Fall 2024 Senior Capstone Projects in Industrial, Manufacturing, and Systems Engineering

Fall 2024 - Industrial Engineering Capstone Design

DFW Inventory Control Model

This project focuses on developing a robust inventory control model for DFW International Airport to predict usage and budget, aiming to reduce stockouts by 10% and decrease inventory and related costs by 5%. DFW Airport handles extensive passenger traffic that directly affects inventory needs. Traditional methods of predicting custodial inventory led to frequent over and under stocking. Our project, initiated through collaboration with airport personnel, leverages IE principles to streamline inventory management ensuring economic efficiency and sustainability. The inventory control model represents a scalable solution for DFW international airport, offering a systemic approach to managing inventory that can be adapted to other terminals. The project underscores the importance of data-driven decision making in operational settings and will allow the Inventory Clerk to do less monitoring of the custodial inventory supply and focus more on rolling out Inventory Smart to the rest of the airport.

Traulsen: Increasing Process Efficiency

This project outlines the application of the DMAIC methodology conducted with ITW Traulsen. The project aimed to enhance the efficiency of Traulsen's largest production line (the G line). By using time studies and line balancing, a reduction in cycle time and labor force was achieved, while increasing cycle time efficiency. At the end of the project, a future process map was created to demonstrate the possible flow of each process with their respective tasks. The current production line has a cycle time efficiency of 47.77%, while the proposed production line boasts a cycle time efficiency of 65.47%. With implementation of the newly proposed production line process, the company could achieve a 62% reduction in labor required for operation, a 31% improvement in cycle time, and an 83.97% decrease in non-value-added time. This implementation would not only enhance operational efficiency but also significantly streamline production processes, positioning Traulsen for sustained future success.

MSL Racing Inventory Management Optimization

MSL Racing is a motorsports company founded in 2022 and has provided services for young kart drivers competing in youth league divisions across the DFW metroplex. MSL Racing, being a smaller organization compared to more established names in the karting community, operates under relatively scrappy conditions to service all the clients they manage during each event. The functionalities of our team designed Excel-based inventory management system provide actionable insights that were previously unavailable, making it easier for MSL to make informed and timely decisions. The system’s reliability and ease of use during these trials demonstrated its readiness for full-time integration, paving the way for long-term improvements in MSL’s operations and have laid a strong foundation for MSL’s future growth by addressing immediate needs and opening doors for enhanced financial and operational control. 

JHBP: Forklift Maintenance Shop Layout

The “Forklift Maintenance Shop Layout Optimization” project addresses safety risks and operational inefficiencies at JHBP’s Cleburne plant. Using DMAIC, the team analyzed maintenance queueing challenges, identified root causes of congestion and disorganization, and proposed solutions: a roofed awning for organized queueing, receiving area expansion for improved space capacity, and proximity mirrors to enhance visibility and safety. The project aims to reduce downtime, enhance safety, and streamline workflows while adhering to 5S, Zero Harm, and Continuous Improvement standards for sustainable improvements.

Siemens: Manufacturing Engineering System Design

This project focuses on enhancing the traceability of the production process of Low Voltage Switch Gear at Siemens’ Grand Prairie facility. Utilizing DMAIC methods such as Process Mapping, Power-Interest Charts, Fishbone Diagrams, and 5 Whys were employed to gain a better understanding of the process. By ensuring that consultations were held with mechanics, wirers, supervisors, engineers and management, a broad range of opinions were considered in the creation of the MES requirements. Out team designed a workstation and SOP to facilitate the use of the MES on the floor. The results of this project will help provide a seamless transition into the use of the MES during its rollout phase. The layout update provides a designated spot for the mobile stations with scanners which allows easy access to required drawings and Bill of Materials for working orders.