholstery Cell

Student Team: Mooad Al Wakil, John Corley, Tanner Drew, Evelyn Stouse

Vanguard Furniture currently has a decentralized upholstery division, leading to wasted floor space, minimal line balancing, and a high error rate. The senior design team designed new layouts for consolidating upholstery. The results reduced total utilized space by 40%, added the option for line balancing, and enabled future expansion.

NC State University

Wake Community-University Partnership

Student Team: Gerardo Morado, Sarah Russell, Christal Walker

This team’s goal is to complete a feasibility analysis on the viability of co-hub working spaces in Southeast Raleigh. They aim to develop a business plan and financial model that meets the community’s needs. Their data is gathered through conversations with local coworking space owners, surveys sent to the members of Southeast Raleigh, and relevant co-hub research.

Wolfpack Pharma

Won 3rd Place

Wolfpack Pharma

Student Team: Madison Crick, Luke DeVal, Matt Dowd, Sydney Floyd

Wolfpack Pharma is building a warehouse to expand storage/manufacturing capacity and needs a scalable modeling system using palletized movements to predict their future state process. The senior design team created a spaghetti diagram to plan a traffic pattern, a Simio model to illustrate anticipated AMR requirements, and a user guide as instructions.

*This is a representation of a real company for whom we are honoring their NDA requirements