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Manufacturing Engineering

Assembly and Shipping Process Optimization


Sponsor: Hunt & Hunt, Ltd

Student Team: Jacob Caraway, Kyle Rainosek, James Gibbs, Sean Varela

Faculty Advisor: Dr. Austin Talley

Hunt & Hunt Ltd (H&H) manufactures oil fracking guns used to break pockets deep underground in order to collect oil. H&H runs a 100,000 sq. ft. multi-task volume manufacturing facility focused on high-speed automated CNC machines.

This project is focused on optimizing H&H’s Assembly and Shipping process. H&H has requested that the team reduce the cycle time of each part that goes through the process. H&H would like to reduce this process time because it can potentially reduce their labor costs and each of the steps in the process involve nonvalue added time to the products. The project has a large scope due to the fact that this process contains many steps and the team will need to modify many of the steps with innovative ideas and tooling in order to meet H&H’s time reduction goals.

Sequence IIIH Lubricant Test Process Optimization


Sponsor: Intertek Automotive Research

Student Team: Cory Masterman, Steven Bernick, Solange Palumbo

Faculty Advisor: Dr. Austin Talley

Intertek Automotive Research is an engine testing facility located in San Antonio, Texas that has the capability to test a broad range of engine types and sizes. Intertek is preparing for an increase in sequence IIIH lubricant tests and would like to reduce the test engine processing time as much as possible. This project focuses on three main areas that could use improvement: quality control testing of p-tubes, work station layout, and a production schedule for a higher volume of tests.

Toyota Tailgate Jig Design


Sponsor: Toyota Motors

Student Team: Marcus Mitchell, Zach Sadler, Cory Pace, Mike Pedraza

Faculty Advisor: Dr. Austin Talley

The two million square foot Toyota manufacturing plant located in San Antonio, Texas is where every Toyota Tundra truck in the United States is manufactured. Approximately 1,050 trucks are produced daily.

The Toyota team has been tasked with optimizing the current jig used to hold the tailgate up to the bed within a range of 50mm-150mm from complete closure while transporting the tailgate in the assembly process. The current jig requires the team-member to reach over deck and potentially mutilate surface. The new design must be strong enough to withstand tensile force of the tailgate and keep the installation time within five seconds, while also keeping the number of mutilated parts below the current state.