Past Senior Design Projects

Past Senior Design Projects

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 2020

Senior Design Sponsor | Bosch

Won 1st Place

Bosch
Student Team: Zach Arledge, Sarah Gidley, Kristine Kesling, James Pinson, Meredith Rhoney

Bosch is a large home appliance manufacturer in New Bern, NC. They want to shift its dishwasher manufacturing assembly line from lot sizes of 120 to 24 by 2023. This shift will provide more flexibility and increase customization opportunities. The project’s goal is to reduce product transfer times by 60 percent.

The student team first studied the requirements and then redesigned the mobile carts to hold parts in multiples of 24. Since Bosch’s vendors will be using the solution as well, the new carts had to meet their specs also. The new design not only met Bosch’s average weekly demand but was more ergonomically sound than the original.

Senior Design Sponsor | CVG - Commercial Vehicle Group

Commercial Vehicle Group (CVG) – A
Student Team: Caroline Baldauff, Bethany Colglazier, Aditya Patel, Spencer Hebert

CVG is a global vehicle supplier with production facilities in North Carolina. They want to improve on-time delivery and reduce freight costs due to inaccurate shipments. This project will provide CVG with a real-time production tracking system.

The student team improved the company’s shipping process by placing four scanners and a barcode reader in strategic locations. Along with an automated picklist generator, they were able to cut non-value-added time and reduce the risk of manual entry errors.

Senior Design Sponsor | CVG - Commercial Vehicle Group

Commercial Vehicle Group (CVG) – B
Student Team: Chris Hill, Scott Laing, Santiago Morales, Xiwen Xu

CVG supplies vehicle parts to the world from its production facilities in North Carolina. Their current shipping process and facility layout lead to mis-shipped and mislabeled items.

The ISE team provided a real-time production tracking system that provides data for key performance indicators (KPI). Using SIPOC, fishbone diagram and simulation, they identified bottlenecks as well as locations to provide KPI’s. The team recommended installing four 2D barcode readers within the production line for greater production control.

Senior Design Sponsor | Dell EMC

DellEMC
Student Team: John Casabonne, Farrah Jordi, Joseph Magnuson, Kyle Williams, Caroline MacDowell

DellEMC’s Apex, North Carolina facility processes thousands of products each day for their Field Return Material (FRM) Disk Drive Return to Vendor (DDRTV) process. To process these components, the current layout of the facility needs to be more efficient.

The team conducted a work analysis and created a simulation to optimize the workflow of a specific cell. To accommodate the cell for a smaller headcount, the students reduced the queueing area size. This minimized the walking distances between stations. Through this simulation, they also removed unused equipment and inefficient work steps.

Won 3rd Place

Dispensary of Hope
Student Team: Lauren Arnold, Emma Moore, Claire Mayo, Emily Carberry

Dispensary of Hope is a non-profit pharmaceutical distributor that needs optimization models to provide information and develop a growth strategy.

Using their models, the ISE team generated three different lists. These each had ten communities on which the company should focus. This focused lists led to the most significant community impact and a Minimum Viable Product (MVP) algorithm. The MVP quantifies their service level to its current sites, the demand for their services across the country (broken down to the county level) and the National Provider Index’s list of non-profit pharmacies. This data analysis will allow the Dispensary of Hope to target non-profit pharmacy partnerships.

Senior Design Sponsor | KBI Biopharma - A

KBI Biopharma – A
Student Team: Jaiden Augustine, Aiden Berry, Abdullah Al Fadhil, Matthew Rholl

KBI is a biopharmaceutical manufacturing company. They produce batch pharmaceutical products for use in clinical trials and other testing. However, the scheduling of batches is a manual process without specific optimization criteria.

Using Orchestrate software, the student team could schedule 5 percent more batches based on the previous year’s historical data. They were also able to cost-justify the software expense. While analyzing nighttime cleaning schedules, the team was able to generate extra profit.

Senior Design Sponsor | KBI Biopharma - A

KBI Biopharma – B
Student Team: Lingchao Mao, Jacob Marek, Tara Martin, Noah Wenk

KBI Biopharma specializes in cell-line manufacturing, drug development and analytical and formulation development. Efficient process monitoring is critical as some processes can run for 14 to 20 days. Current software is unable to combine multiple data streams into one display.

The ISE team used OSI Pi software to make dashboards that showed the upstream and downstream processes. These dashboards also track equipment effectiveness and product quality.

Senior Design Sponsor | NC State College of Veterinary Medicine

NC State Veterinarian Medicine
Student Team: Sam Bauers, Nolan Fischer, Marzanne DeLapp de Anaya

The NC State College of Veterinary Medicine (CVM) Laboratory Animal Resources (LAR) and Central Procedures Laboratory (CPL) receives 1600 animal research requests yearly. LAR and CPL supply necessary services to the CVM. This system is a massive logistical challenge, and their current process is error-prone.

The student team was able to streamline activity at the facility by developing new versions of the LAR’s forms. The new processes provided the CVM team insight into all requests that are coming down the pipeline. The ability to forecast usage allows the clinic to plan for supplies and capacity, and it also allows for predetermined resource use.

Senior Design Sponsor | Novo Nordisk

Novo Nordisk – A
Student Team: Ross Bolla, Katherine Bygate, Tyler Conrad, Ben Janzow, Sarah Trinkle

Novo Nordisk is a Danish pharmaceutical company specializing in products for diabetes and obesity. The operators in their finished product department had significant idle times, and Novo Nordisk needed a solution. Solving this issue would avoid low product output per operator rates.

The ISE team was able to create a standard staffing and workforce plan for all seven assemblies. With their analysis, they also produced a perfect-state simulation and developed a standardized staffing schedule. The team was also able to create models that improved assembly line coverage as well as cross-training responsibilities for all future state possibilities.

Senior Design Sponsor | Novo Nordisk

Novo Nordisk – B
Student Team: Will Burns, Iman Fisher, Englyn Harris, Alana Oktay, Vishal Sharma

Novo Nordisk is a Danish pharmaceutical manufacturing company and is the largest producer of insulin in the world. Currently, their Clayton, NC facility’s onsite storage exceeded their target capacity. This excess led to the scrapping of production material and increased production costs.

The ISE student team used past data to create more onsite storage space for components of Novo Nordisk’s newest product. They also calculated the flow of products through the facility to account for the product volume cut overflow.

Senior Design Sponsor | Patch Rubber Company

Won 2nd Place

Patch Rubber Company
Student Team: Kathryn Barnes, Charles Blum, Johnny Davis, Eli Wilson, Kevin To

Patch Rubber is a leader in industrial rubber and traffic marking products. Production capacity, layout efficiency and product scheduling are areas needed to support Patch Rubber’s continued growth.

The ISE team was able to create several system improvements through data analysis. These included work standards and line layouts. It also included extra processing equipment as well as scheduling enhancements. Their solution lowered production times and increased throughput. This improvement led to significant capital investments in a 3-week ROI.

Senior Design Sponsor | Qorvo

Qorvo
Student Team: Tyler Anne Giglio, Mithila Khare, Logan Harris, Christian Ebhote, Chelsea Metzger

Qorvo provides the core technologies found in mobile, network infrastructure, and IoT. Their Greensboro, NC operations focus on the assembly of customer-driven prototypes. Accurate factory commit dates (FCDs) are crucial to the plant’s competitiveness and the success of its clients.

Using process-mapping tools, the senior design team built a simulation of a multi-scenario product build process. They then used their ISE skills to model Qorvo’s production system. The simulation tool allows company planners to predict FCDs with much higher accuracy. It also provides more benefits in job and resource scheduling.

Senior Design Sponsor | Ribbon Communications

Ribbon Communications
Student Team: Rachel Dilley, Khoa Huynh, Courtney Jones, Miriam Lavelle

Ribbon Communications installs custom communication infrastructure across North America. Each one of their projects requires close collaboration and communication in four areas. These are fulfillment, deployment, logistics, and the warehouse. Currently, too much time is being wasted sharing information via email. This waste also leads to low productivity.

The ISE students used surveys to understand the processes and their shortfalls. They designed a system that uses resident data and signaling capabilities to streamline and automate information sharing. Their solution has led to an 84 percent improvement.

Fall 2019 | Photo Gallery

Senior Design Sponsor | ABB

Voted Fan Favorite

ABB
Student Team: Jacob Green, Rebecca Griffin, Matthew Parker, John Schell

ABB is a world-class leader in power systems products. The senior design team created a user-interface application that allows users to search for previous successful projects. Once a user inputs search criteria, the application will return the data of past successful projects with similar search characteristics. The user can view costs (supplies, labor, etc.) to gauge pricing for a new project.

Senior Design Sponsor | Carolina Country Snacks

Won 1st Place

Carolina Country Snacks
Student Team: Kevin Church, Jasmine Cooper, Ashton Daniel, Zack Hoeksel

Carolina Country Snacks produces pork skin snacks and a variety of other snack foods. They wanted to improve throughput and optimize bagging operations. The student team gathered shop-floor data to create production standards. They also identified bottlenecks within the production processes, increased bags per minute and cut changeover times.

Senior Design Sponsor | GSK

GSK
Student Team: Claudia Alvarado Espino, Yash Mathradas, Alberto Sucre, Samantha Winterrowd

GSK, a global pharmaceutical manufacturer, wanted to increase the throughput of their metered dose inhalers (MDI) product line. The student team analyzed the packaging process and investigated inefficiencies. The student team made recommendations on machine speeds and operator placement to increase throughput by least 3% while maintaining product quality. A SIMIO simulation model of the packaging line was developed and used to confirm their results.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Steven Lepore, Samuel Stump, Conner Walker

NC State Sports Medicine serves the entire University’s athletics organization. The staff wanted to improve the current manual sign-in processes that include binders of forms and data and no standardization across teams. The senior design team analyzed the entire process and developed an App to streamline the sign-in process. They improved data collection methods and provided a means to share information about an athlete’s rehabilitation.

Senior Design Sponsor | Patch Rubber Company

Won 2nd Place

Patch Rubber Company
Student Team: Pedro Fernandez, Julia Hansen, David Newkirk

Patch Rubber is one of the world’s leading manufacturers of traffic marking tapes. They are expanding into the patterned traffic marking tape market. The student team analyzed product changeovers and current tape processing methods and recommended new SOPs, technologies, and solutions. This allowed for not only a smooth introduction of Patch Rubber’s new product but decreased product changeover times by at least 20%.

Senior Design Sponsor | Note in the Pocket

Note in the Pocket
Student Team: Alexander Balabanov, Matthew Nega, Samuel Young

Note in the Pocket is a non-profit organization that serves Wake County to provide clothing for students in need. They are looking to double their current capacity while serving more children with greater efficiency. The student team established periodic goals for the organization to determine if growth is being met, while also recommending process improvements.

Senior Design Sponsor | Novozymes

Novozymes
Student Team: Ethan Miller, Nicole Niemer, Trent Ploeger

Novozymes is a world-wide producer of commercial enzymes for the food, beverage and household care industries. Unique processing equipment requires expensive maintenance parts that are challenging to source. The team studied additive manufacturing methods to reduce the cost of inventories. The senior design team analyzed the different parts to see which can be 3D-printed. They also looked at alternative manufacturing solutions in case additive manufacturing was not cost-effective.

Spring 2019 | Photo Gallery

Senior Design Sponsor | Century Furniture

Century Furniture
Student Team: Juan Arias, Lisa Grossman, Zachary Johnston

Century Furniture has used the same method for setting fabric waste factors for the last 35 years. These factors play a critical part in determining how much fabric they purchase. The student team’s goal is to discover if there is a more accurate method for determining waste factors and improving inventory accuracy, costing of fabric grades, and customer satisfaction.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG – Concord
Student Team: Victoria Atkins, Brycen Moser, Zoltan Pukanecz

CVG’s Concord facility produces custom-designed products using three types of plastic manufacturing technologies: injection molding, reaction injection molding, and thermoforming. Up until now, they have used an Excel spreadsheet for their injection molding production schedule. The student team’s mission is to develop an automated system that combines their order data from several sources with their equipment availability to streamline their production scheduling process.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG – Concord
Student Team: Joshua Espinoza, Sarah Hartzog, Alexander Janus

CVG’s Concord facility produces custom-designed products using three types of plastic manufacturing technologies: injection molding, reaction injection molding, and thermoforming. As demand has grown, corrugated materials have been stored in random locations this leads to big inefficiencies in the production processes. The student team’s goal is to discover the best way to store these materials to optimize their retrieval and replenishment.

Senior Design Sponsor | CVG - Commercial Vehicle Group

Won 1st Place

CVG – Kings Mountain
Student Team: Wesley Jones, Carl Johnson, Sarah Troxell

Workers at CVG’s Kings Mountain facility apply a sealer to clean water out of the joints of Mack Truck cabs manually. This can cause inconsistent amounts of sealer in the drip rail as well as missing areas altogether. The student team’s job is to create processes to reduce defects before they reach final inspection, therefore, reducing the number of customer complaints. Finally, having these upgrades pay for themselves in the first year.

Senior Design Sponsor | Duke Energy

Duke Energy
Student Team: Gustavo Darquea, Joanna Fletcher, Matthew Halsted, Jacob Nagy

Duke Energy has several call centers that answer millions of calls from their customers many of which are routine transactions. There are often inconsistencies among these transactions. Duke Energy wants to provide a consistent experience for their customers while at the same time improve the productivity and efficiency of their customer service representatives. The student team’s goal is to develop processes that will reduce the average handle time the routine transactions and predict how these processes will improve customer satisfaction.

Senior Design Sponsor | GSK

Won 2nd Place

GSK
Student Team: Madelyn Lammert, Gibson Russell, LaurieBeth Shapiro, Benjamin Talbert

GSK wants to scale up the production of its multi-dose dry powder inhaler line that treat respiratory conditions like asthma and COPD. They want to make sure they maximize the use of the space in their facility. The student team’s job is to create a simulation model that can be used to figure out what is the best use of its facilities, product mix, and staffing.

Senior Design Sponsor | Lenovo

Lenovo
Student Team: Caitlin Daugherty, Troy Luddy, Alexandra Porter

Due to limited space and substantial growth at their US Fulfillment Center, Lenovo is running out of room to store inventory and wants to avoid having to purchase another facility. The student team’s goal is to develop new methods for optimizing storage space and automating the material handling processes.

Senior Design Sponsor | Redhat

Red Hat
Student Team: Anton Ipsen, Nishant Singh, Stewart Spanbauer

Driving product awareness and interest is a critical factor of success for any business. Red Hat wants to research ways to optimize the traditional methods of Demand Generation and measure how much awareness they create. The student team’s goal is to discover the effectiveness of “Blitz” Campaigns, such as mass cold-calling, and offer recommendations on whether they should continue with this campaign compared to lead generation.

Senior Design Sponsor | Secmation

Secmation
Student Team: Brian Chen, Rachel Hicks, Jackson Hudson, Kyle Rogers

The chemical manufacturing industry must take great care in handling and storing the chemicals they produce. Secmation wanted to develop an Unmanned Ground Vehicle system for use in the Leak Detection and Repair (LDAR) process to increase safety and cut environmental impact. The student team’s job is to define the LDAR tasks and methods for performing those tasks. These tasks will then be used to figure out the requirements for robot mobility, manipulation, and sensing capabilities needed. We will also build a draft proposal to obtain funding for our robotic LDAR concept.

Senior Design Sponsor | Syntec

SynTec
Student Team: Madeline Caringi, Alexis Jones, Nicola Sink

Due to limited space, there is a production line balancing issue at SynTec. The small order sizes and small space for storage mean that orders have to be placed on the same pallet, requiring workers to move the parts for newer orders to reach older ones. The student team’s job is to develop a solution that will eliminate the need to stack orders without reducing the output possible.

Senior Design Sponsor | Syntec

SynTec
Student Team: Sean Murray, John Poff, Elizabeth Underkoffler

To better gauge whether or not new employees are effectively learning during training, SynTec wants to create learning curves to better understand employee learning. The student team’s goal is to develop learning curves for every operation in our area.

Senior Design Sponsor | The Medicine Shoppe

Won 3rd Place

The Medicine Shoppe
Student Team: Adelyn Ballard, Hannah Caison, Madison Huckabee, Macie Ware

Medication non-adherence is a serious problem in the US. The Medicine Shoppe is helping address this problem by expanding the number of pills in a pre-made pack. However, problems related to delivery and inventory have occurred as the program grows. The student team needs to determine how many seniors live in a predetermined zone and define the time period of the insurance agencies. This will allow cash flow to be mapped out and controlled.

Senior Design Sponsor | Wright Global Graphics

Wright Global Graphics
Student Team: Joseph Scott, Matthew Simpson, Austin Soell

Due to the desire to downsize, Wright Global Logistics would like to condense its number of facilities to two. The student team’s job is to analyze the footprint of Wright Global Logistics and make recommendations on how to optimize their space. The goal is to reduce the number of buildings used by one.

Fall 2018 | Photo Gallery

Senior Design Sponsor | Altec

Altec
Student Team: Rollin Jenkins, Spain Niemer, Mikayla Slomski

Altec has recently purchased a new facility located nearby its existing campus. They are planning to move all fiberglass operations to the new building. The senior design team developed a solution to transport parts between the two facilities for the manufacturing process.

Senior Design Sponsor | Duke Health

Duke Health
Student Team: Stephen Bryant, Mallory Meissner, Jaliyah Scott

Duke Outpatient Clinic provides primary care and specialty services to a range of patients. Using discrete event simulation, the Duke team has generated scheduling and staffing recommendations to reduce patient wait times and bottlenecks within the system, while providing end to end visibility of healthcare processes at the clinic.

Senior Design Sponsor | HSM

HSM
Student Team: Trevor Bryant, Adam Dorr, Kurtis Konrad, Stephanie Stugg

At HSM Solutions, the plant is experiencing a lack of visibility in their labor and inventory metrics. The student team has designed a system to begin automatically digitizing the information. This system will also reduce unplanned downtime by properly scheduling hand-cutting operations.

Senior Design Spoonsor | IBM

Won 2nd Place

IBM
Student Team: Rodrigo Cabrera, Shadia Garrison, Matt  Hutmacher, Rachel Nagley

IBM wanted to develop a more efficient globally standardized process for reporting its part delivery timeliness (PDT) metric. The ISE team collaborated with several global regions to outline their current processes and used this analysis to create recommendations that dramatically reduced IBM’s PDT reporting time and increased global consistency.

Senior Design Sponsor | Secmation

Secmation
Student Team: Samantha Labertew, Owen Spangler, Matt White

The chemical manufacturing industry must take great care in handling and storing the chemicals they produce. Secmation wanted to develop an Unmanned Ground Vehicle system for use in the Leak Detection and Repair (LDAR) process to increase safety and cut environmental impact.

The ISE student team created a proof of concept simulation that showed design specifications and updated the business case in hopes of receiving funding for the sponsor.

Senior Design Sponsor | Tindall Corp

Tindall
Student Team: Brian Chen, Tanya Lagunas, Jessica Nolting

Tindall’s concrete manufacturing process was not automated due to the fact that each piece was custom-built for a specific job. Manual work gave room for errors with incorrect measurements and faulty pours.

The senior design team used JMP to perform a process capability analysis with data collected at the facility. They made process improvement recommendations based on the results and the observations made at the facility.

Senior Design Sponsor | VA Prime Clinic

Won 1st Place

VA PRIME Clinic
Student Team: Michelle Naclerio, Will Duley, Jianan Tang

In the past, patient scheduling at the Durham VA PRIME Clinic created high wait times for the patients.

The student team developed a comprehensive simulation model of the center to help identify the main problem areas and provided suggestions to help mitigate these issues.

Spring 2018 | Photo Gallery

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar
Student Team: Grant Fatyol, Brent Goldstein, Lizzy Kroeger, Meghan Murphy, Bobby Rosene

The purpose of this project is to analyze and model the Cab and CTL subassembly operations to aid in the visualization of Caterpillar’s supply chain. Using the developed simulation model, recommendations to eliminate waste and optimize efficiency will be generated with the goal of making the Sanford plant the most efficient facility within the company. The simulation model should also be constructed in a manner that allows for it to be scaled up and applied to other operations in the future.

Senior Design Sponsor | Century Furniture

Century Furniture
Student Team: Garrett Becker, Will Biberdorf, Travis Propst, Bo Starnes

Our purpose is to evaluate the forecasting model used by Century Furniture in Hickory, NC. Once we define the forecasts’ accuracy of the current model, we will compare it to at least three additional models. Is the current method of the thirteen-week moving average the best way to forecast demand for chair frames and fabric, or is an alternative model better?

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Emily Lubnow, Troy McLaughlin, Lindsey Rutledge, Cameron Shaffer

CVG wishes to automate their cab inspection process to avoid human error. Once the project is completed, CVG will benefit from more efficient inspection methods with fewer errors and have a searchable, digital database. Elective options for cabs will be the main focus of inspection. Units will be locked in until each elective option has been visually inspected by quality assurance personnel.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Nathan Hilbrands, Ricardo Sucre, Erin Williams

The movement of product through CVG Concord’s S-Rim (Structural Reaction Injection Mold) vehicular dash cell is extremely inefficient, with excessive touches, accumulations of WIP, and excess labor to achieve the end result. How can the current design be optimized to increase productivity and create a more robust and capable production process and value stream?

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Katie Brock, Andrew Daigle, Cassi Nager

Optimize the current inefficient use of warehouse space in the CVG Concord facility which is affecting the flow of materials throughout the facility. Intended results include the organization of equipment and queued inventory to better utilize facility space to reduce high material handling and transportation costs.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Brent Johnson, Ankusha Kumar, Sean McGovern

Currently, CVG has no method of recording OEE and key performance metrics for the IM, RIM, and Thermoforming operations. the goal is to develop a tool in Access to represent and display the information so upper management can have a better understanding of performance in the plant on a daily basis. Once each individual process is monitored using this tool, the team will also adapt our tool for OEE of the entire plant.

Senior Design Sponsor | Honeywell

Honeywell
Student Team: AJ Cole, Tanner Harris, Rachael Hoellig, Aaron Thomas

The inefficient use of space in the Honeywell Raleigh Lab limits new product introduction and new product enhancement (NPI/NPE) process efficiency and reduces the safety of the testing facility. There is a limited amount of workspace in the Raleigh location and low utilization of the tools and materials. Also, the space limits the ability to meet spatial requirements. The problem is expected to increase as production increases. How can Honeywell locate equipment and NPI/NPE resources to increase efficiency, improve lab safety, and consolidate space?

Senior Design Sponsor | NC DOT

NC DOT
Student Team: Charlene Ballard, John Bensink, Anna Costa, Sam Ferry, Zack Kelley

Without the direct approval of funding from the legislative, the NCDOT is unable to complete necessary tasks as the need arises. The purpose of this project is to propose suggested facility rental rates so that the NCDOT can produce a profit internally and have money available in a revolving fund to spend on high priority tasks as they arise. What rate should be assigned to each building category?

Senior Design Sponsor | NC DIT

Won 3rd Place

NC DIT
Student Team: Sydney Green, Greg Hauser, Tochi Ogu, Alec Thomas

This project is being pursued to help the State Chief Information Officer, Chief Customer Service Officer, and managers to help indicate the improvement needed in the NC Department of IT. The team will produce a process road map for implementation at NCDIT to improve and allow for easy access to information for their reporting system. With this, they also hope to improve the performance of each team within NCDIT.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Ryan Halford, Lindsey Spiwak, Kelly White, Taylor Wingate

The NC State Sports Medicine Program wants to ensure that they meet the NCAA requirements for concussion and injury management and continue to evolve, providing the most efficient healthcare to their athletes. The program has already identified that the current process can lead to miscommunication and lacks documentation. They are concerned about students’ safety and potential lawsuits. How can the protocol be evaluated and streamlined to establish clear procedures that are effectively monitored and understood?

Robbins Area Christian Ministries

Won 2nd Place

Robbins Area Christian Ministries
Student Team: Julie DeVita, Tori Johnson, Dyllan Moss, Davis Mossman

Prepare, plan, and establish a food pantry for the Robbins County church group, in order to feed the local population. Once completed, the pantry will serve as a smooth-running, easily understood facility. It will provide for those in need, as well as having a flexible and dynamic storage system.

Senior Design Sponsor | SAS

SAS
Student Team: Natalie Barbu, Max Davis, Cort Hlavin, James Ross Ally Schueneman

SAS is currently using Excel as the main planning tool for venue and catering orders for its Global Forum Event. The spreadsheet(s) are not performing automatic calculations related to costs and food/beverage orders for large customer events. What is the best way to implement a new user-friendly and automated planning tool that will determine overall financial impact, behavioral analysis, customer experience and provide connections between event and sales leads/software revenue?

Senior Design Sponsor | SAS

Won 1st Place

SAS
Student Team: Savannah Abel, Ben Craver, Philip Greco, Annie Lin, Michael Rosenberg

The senior design team will analyze the transportation needs of students who live further away from the public schools in Boston, MA. This project will identify inequities and propose solutions with respect to the needs of students whose commute require shuttle buses and MBTA utilization. The team will analyze the students that are eligible for these shuttle buses and report statistics on potential inequities in this shuttle bus program. In addition, the team will propose alternatives on how to more efficiently transport these outlying students to and from the schools.

Senior Design Sponsor | SAS

SAS
Student Team: David Angelucci, Will Margolin, Carter McKinstry, Ethan Stewart, Danielle Sumner

The purpose of this project is to optimize current data collection and tracking of large event expenditures by implementing updated version management and access control.

Senior Design Sponsor | Secmation

Secmation
Student Team: Addison Garrigus, Dylan Kane, Michael Londa, Brandon Thio

Secmation is currently focused on providing information security services. They are looking into potentially expanding their business into the UGV market. What is a reasonable industry use for UGVs that Secmation can pursue?

Senior Design Sponsor | Toshiba

Toshiba
Student Team: Amy Bevilacqua, Nicole Brugnoli, Anjali Mani, Jeremy Mason, Joshua Ratliff

Toshiba wants to compete with the online shopping trend by redoing their front end process to keep up with technology and process improvements that are changing the way customers interact within retail. Accommodate to customer demographics according to their individual needs and behaviors through our group’s alignment with the target market.

Fall 2017 | Photo Gallery

Senior Design Sponsor | Caterpillar, Inc.

Won 2nd Place

Caterpillar
Student Team: Everette Jordan, Catherine Root, Michael Schlesinger

Caterpillar, Sanford Operations, assembles several varieties of Skid Steer Loaders. In order to increase production levels, process flow analysis will be used to model and evaluate current standard work in the Post Assembly Process.

Optimization of flows and the elimination of waste within the process will be primary objectives, which may lead to layout and staffing changes, among other recommendations.

Duke Energy Logo

Duke Energy
Student Team: Addie Jackson, Lisa Peacock, Clay Stroud, Alicia Vazquez, Anthony Williams

In an effort to better serve customers and open new service markets, Duke Energy’s Digital Infrastructure Team will leverage prepositioned assets, namely streetlight poles, as city-integrated digital centers poised to enhance communities and the visitor experience.

The NC State senior design team will conduct research to expose use cases for the camera and public Wi-Fi networks within the Raleigh beltline, culminating with a recommendation to Duke Energy to serve as a basis for future smart city deployment. A scalable, cost-conscious building block model of a sustainable digital infrastructure system that emphasizes optimal asset location and expandable service for a broad spectrum of communities will be the project’s target deliverable.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Anna Honnold, Cassidey Sowards, Margaret Tobey

Currently, NC State Sports Medicine requires its student-athletes to document medical histories, which are then transcribed into soft-copy form and uploaded to independent, health tracking and records management systems. In order to reduce time and increase accuracy throughout the initial and subsequent information-gathering phases, a paperless, electronic documentation system that leverages software automation tools to assist reviewers is needed.

The project will focus on system functionality, including ease of use, information sharing and upload to third-party software systems. Compliance with regulatory agencies, relevant laws, guidelines, and standards (HIPAA, FERPA, & NCAA) will all be key metrics throughout the project, and upload it to third-party software systems. Compliance with regulatory agencies, relevant laws, guidelines, and standards (HIPAA, FERPA, & NCAA) will all be key metrics throughout the project.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Madeleine Fleming, Chris Kelly, Colin Nolan-Cherry

NC State Sports Medicine currently uses FileMaker, a software application development platform, to build smart device “apps” to manage equipment inventories and the distribution of over the counter (OTC) medication. Where the NCSU Sports Medicine Department is satisfied with current system performance, limitations exist in the area of tracking prescription medications.

This project will provide an accurate and robust, real-time electronic method of keeping track of medications prescribed to student-athletes, so described under the guidelines set forth by NATA. Furthermore, methods of providing the NC State Sports Medicine Staff with a way to ensure no contraindications of medications will be an integral component of the tracking/management system.

Senior Design Sponsor | Vanguard Furniture

Won 1st Place

Vanguard Furniture
Student Team: Evan Heath, Hossam Eldin Helal, Lauren Houston

Vanguard, a build-to-order upholstered furniture manufacturer, currently employs assembly methods that promote excess movements and pose potential ergonomics hazards.

Improving Vanguard’s upholstery processes and a redesign of in-process transportation methods (e.g. lift carts) will help Vanguard realize undiscovered efficiencies and increase production rates, all within the framework of a safer work environment and one that promotes the damage-free movement of goods.

Spring 2017 | Photo Gallery

Senior Design Sponsor | Century Furniture

Won 1st Place

Century Furniture
Student Team: Taylor Badgett, Rachel Longenecker, Sean Nanagas, Andrew Nyce

Century Furniture’s sofa manufacturing plant was stocking out of common frame component parts, affecting schedules and disrupting manufacturing operations.

The ISE student team analyzed part storage and ordering methods and rules and developed lot size and reorder models that optimize part availability while minimizing carrying costs, thus respecting desired schedules and forecasts.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Emily Buchenberger, Logan Lane, Austin Minton

New automation has recently been installed at the Commercial Vehicle Group (CVG) plant location in Kings Mountain, NC in support of the next generation Cab system. Even with the newly implemented capabilities, the management team does not believe that functionality for weld gun performance has been optimized.

The ISE team optimized the maintenance schedule and improve process productivity by developing a real-time process monitoring system.

Senior Design Sponsor | CVG - Commercial Vehicle Group

CVG
Student Team: Ben Jones, Mitchell Chalker, Jenna Misenheimer

Existing analog electro-coat processes at Commercial Vehicle Group’s (CVG) Kings Mountain, NC vehicle manufacturing facility use analog and manually operated controls to modify bath operating temperatures. Present methods discourage quality initiatives and are inefficient by today’s standards.

To solve the problem, the ISE team developed an automated system to monitor, collect and report vital process information, and control temperature as well as improve quality performance.

Senior Design Sponsor | Coty

Coty
Student Team: Lauren Garrett, Kalene Hanson, Justin Mauney, Andrew Page

Changeover times between fragrances and associated packaging are inconsistent and wasteful. With the goal of reaching one minute per changeover, the ISE student team improved changeover time by at least 15 percent by analyzing and controlling process centerlines. By eliminating paper logbooks and converting over to a database-driven system, efficiencies with regard to staffing, changeover strategies, run-size strategies, and SKU filling were achieved.

Senior Design Sponsor | Coty

Coty
Student Team: Josh Barclay, Jacob Quinn, Max Uhlig

Bulk losses due to changeover inefficiencies and improper filling of skincare equipment are of cost concern to Coty.

To solve the problem, the ISE student team designed and implemented a process standardization matrix-based around specific key process parameters. The project promoted a 20 percent improvement by way of loss reduction. Quality and production worker training levels will follow as impactful improvements.

Senior Design Sponsor | Coty

Coty
Student Team: Andrew Barmer, Jennifer Frix, Derrick Sprague

Quality and safety are highly visible at the Coty manufacturing plant. Data captured in these areas are valuable and can be used to justify future capital projects. Data already captured have not been quantified into specific costs related to safety or quality.

The ISE student team data mined and identified the leading, lagging, and intangible costs of any particular safety or quality incident and developed a tool that management will be able to use to benchmark Coty’s performance against industry competitors.

Senior Design Sponsor | Dell EMC

Dell EMC
Student Team: David Carpenter, Marian Hudson, Jeremy Lamb, Ryan Stevens

Dell EMC maintains staging inventory for its manufacturing facility at an off-premises warehouse. Besides general inefficiencies observed, racking safety standards enforced at sister facilities have not been implemented at this location.

The ISE student team standardized processes and established best-practice policies related to these activities in an effort to save on warehousing costs, reduce and eliminate safety risks, along with enhancing intra-facility communications.

Senior Design Sponsor | DIME Lab

DIME Lab
Student Team: Jerry Coleman, Austin Colvard, Sigrun Kraehe, Madison Souder

A common customer complaint is that it takes too long to find a suitable vendor that can produce a part, prototype or otherwise, in a “quick-turn” manner.

To solve the problem, the ISE team surveyed 15 local manufacturers and captured data on machine capacity, utilization, order types, how new business is found and the information on the overall quoting process. The team then developed a capacities and capabilities database and provided a simulation tool that reflects machine capacities, scheduled utilization, order and material diversity, as well as quoting parameters.

Senior Design Sponsor | GE

GE
Student Team: Laura Geary, Trent Jones, Ryan Long, Drew Pierce

The 63L Automated Transfer Switch production line is not running efficiently due to a substantial number of defects encountered in the assembly process. The current process state is contributing to lower than desired throughput and lower profits.

The ISE team performed production line flow and balance analyses and designed, iterated and tested new pick carts for production. Through optimization, defects were drastically reduced and throughput increased by at least 10 percent.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Lilah Conley, Mark Denton, Connor Sweeney, Ashley Williams

The NC State Sports Medicine provides student-athletes with Over the Counter (OTC) and Non-steroidal (NSAID) medications. Currently, there is no standard procedure to track medication, which presents safety as well as regulatory concerns.

The ISE student team developed an IOS-compliant tracking system for NC State Sports Medicine Athletic Trainers.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Bailey Davis, Shane Dodd, Ian Goldberg, Taylor Purvis

The NC State Sports Medicine Department relies heavily on the transfer of paper documentation and email trails when it comes to onboarding new employees and the licensure and training of current employees.

To solve the problem, the ISE team determined and implemented the best available system and methods for paperless data management.

Fall 2016 | Photo Gallery

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar
Student Team: Mahmoud Ghoneim, Vika Kiseleva, Sam Nichols, Rebecca Towns

Caterpillar has three production lines (frames, lift arms and roller frames) that are not operating at optimal levels. They want to streamline these operations and improve productivity and control.

To solve this problem, the ISE team will create a simulation model for each individual production line. The team’s goal is to use the model to decrease nonproductive time on the lines by 20 to 25 percent. In the future, Caterpillar engineers will continue to use the model as a decision-making tool for testing possible improvements to their production lines.

Senior Design Sponsor | Joyce Farms

Won 1st Place

Joyce Farms
Student Team: Cole Hamilton, Devin Kelly, Matthew Wadsworth, Brandon Walton

Joyce Farms wants to improve several aspects of their chicken processing production lines (French breast, French breast boneless skinless and chicken breast boneless skinless). They are looking to reduce processing time, product touches and travel distance.
Using value stream mapping techniques, the ISE team will develop a list of changes to improve the system. The team’s goal is to reduce process flow time, the number of product touches and travel distance, as well as regain pallet storage racks. This will be beneficial in controlling inventory and reducing costs.

Senior Design Sponsor | Moen

Moen
Student Team: Caleb Cushing, Claire Hooks, Matthew Kloeblen, Cindy Sink, Caleb Wilson

At Moen’s New Bern Plant, materials arrive from the component warehouse and are then transferred to the production floor using several different methods of transportation. This system causes internal routing delays and it creates an unsafe and inefficient workplace.

The ISE student team will track this internal traffic flow and provide recommendations for a designated route path. The goal is to optimize the plant traffic flow, the number of trucks and the number of workers needed for each shift.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Olivia Adams, Chase Jackson, Lydia Lloyd, Seamus Williams

NC State Sports Medicine utilizes many forms and software programs to collect and store health-related data that is then shared with other internal and external departments. They want to streamline the process of gathering, reviewing, acting upon and disseminating this information.

The ISE student team will make the process more constructive, comprehensive and easy for users and recipients. The goal is to provide the highest quality of healthcare while increasing workflow efficiency.

Senior Design Sponsor | Piedmont Aviation

Piedmont Aviation
Student Team: Jalen Feaster, Zach Gabriel, Brian Hessand, Jonathan Lovin

Piedmont Aviation offers its customers a 30-day guarantee on landing gear repairs. The necessary parts for these repairs are not arriving in time for Piedmont to meet the 30-day mark. The layout of the facility is not optimal and is contributing to the delays.

The ISE student team will gather process times for landing gear overhauls and then create a simulation model to analyze the process for improvements. They will also identify the top 10 parts used in landing gear repairs and develop an inventory policy for storing parts on-site.

Senior Design Sponsor | Precor

Precor
Student Team: John Bolla, Justin Jablonski, James Shirley, Taylor Wilt

Precor has invested in a new robotic welding cell featuring quick-change tooling capability. They need to improve the staffing, supermarket size, lot sizes and scheduling methodologies for the cell.

The ISE student team will assess the robotic welding cell’s current capacity, usage, and bottlenecks. The team’s goal is to create a plan to improve system capacity and effective usage of the robot’s time.

Spring 2016 | Photo Gallery

Senior Design Sponsor | ATI

ATI
Student Team: Eric Nagy, Michael Hartsell, Alex Self

ATI uses a process called Hot Isostatic Pressing in order to condense specialty metals to ensure perfect density. ATI has recognized that the canister used is an integral part of the process cost.

The ISE student team has been conducting a cost analysis on multiple different ways to manufacture the canister.

Senior Design Sponsor | ATI

ATI
Student Team: Melanie Card, Jesse Hogg, Steven Spalding

At ATI, canisters are filled with metal powders and disturbed in order to reach the highest packed density as possible. ATI currently uses a vibrating table in order to disturb the powder.

The ISE student team’s goal was to find the best way to disturb the powder and increase the packed density.

Senior Design Sponsor | Big Rock Sports

Big Rock Sports
Student Team: Jason Best, Max Copeland, Liz Hester

At Big Rock Sports Distribution Center, high amounts of hunting, guns, and fishing products are received every day. This yields the need to organize and stock the warehouse at a high and efficient pace.

The ISE student team implemented changes in the stocking process by creating simulations that would minimize the time it takes for an item to go from dock to stock.

Senior Design Sponsor | Century Furniture

Won 2nd Place

Century Furniture
Student Team: Ryker Andrews, Marissa Grisham, Janie Lyerly, Corbin Rhoads

Century Furniture has two upholstery facilities in Hickory, NC that share fabric inventory. The project targets optimizing the storage location of each material and reducing the number of fabric transfers between the two facilities.

The ISE student team created a VBA tool that analyzes usage data from SAP and recommends a home storage plant based on where primary consumption occurs.

Senior Design Sponsor | Coty

Won 1st Place

Coty
Student Team: Gene Huneycutt, Sarah Rogers, Matthew Westbrook

Currently, labor tracking methods at the Coty Distribution Facility are reflected as an aggregate total. When a worker clocks in for the day, there is no granular breakdown for what type of work they are doing.

The ISE student team created a database for monitoring actions throughout the day.

Senior Design Sponsor | Dyer Mobility

Dyer Mobility
Student Team: Kali Drake, Sarah Hasan, Doug Petrea

Dyer Mobility is seeking to become the industry leader of disability services solutions. It is currently considering how to best provide personal mobility devices to manual wheelchair users at universities.

The ISE student team created the decision tools needed for management which contain market research, user testing data, and economic analysis.

Senior Design Sponsor | EMC

EMC2
Student Team: John Carver, Joe Figueroa, Mahlon Matthews

EMC products have ‘Kits’ that go along with all products that contain necessary materials for proper installation. These Kits are stored on the production floor nearest to the pack-out line where the Kits are packed with the final products.

The ISE student team has created a future state layout to optimize kit storage.

Senior Design Sponsor | Enloe High School

William G. Enloe High School
Student Team: Michael Blum, Emmanuel Horton, Jia Lin

Enloe High School’s current carpool lane has become a traffic nightmare and a danger to students. Parents line up in two or three rows of vehicles, and sometimes traffic backs up for over a half-mile.

To make the carpool experience less frustrating for parents and safer for students, The ISE student team will resolve the problem using existing infrastructure and a new carpool method with enforcement policies.

Senior Design Sponsor | Flanders

Flanders
Student Team: James McKinley, Katelyn Shuping, Chandler Thames

Flanders manufacturers a high volume of fiberglass air filters. Due to the volume of production, Flanders is currently experiencing a high waste disposal cost for their fiberglass scrap.

The ISE student team focused on reducing the amount of scrap going to the landfill, thus reducing this cost.

Senior Design Sponsor | Guerbet

Guerbet
Student Team: Lindsay Emer, Elle Howe, Matthew Mullen

Guerbet produces syringes and vials containing various types of Contrast Imaging solution; a solvent used in MRIs and X-Rays to enhance the image. During the manufacturing process, an unknown amount of solution loss occurs.
The ISE student team will first identify the type of solution, then quantify the amount of loss, and finally develop a solution to reduce the level of loss.

Senior Design Sponsor | Guerbet

Guerbet
Student Team: Zachary Bostick, Westley Forbes, Benjamin Rachunok

At Guerbet, radiological contrast material is produced by mixing various powdered metals in solution. This process is currently handled manually with great labor requirements.
The ISE team has proposed semi-automated solutions to the powder mixing process, reducing labor expenditure and excess material loss.

Senior Design Spoonsor | IBM

IBM
Student Team: Braeden Barr, Karim Habbal and Taylor Smith

IBM provides technical support services for its hardware clients. As part of the support process, each customer receives a survey. The survey is processed through a website and then manually extracted, analyzed and distributed.

The ISE student team automated the data extraction process, as well as improved analytical results to increase productivity savings and survey score results.

Senior Design Sponsor | Lenovo

Lenovo
Student Team: Blaine Little, William Martin, Nicholas Remy

At Lenovo, orders are comprised of different products and depending on the weight and quantities of products in each order is either shipped via a bulk shipping process or through a small pack process.

The ISE team modeled the current processes in a simulation and manipulated the simulation to come up with an order cut schedule that optimizes outputs for operators to follow.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Felix Cantos, Todd Goldfarb, Julianne Spencer

NC State Sports Medicine orders $100,000 worth of supplies annually without an inventory control system. This has led to a lack of visibility of reorder points for supplies.
The ISE student team has created a financially-acceptable system that tracks inventory in a user-friendly way.

Senior Design Sponsor | NC State Sports Medicine

NC State Sports Medicine
Student Team: Codi Massey, Hiro Sato, Kady Ward

The NC State University Rifle Team’s shooting suits are prone to microbial growth. There is no adequate standardized protocol to reduce and inhibit the growth of microbes.

The ISE student team will provide and implement a protocol for the prevention and sanitization of microbial growth on the rifle shooting suits.

Senior Design Sponsor | Tindall Corp

Tindall
Student Team: Alex Lott, Aniket Desai, Eric Draeger

Since the construction of Tindall’s warehouse in 2008, it has never been properly laid out and the stirred production materials have never been well-organized.

Using knowledge of EOQ and reorder points, the ISE student team recalculated inventory levels and redesigned the warehouse to help keep materials organized and improve material picking times as well as ensuring that business-critical materials never run out of stock.

Senior Design Sponsor | Web Assign

Web Assign
Student Team: Marie Erickson, Nicole Hamilton, Kelly Pomeroy

WebAssign creates and codes questions to be published into online learning modules. They are looking to increase capacity for the future.

The ISE student team improved department-wide efficiency by focusing on three main areas; agile scrum practices, a data analysis tool, and continuous education.

Fall 2015 | Photo Gallery

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar
Student Team: Daniel King, Adam Rafalowski, Anna Renfro, Blake Rosier

Caterpillar plans to increase its production in its Sanford location by 17% per week. They discovered that the method for creating the weekly build schedule is inefficient. It currently takes 190 minutes to create the schedule in Excel. The ISE student team will create an automated scheduling tool using VBA and form controls. The tool will seek to reduce the scheduler’s processing time by 95%.

Senior Design Sponsor | EMC

EMC2
Student Team: Adam Betzwieser, Seth Bryan, Roy Millberg, Jace Weddington

EMC2 orders raw materials from overseas that can arrive well before they are needed for production. They store these materials in an off-site storage facility. EMC estimates that they recycle 30 tons of packaging materials per month. The ISE student team plans to reduce the amount of waste in the packaging operations at EMC’s Apex facility. At the same time, they look to reduce the cost of packaging materials.

Senior Design Sponsor | Flanders

Flanders
Student Team: Matthew Billings. Taoufik Falsy, Kayla Summer, Christopher Turner

Flanders produces almost half a million air filters per year. They currently buy the filter’s metal frame, called a header, from an outside supplier. Flanders estimates they can save $500,000 a year by installing an in-house production line. The ISE student team plans to determine which sizes are viable for in-house production. Their goal is to develop the layout, workflow, material handling, and storage for the new production line.

Senior Design Sponsor | Lenovo

Lenovo
Student Team: Rachel Gibson, Brian Linn, Nathan Mauney, Addison Warden

The Lenovo distribution center has plans to take on more responsibilities. The current layout of the Customer Solution Center (CSC) is taking up too much space and has become inefficient as the facility’s demands have increased. The ISE student team plans to create a flexible work area to accommodate for fluctuating demand. Their goal is to reduce the footprint of the CSC work area by at least 10% as well as increase capacity by 20%.

Senior Design Sponsor | Novozymes

Novozymes
Student Team: Ryan Bishop, Thomas Martin, Tim Moody, Christopher Sippel

Novozymes has three production lines. One uses newer technologies that can operate at a faster and cheaper rate. They currently use a deterministic calculation to compute various production scenarios. This process has many steps that are stochastic in nature which makes their calculation risky. The ISE Student team plans to create a simulation model to capture the random nature of the process to deliver key statistics.

Senior Design Sponsor | Trivantage

Trivantage
Student Team: Tyler Melvin, Rachel Oneyear, Kristin Teague, Paul Whitley

Trivantage’s current packaging and shipping are inefficient and do not factor in the variety of orders. They want to streamline to process and increase their profit margin by 30%. The ISE student team has three solutions to the problem. They plan to change the multiple branch shipment logic, standardize the logic in choosing box size and review Trivantage’s discount freight program.

Senior Design Sponsor | Trivantage

Trivantage
Student Team: Jonathan Addison, Zach Bouren, Charles Copeland, Cam Simmons

Trivantage’s current return rate for orders is above the industry average of 1%. They want to reduce their return rate to less than 1% which reduces costs and improves their customer satisfaction. The ISE student team plans to use multivariate analysis to discover trends in Trivantage’s return data. They want to find the underlying reasons for the high quantity problems, then develop solutions to solve these problems.

Spring 2015 | Photo Gallery

Senior Design Sponsor | AKG Thermal

AKG Thermal Systems
Student Team: Rachel Black, George Korn, Emily Peeler, Samuel Wurst

AKG Thermal Systems wanted to implement a continuous improvement plan as well as lean manufacturing principles to support their growth and need for increased order fulfillment capacity. Specifically, they wanted to reduce the time of the scheduling and assembly processes. The ISE student team created an automated program that prioritized orders and improved the overall assembly and shipping process.

Senior Design Sponsor | Big Rock Sports

Big Rock Sports
Student Team: Charles Clayton, Chris Dodds, Nick Lepore, Pat Nager

Head Quarters Taxidermy Supply (Big Rock Sports) needed to improve their current process for manufacturing Habitat materials to meet the growing demand. The ISE student team created a more efficient process to allow HQ to mass-produce Habitat materials by designing a new floor layout, applied 5S and created a shop floor control system.

Senior Design Sponsor | Big Rock Sports

Big Rock Sports
Student Team: Justin Ferguson, Zach Little, Jonathan Page, Kyle Trainor

At Big Rock Sports, orders are comprised of different products made in multiple cells. Once an item is finished in its cell and boxed, it is sent to the merge area to wait for the rest of the items in the order. Some items can wait for days in the merge area for the rest of the items to be completed. The ISE Student team created a schedule for each item in an order to be started so the entire order will arrive in the merge area at the same time, thus reducing the number of time orders spend in the merge area.

Senior Design Sponsor | Cummins

Cummins
Student Team: David Goyer, Hannah Leskovec, William Nifong, Christian Peterson

At Cummins, Inc., engines must be properly closed off to any water before being washed. If water gets into the engine, it is considered defective and must be reworked. Currently, the task of closing off engines to any water is handled by the operator. The ISE student team created a robust, systematic way to identify to the operator which caps are needed for each engine as they come through the Pre-Wash station. The system eliminated the trial and error method for determining the appropriate masking.

Senior Design Sponsor | Cummins

Cummins
Student Team: James Beall, Kevin Gahagan, Jerel Jordan, Ethan Miller

At Cummins, Inc., the process for masking an engine in the pre-paint station is not standardized and is performed, by memory, by the operator. Combine this with the fact that there are no quality control systems to ensure the maskings are correct and all to often the results are customer disapproval and loss of profits. The ISE student team created a system or framework to provide error proofing and a standard means of masking engines.

Senior Design Sponsor | EMC

EMC2
Student Team: John Hajnos, Alexander Hodge, Mark Trongdon

At EMC2, orders are comprised of different products made in multiple cells. Once an item is finished in its cell and boxed, it is sent to the merge area to wait for the rest of the items in the order. Some items can wait for days in the merge area for the rest of the items to be completed. The ISE student team created a schedule for each item in an order to be started so the entire order will arrive in the merge area at the same time.

Senior Design Sponsor | EMC

EMC2
Student Team: Kristin Gavin, Ismail Lekorchi, Noah Linger, Alex White

EMC2 has decided to create its own stinger tools because current stingers have a 12-week lead time to order. This problem has reached the point at which the company may miss shipment goals and management wants to ensure this does not occur in the future. The ISE student team created a program to forecast the number of stingers needed one, two or multiple quarters out.

Senior Design Sponsor | Flanders

Flanders
Student Team: Charles Klecker, Malcolm Stephen, Andrew Wenk

Flanders is currently transitioning from a hot glue to a cold glue lamination process. Because of the cost savings, Flanders will be adding more cold glue lamination machines into its facility to meet the high demand. Flanders wants to standardize its entire lamination process, from raw materials to the location of the finished rolls. To accomplish this, the ISE student team studied the current inventory flow and operating procedures in order to increase productivity to meet the high demand.

Fall 2014 | Photo Gallery

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar

Caterpillar is the leader in building the world’s infrastructure and in enabling progress for millions of people around the globe. To stay an industry leader, Caterpillar implements constant improvements to their production facilities. Currently, they are looking to reduce the cycle time and cut maintenance time of the first three cells of the lift arm assembly line. The ISE team’s project is to install a material handling system. The system must improve ergonomics, safety and cycle times while reducing maintenance downtime.

Senior Design Sponsor | EMC

EMC2

EMC2 is a leading provider of IT storage hardware solutions. They promote data backup and recovery and speed up the journey to cloud computing. Currently, they store all materials in their warehouse’s “supermarket.” Workers deliver these materials to different cells throughout the warehouse. Some materials are delivered to many cells, while others are only delivered to one cell. The ISE team’s project is to compare this current delivery method with alternative method that improves material flow and decrease storage.

Senior Design Sponsor | Flanders

Flanders

Flanders is the largest manufacturer of air filters in the United States. Industries like HVAC, semiconductor manufacturing, ultra-pure materials, biotechnology, and pharmaceuticals use their products. Flanders design, manufacture, market, and distribute air filters and related products. Currently, Flanders is automating their production lines and wants to install a Baxter robot. The ISE team’s project is to figure out the optimal placement for the robot to increase daily line capacity. They are also working to decrease the amount of defects produced and reduce labor costs.

Senior Design Sponsor | Siemens

Siemens

Siemens is a global powerhouse in the fields of electrification, automation and healthcare solutions. They have around 362,000 employees and business activities in almost all countries in the world. Currently, the repair process of their stationary gas turbine components is not operating at optimal levels. The ISE team’s project is to improve lead times and reduce costs in the repair process.

Senior Design Sponsor | Sports Endeavors

Sports Endeavors

Sports Endeavors is the leading expert in soccer, rugby and lacrosse equipment. The sports they represent are the sports for which they have a personal passion. It is this passion that gives them unique insight into the needs of their customers. The ISE team’s project is to improve the process by reducing the impact of bottle necks and system errors. The team will create time standards for each station, then work on optimal resource scheduling plans to facilitate on-time deliveries.

Senior Design Sponsor | Tindall Corp

Won 1st Place

Tindall Corp.

Tindall is an industry leader in precast, prestressed concrete systems. They provide long-term performance and financial viability in all parts of the project. Currently, Tindall wants to streamline the process for maintaining their equipment. The ISE team’s project is to develop a system that would allow workers to add / view maintenance records. The system will also allow workers to print out the needed weekly maintenance requirements.

Senior Design Sponsor | Urban Ministries

Won 2nd Place

Urban Ministries

Urban Ministries of Wake County lessens the harmful effects of poverty by meeting basic needs for food, shelter and health care. Currently, they would like to create a better process to manage their pharmacy inventory. The ISE team’s project is to develop an electronic system for inputing and managing the drug inventory levels. They must also create ways to reduce the amount of money spent on inventory.

Spring 2014

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar

To maintain its position as an industry leader, Caterpillar implements constant improvements in their production facilities. Currently, limited floor space, long wait times from the bottleneck of the process and large, bulky pieces of work lead to inconsistent work in progress (WIP). The ISE team’s project is to optimize crane usage and product flow, have no parts stored on floor and have optimal WIP. All the while maintaining established safety guidelines.

Senior Design Sponsor | EMC

EMC2

EMC2 is a leading provider of IT storage hardware solutions to promote data backup and recovery and accelerate the journey to cloud computing. Currently, the stockroom has been moved off-site which in turn has increased the potential of internal stock-outs, causing lost capacity or even missed shipments. The ISE team’s project is to analyze and optimize the new processes with a goal of reducing internal stock-outs by 10 percent.

Senior Design Sponsor | John Deere

John Deere

From tractors and engines to construction, forestry and turf care equipment, John Deere provides equipment, tools, technology and services that fit the needs of a changing world. Currently, the late configuration area of the warehouse has experienced significant growth in the last year and needs to have its processes optimized to increase effective production. The ISE team’s project is to identify and prioritize opportunities for improvement, develop the ideal future state process, create an implementation plan and begin the process improvement concepts.

Senior Design Sponsor | Liquip International

Liquip International

Liquip International’s Aviation Division engineers and manufactures a wide range of aviation refueling products including refuelers, hydrant dispensers, stationary hydrant carts and filter vessels. Currently, the cellular vehicle assembly operations lack standard work and standard operating procedures. The ISE team’s project is to create standard work for all assembly functions to provide a predictable and consistent build cycle that reduces both product lead-time and overall cost.

Senior Design Sponsor | Nomacorc

Nomacorc

Last year, Nomacorc produced over two billion wine closures with the best possible wine preservation performance so that the consumer’s experience is exactly as the winemaker intended. Currently, Nomacorc has no means to model or analyze their extrusion area. The ISE team’s project is to create a simulation model of the extrusion area for the purpose of testing different equipment and personnel scenarios to determine the optimal production layout.

Senior Design Sponsor | Novozymes

Novozymes

Novozymes’ core business is industrial enzymes, microorganisms, and biopolymers. They employ in-house projects, strategic alliances, and acquisitions to enter new business areas. Currently, the turnaround time of fermentation equipment is planned for 16 hours but that plan is not monitored. The ISE team’s project is to optimize the turnaround process by standardizing the process and create a visual tracking tool to monitor performance which, in turn, will reduce waste and improve efficiencies.

Senior Design Sponsor | Revlon

Revlon

Revlon’s manufacturing plant in Oxford, NC is the largest cosmetic plant in North America producing 400 million pieces per year ranging from nail enamels to shampoo and conditioners. Currently, the machine tooling changeover needs to be improved to limit the amount to downtime. The ISE team’s project is to optimize the machine tooling changeover of key manufacturing lines by addressing time changeovers, task lists for line changeover, sequences using SMED and 5S principles and shadow board changeover carts. Finally, the team will monitor the enhanced changeover.

Senior Design Sponsor | Triumph Actuation Systems

Triumph Actuation Systems

Triumph Actuation Systems is an international supplier of aerospace components and systems. All of their assembled products are 100 percent inspected on test stands to verify functional abilities. Currently, the test stands are not universal, operators are not cross trained and there isn’t a testing schedule. The ISE team’s project is to create an interactive schedule to prioritize testing of these assemblies. This will involve; work studies of setup/cycle time/teardown, simulations of various scenarios, statistical likelihood of passing test and planned shutdowns for maintenance.

Senior Design Sponsor | Urban Ministries

Urban Ministries

Urban Ministries of Wake County lessens the harmful effects of poverty by meeting basic needs for food, shelter and health care. Currently, the roads surrounding their open door clinic lacks control of speed limits, entry and exit to businesses and there are no pedestrian or bus easements. The ISE team’s project is to study access to the Urban Ministries location, current traffic patterns and make recommendations on how to improve safety.

Fall 2013

Senior Design Sponsor | Caterpillar, Inc.

Caterpillar

With large volumes made at the facility, improvements are constantly being implemented as the facility increases production and the company strives to maintain their position as an industrial leader. The design team will focus on the manufacturing cell that welds the arms of the loader. With increasing demand, every improvement possible, from eliminating downtime to efficient movement of materials, is crucial. This project will concentrate on the conveyor system between the manual and automated welding stations for the lift arms with a focus on material handling within these cells.

Senior Design Sponsor | EMC

EMC2

The purpose of this project is to clearly define the current functions of the internal parts distribution network at the EMC Apex facility. The team will create a model to represent this system in order to provide EMC with a data-driven benchmark of their process. Additionally the students will propose recommendations to improve this process focused on various performance measures.

Senior Design Sponsor | Novozymes

Novozymes

The purpose of this project is to improve the utilization of the maintenance process in which parts are delivered to the mechanics on the production floor. The objectives of this project are to eliminate waste in the delivery process such as waiting and duplicating tasks, to develop standard procedures and explore other possible storage systems for the parts. The recommendations for this project will span from process changes to changes in centralization or decentralization of maintenance related inventory.

Senior Design Sponsor | Revlon

Revlon

The purpose of our project is to improve the overall performance of one or two of the top 15 lines in Revlon’s factory. In order to accomplish our goal we will first validate current line performance versus theoretical line performances. After our process benchmarking is completed, we will then identify opportunities for process improvements in order to improve line productivity.