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Industrial Engineering

These projects are part of a one-semester only sequence. They are functionally complete.

Design and Implementation of Black-Tape Application Process Efficiency Improvement

Sponsor: Toyota Motor Manufacturing Texas, Inc.

Student Team: Paula Cruz Acosta, DeCari Beard, Juan Silva Febres, Travis Starr

Faculty Advisor: Mr. Jerel Walters

Toyota Motor Manufacturing Texas, Inc. in San Antonio is the home of the Toyota Tundra and Tacoma pickup trucks.  Operations began in 2006.  The plant received the 2008 J.D. Power and Associates Silver award for Assembly Plant Quality in North and South America. This is a first-of-its-kind honor for a Toyota plant in its first year of production operation.

In the final stage of the painting process, black tape is placed on the window frame.  The focus of this project is to improve black-tape application process efficiency by reducing material inventory, implementing FIFO, reducing unnecessary operator motion, and reducing energy consumption of heating material.


Design of Inventory Management System to Optimize Inventory Levels and Reduce Inventory Costs

Sponsor: Drake Industries – Austin, Texas

Student Team: Alex Cooper, Pedro Avila Jimenez, Ryan Dominique, Andres Moreno, Braden Speer

Faculty Advisor: Mr. Jerel Walters

Drake Industries is a manufacturer of high-quality durable labels, data plates, and ID tags. For almost 50 years, Drake has earned the trust of private industries, US, state & local governments and NASA. Production operations are configured to support fast, small runs for test products and prototypes as well as mid-sized runs for regular production. They serve customers in a wide variety of industries from oil and gas to food and beverage.

With a broad spectrum of customers and products, Drake recognized the need for a more efficient inventory management system. This project will develop an inventory management system to optimize inventory levels and reduce inventory costs with the capability of being incorporated into a future ERP system.


Design and Implementation of Parts Transportation Cart to Improve Process Efficiency at Signify

Sponsor: Signify

Student Team: Hunter Fannin, Destinee Ware, Brandon Yarbrough, Kyle Zimmerman

Faculty Advisor: Mr. Jerel Walters

Signify is the new company name of Philips Lighting, having spun off from Philips to become a separate company in 2016. Signify is the world leader in connected LED products, systems, and services. Founded as Philips in Eindhoven, the Netherlands, they have led the lighting industry with innovations that serve professional and consumer markets for more than 127 years. With operations in more than 70 countries and 32,000 people worldwide, Signify generated sales of approximately $8 billion in 2017.

Signify's facility located in San Marcos, Texas focuses on the assembly of outdoor lighting products. After recognizing that product lead times were significantly longer than their competitors, Signify initiated a Factory of the Future program. This project, under the umbrella of the Factory of the Future program, will develop a transportation cart to improve process flow and reduce the movement of employees while transferring parts and pulling carts.


Design and Implementation of Daily Operator Schedule Assignment System

Sponsor: Intertek Automotive Research

Student Team: Cassandra Krapfl, Ryan Luehlfing, Mark Mahoney, Emily Rejack

Faculty Advisor: Mr. Jerel Walters

For over 60 years, the Intertek automotive testing facilities in San Antonio, TX have been providing customer-focused independent testing services for the automotive and fuel and lubricant industries. Services include engine emissions, performance, development, and durability, vehicle performance and durability, fleet evaluation services, fuel system components testing, evaporative emissions testing, permeation testing, SHED testing, analytical (chemistry) testing, and fuel and lubricant qualification testing.

Intertek has a dynamic testing operation with a large number of customers, test protocols, and reporting requirements. A variety of tests are required at specific times on up to 40 different test cells. This project will design and implement a daily operator scheduling system to improve operator utilization, ensure tests are completed at the required test-cycle times, and avoid overlapping operator assignments.


Analysis and Determination of Cost-Effective Battery Module Packaging

Sponsor: Aggreko – Austin, Texas

Student Team: Joshua Erwin, Madison Boyle, Stephen Crawford, Esther Mneney

Faculty Advisor: Mr. Jerel Walters

Younicos pushed the boundaries of the energy world for more than a decade. In that time they deployed 220 MW of battery storage capacity in almost 50 projects worldwide.  In 2017 Younicos became part of team Aggreko, first as a 100% subsidy, then as an integral part of the company. This brought together experts who know exactly how to seamlessly integrate and manage all forms of power, including thermal, renewable and energy storage.

Aggreko is currently releasing the next generation energy storage system and planning the process of installing these systems on a global scale that includes a rental business model. This project will research the longevity of packaging materials in various climates and environments, create a cost analysis of different processes of storing or disposing of the battery shipping packaging at projects sites, and determine the most cost-effective solution.