Skip to Content

Manufacturing Engineering

Perforating Gun Packaging Optimization


Sponsor: Hunt & Hunt, Ltd

Student Team: Logan Alder, Cinthia Fuentes, Stephen Mings, David Toifl

Faculty Advisor: Dr. Austin Talley

Hunt & Hunt Ltd (H&H) is a 100,000 sq. ft. manufacturing facility located in Houston, Texas that produces 20,000 perforating guns for the oil fracking industry per year. Their production is expected to go up to 50,000 perforating guns per year in February 2018.

The Hunt & Hunt project is focused on optimizing the process of banding and wrapping the perforating guns in order to reduce the amount of time and labor. The current process requires 1-2 employees as well as a forklift to lift the pallet. The goal of this project is to design a product that will strap and wrap the perforating guns more quickly and more efficiently than the process that is currently in place.

Caterpillar Foolproof Fixture


Sponsor: Caterpillar

Student Team: John Slupsky, Scott Peabody, Tim Kunze

Faculty Advisor: Dr. Austin Talley

The Caterpillar facility in Seguin, TX, manufactures a variety of industrial engines, one of which is the Cat® C15 ACERT™ Diesel Power Unit. At a specific operation on the C15 assembly line, a mount is hydraulically pressed onto an adapter plate. Currently, an operator sets an adapter plate into the press, places a mount loosely over the top of the adapter, aligns the parts visually, then starts the press. Visual alignment of the parts is substandard to a mechanical means, as it is easy to misjudge and produce an asymmetric part. Such parts often fail to meet specifications or experience damage, depreciating the part to scrap.

This project strives to design a poka-yoke (otherwise known as foolproof) fixture for this station. Such a fixture will improve production quality by reducing scrap rates, by providing a mechanical means of alignment between the adapter, mount, and press. The fixture should also allow for a reproducible gap size, within strict specification, to be achieved. As extraneous features, the fixture is prospected to reduce the severity and number of operator movements, and will alert the operator is the fit is out of spec.

Mechanical Key Control System Design


Sponsor: Key Warden

Student Team: Cole Korte, Matt Rodriguez, Shelby Vasconcellos-Murphy

Faculty Advisor: Dr. Austin Talley

Key Warden, a company located in New Braunsfels, Texas, sells high-security electronic key management systems manufactured by Morse Watchmans. As the Texas distributor of Morse Watchmans products, Key Warden offers effective solutions to the key control problems of many facilities including hospitals, universities, government offices, and correctional institutions.

However, these systems can cost tens of thousands of dollars, and for many companies such high-technology is not needed. This project focuses on designing a mechanical key system that still mandates accountability, but at a much lower cost. A mechanical key system would be perfect for companies such as auto dealerships, apartment communities, and other facilities that have individuals handling many different keys.

Intertek Dexos© SPI Process Optimization


Sponsor: Intertek Automotive Research

Student Team: Paden Albin, Doug Reekie, Avi Groff

Faculty Advisor: Dr. Austin Talley

Intertek Automotive Research is a fuel and lubricant testing facility that works with both the automotive manufacturers and oil companies to certify oil and fuel for use in the manufacturers vehicles. This project focuses on GM Dexos oil certification and pre-ignition testing for General Motor's 2.0L LHU turbocharged inline four that is currently used in several vehicles. This project focuses on the optimization of the entire process from start to finish consisting of; engine teardown and rebuild, sensor testing and calibration, to installing and running the engine on a dyno to simulate real world conditions.

NASA Drifter Project


Sponsor: National Aeronautics and Space Administration (NASA)

Student Team: Nathan Holtman, Heejoo Lee, Joshua Torres, Brian Tusa

Faculty Advisor: Dr. Austin Talley

The NASA Drifter Project will facilitate the collection of large amounts of water quality data from a variety of locations and water sources. The drifter data will come from five different sensors: PH, Salinity, Temperature, Total Dissolved Solids, and Total Dissolved Oxygen.

Texas State University has elected two teams of students to work on this project, one focused on Electrical Engineering aspects, and the other focused on the Manufacturing/Mechanical Engineering aspects of the project.