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Industrial Engineering


Mobile Pantry Service Optimization at Central Texas Food Bank

Sponsor: Central Texas Food Bank

Student Team: Michael Colegrove, Sean Greenan, Kendall Jordan, Emilia Ochoa

In 2016, Central Texas Food Bank moved to a new facility located in Austin, Texas where they provide underprivileged families in the Central Texas area spanning 21 counties with food. One of their many service approaches is a mobile pantry. By taking the food directly to clients, the mobile food pantries fill geographic and service gaps in emergency food assistance by providing Central Texans in need with basic staples, frozen foods, fruits, and vegetables where local food assistance services cannot keep up with demand. The Mobile Pantry Program served 2,663,516 pounds of food through 42 sites, to 174,840 individuals, last year alone.

Our project aims to optimize a schedule that would allow a truck to leave at full capacity and visit multiple sites in one trip while meeting given constraints. These constraints include: the route time between sites, driver and coordinator availability, matching site demand with the weight and capacity of the trucks, and the compatibility of site size and truck size. Through simulations built in Simio and standard forecasting models, we will be able to optimize truck to site delivery schedules at ideal truck capacity.

 

Case Study


In-Line Kanban System Integration at Philips Lighting

Sponsor: Philips Lighting

Student Team: Alex Schneider, Daniel De Amat, & Jesse Torres

The Philips Lighting facility in San Marcos, TX focuses on the assembly of outdoor lighting products. The assembly lines are kept stocked by their supermarket, a section of shelves stocked with commonly used components. Parts are sometimes found to be defective or broken upon being used at the assembly stations. Parts are pulled from the warehouse, stocked in the supermarket, and then given to the assembly line as needed. The in-line Kanban system will minimize material handling by organizing the material bins on the assembly line to maximize the number of components on the line. This will reduce material handling from the warehouse by requiring fewer pick orders and will contribute to fewer losses from defective components.

 

Case Study


Developing an Operational Manual for Tokyo Electron

Sponsor: Tokyo Electron America

Student Team: Kathryn Turman, Thomas Ebrom, and Paul Silva

Tokyo Electron America (TEA) is the U.S. Sales and Service headquarters for Tokyo Electron Limited. Tokyo Electron is a Japanese semiconductor company, headquartered in Minato-ku, Tokyo, Japan. Tokyo Electron is one of the largest semiconductor and FPD production equipment companies worldwide, currently owning ¥54.9 billion in capital and projected to have Net Sales of 1,130,000 millions of yen this fiscal year.

The project will conclude with an interactive manual, covering all software utilized by the planning department. Currently the only training interfacing all the software together, for the planning department, is one-on-one training by employees. Instead of giving a general overview or an in depth guidebook for each software, the planning department desires a very specific manual. One detailing what and how the planners operate on a day-to-day, month-to-month, and critical situation basis. As part of the PDCA process, On-Time Delivery (OTD) performance is measured through the use of a Power BI dashboard, showing “hits” and “misses”. Publication of the BI report is pending, several updates, revisions, and have additions implemented. The goal is for this report to not only be used by upper management, during monthly review meetings, but also by the planners to track and correct delivery performance by Business Unit, Key Customer, Region, and Part.

 

Case Study


Fastener Organization Redesign Project at Philips Lighting

Sponsor: Philips Lighting

Student Team: Grant Marumoto, Paola Montoya, & Austin Springer

The Philips Lighting facility in San Marcos, TX focuses on the assembly of their outdoor lighting products. In the facility there are over 350 different fasteners used to manufacture these products. When parts run out on the line, a lead is then given the task to go and refill this part from fastener inventory. Material is scrapped and time is wasted searching for parts in this process. Through improvements in organizing the fastener inventory, travel time and non-value work activity associated with searching of specific parts will be significantly reduced. Scrap will also be reduced by redesigning bins to prevent overflow of parts.

 

Case Study


Developing a reliability measure based optimization model for airline crew vacation allocation problem

Sponsor: Sabre Corporation

Student Team: Jordan Givens, Aristotle Garcia, Aaron Trammell, Colton Schram

Sabre Corporation is a travel technology company based in Southlake, Texas. Sabre is the largest Global Distribution Systems provider for airline bookings in North America.

A critical step of crew planning in the airline industry is the crew vacation planning. This project will focus on developing a reliability driven integer optimization model, which constructs an optimal vacation grid over a time-period of one year. The model will be developed in AIMMS or AMPL and solved by Gurobi, the state of the art optimization software. The model generates a daily allocation that maximizes crew satisfaction while ensuring a given level of system reliability.

 

Case Study


A reliability–driven model for airline crew vacation grid optimization

Sponsor: Sabre Corporation

Student Team: Madison Kiefer, Rachel Grout, Devyn Heslep, Douglas Graham

Sabre Corporation is a global technology leader in the travel industry, based out of Southlake, Texas. Sabre began in 1960 as a joint initiative between IBM and Amazon to create a computerized airline reservation system. Being one of the world’s largest software companies to date, Sabre’s technology is utilized by more than a billion people across the world to plan, book, and get to their desired destination as efficiently as possible.

Our team has been tasked with creating a reliability-driven optimization model that uses a grid system to allocate vacation days for airline crew. Throughout this project, we are to prototype a model in Gurobi, an optimization solver, using the Python coding language. Upon completion, we will develop a graphical user interface (GUI) that will allow users to visually interact with our model. A user manual was created to describe how the GUI is used and explain the underlying mathematical optimization model. Our goal is that the above deliverables will benefit Sabre in providing airline companies with an efficient crew vacation scheduling model.

 

Case Study


Visual Factory Management System at Younicos

Sponsor: Younicos

Student Team: Caitlyn Essary, Brianna Wallman, Haydn Hutson, Brian Silvestri

Younicos has recently moved into a new facility in Austin, Texas. The company is a global leader in mobile power by using smart energy and grid solutions based on battery storage.

The Younicos team is in the process of developing a physical board displaying all relevant information regarding current and upcoming projects. The management has noticed a lack of communication between the production floor and the engineers which results in misplaced inventory, project delays, and budget issues. This board will incorporate quality engineering and project management to show a detailed breakdown of current projects in production as well as any issues and status updates. This visual system aims to provide improved communication regarding the details of each ongoing project.

 

Case Study


Impact Analysis of Lot Scheduling Software at Final Phase Systems

Sponsor: Final Phase Systems

Student Team: Karl Stuewer, Sara Oswald, Eric Stroud, Lauren Price

Final Phase Systems provides software and consulting services to optimize manufacturing operations, primarily in the semiconductor industry. Ultimately, the software reduces manufacturing costs and increases on-time deliveries, leading to a profitable business. Final Phase Systems desires to promote the value of implementing its lot scheduling software, but lacks historical data to demonstrate improved production performance. The objective of the project is to analyze customer performance data to determine if critical metrics indicate a positive trend following the implementation of the scheduling software. Our team plans to create two presentations: first to demonstrate potential areas of improvement for prospective customers and second, to show a positive impact of Final Phase System’s lot scheduling software for their existing clients.

 

Case Study


Development of a capacity model for back end operations at Continental Automotive Systems

Sponsor: Continental Automotive Systems

Student Team: Hector Valladares, Mykol Polk, Tara Monroe, Jammie Bailey

Continental Automotive Systems is a German-based company that manufactures multiple automobile components with its main focus being in microchip panels and sensors. Continental is one of the leaders of Industry 4.0 in Texas.

Continental Automotive Systems has a large electronics manufacturing facility in Seguin, TX. This facility builds and ships over 10MM electronic units annually. Each year, Continental receives a production forecast identifying projected volumes for the upcoming 5 years. Continental uses this information to calculate the number of production lines needed to accommodate customer demands. Production is broken up into two sections - front end and back end. By accurately measuring the line cycle times and capacity, this project will develop a capacity model to accurately calculate the number of back end lines needed to meet demand.

 

Case Study


Development of an automated procedure for assigning test stands to technicians at Intertek Automotive Research

Sponsor: Intertek Automotive Research

Student Team: Daniel Resendez, Anthony Solano, Cynthia Juarez-Diaz, Camila Escobar-Guillen

Intertek Automotive Research, located in San Antonio, Texas, provides independent testing services for the automotive industry. This location has three laboratories that span over 750,000 ft2, making it one of the largest automotive and petrochemical testing facilities in the world.

Intertek has identified a on-going problem whereby their approach to assign test stands (e.g. engine or axle) to technicians is inefficient and time consuming. Currently, prior to each shift, the Lead Technician completes a handwritten Test Stand Count Form to document which of the 68 potential test stands are actively running. After this is completed the actively running test stands are handwritten on a dry erase board and manually broken down into assignment(s) per technician for that test stand.

We will create a more efficient and automated procedure for assigning test stands to technicians based upon their qualifications and the tests needed each day. The solution to this problem will positively impact the company by optimizing the test stand assignment process prior to each shift which will reduce cost and save time.

 

Case Study