2024 Design and Research Conference

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Industrial Engineering Senior Projects

Integrated Engineering and Science Building 212.

1:00 p.m.

Lean Manufacturing Project

Team Members: BConnor Alford, Kade Klink, Kirsten Nugent

Sponsor: Hardware Resources

Advisor: Dr. Jun-Ing Ker

Hardware Resources faces inefficiencies in the Trashcan Pullout assembly due to poor layout, slow workflows, and ineffective equipment use, leading to delays, higher costs, and inconsistent output. This project aims to improve efficiency by reorganizing workstations, streamlining processes, and applying lean manufacturing techniques. The team will use time studies, 5S organization, and ergonomics tools to identify and test improvements. Expected outcomes include shorter lead times, lower labor costs, increased production efficiency, and a better work environment. These changes will help Hardware Resources optimize manufacturing operations and enhance overall productivity.

1:30 p.m.

Optimization of Production Process for Specialty Components

Team Members: Camille Coco, Zachary Hebert, Annie Mouton

Sponsor: Mark Tool & Rubber

Advisor: Dr. Jun-Ing Ker

At Mark Tool & Rubber, the introduction of new specialty components has led to extended lead times, increased production costs, and inconsistent quality, falling short of both internal and customer expectations. While promising for repeat business, these components have exposed inefficiencies such as complex manufacturing steps, vendor dependency, inconsistent material application, and frequent rework due to quality defects.
This project aims to optimize the coating process while balancing efficiency, quality, and cost. Our objectives include: reducing centralizer production time by 10–15 days, lowering average defect rates to less than 2 defects per part, reducing centralizer coating costs by up to 25%, improving process efficiency and promoting a sustainable culture of continuous improvement.
We will apply Lean Six Sigma tools within the DMAIC framework to achieve these goals, including SIPOC diagrams, process mapping, root cause analysis (Fishbone, 5 Whys), Pareto charts, KPI tracking, and cost-benefit analysis.
Expected outcomes include reduced lead times and defects, increased reliability, measurable cost savings, and a more scalable, customer-focused production process.
2:00 p.m.

Hydrocrackin’ Down on Preventative Maintenance

Team Members: Bryan Jose, Caden Edwards, Riley Edmondson, Hannah Riddick

Sponsor: Excel Paralubes, Phillips 66

Advisor: Dr. Jun-Ing Ker

Excel Paralubes runs five different input feeds into its Hydrocracker unit to create various base oils. The input feed can clog the Hydrocracker unit’s filters drastically, leading to constant maintenance callouts and eventually overtime hours. There is currently no standardized way to predict filter changes, which causes Excel Paralubes to burn through allotted maintenance hours, material, and labor expenses. This project will streamline the filter changeout process and allow Excel Paralubes to plan for callouts. Through statistical investigation into historical data, including OLS regression and correlation analysis, conclusions about the biggest factors affecting filter performance will be drawn. These conclusions will be used to create an online filter tracker to save overtime callout expenses, predict filter changes within 95% confidence, and streamline current preventative maintenance.