• Turbine performance diagnostics using in-plant instrumentation

      Heaton, C. Edward
      Excessive generating capacity within the electric utility industry has forced utilities to take a closer look at reducing costs. The focal points of cost reduction, as far as this study is concerned, are threefold; 1) relying foremost on the least-cost electric generating units, with secondary reliance on the higher-cost generating units; 2) extending the life of steam turbines so as to minimize costly overhauls; and 3) carefully timing the costly turbine overhauls to ensure that they are not performed prematurely or beyond the point that the costs of the overhaul exceed the benefits of restored performance. All three of these methods of cost reduction can be achieved through the continual, comparative monitoring of steam turbine performance. This paper addresses the problems of monitoring the performance of a steam turbine used to generate electricity. The turbines discussed in this study are General Electric G2 turbines located at the Public service of Indiana's Gibson Generating Station. A performance test method is devised that utilizes existing plant instrumentation and a repeatable test load. Data reduction and reporting methods are discussed. The preliminary test findings indicate that the new testing methods are yielding an accurate representation of the steam turbine's performance.
    • Gibson Station Unit 3 main condenser : tube bundle study

      Beal, Larry J.
      Performance deficiencies in large steam surface condensers are normally caused by fouling on the circulating water side of the condenser. The main condensers at Gibson station continued to experience performance deficiencies after the water-side problems were remedied. The focus of this report is the research and testing performed on the Unit No. 3 main condenser in determining the cause or causes of continued poor performance. The four major areas of research and testing are: testing for localized air pockets on the shell side of the tube bundles, researching for possible methods of improving condenser deaeration performance, visual inspection and analysis of the tube bundles, and the proposal for a project to create lanes in the lower half of each tube bundle. The study carried out on the unit 3 main condenser tube bundles has led to considerable improvement in the performance of the Unit 3 main condenser. This will show the way for improving the performance of the remaining four generating units at Gibson Station
    • Ergonomic study of operations related to PVC pipe compounding

      Ludwig, Paul A.
      Cresline Plastic Pipe Company has become concerned with possible human factor design problems in the Polyvinyl Chloride (PVC) pipe compounding operation. PVC compounding is the addition of minor ingredients to the PVC raw resin to prevent the PVC from degrading and to aid in process control during extrusion. Cresline is currently in the process of increasing the production rate of the PVC compounding operation. An ergonomic study was performed to evaluate current and potential human factor problems. The main focus of the ergonomic study deals with the mixer attendant who manually adds the minor ingredients to the PVC resin. The study evaluates work height levels, vision angles, wrist orientation and manual lifting requirements of the mixer attendant. A revised work area and work flow pattern are developed for the compounding operation. The revised work area is evaluated as it relates to work conditions and with respect to actual cost, also the effects of change in the work area as it relates to the mixer attendant.
    • Justification of distributive process control and data acquisition at Gibson Generating Station

      Dick, Edward Joe
      On July 13, 1988, Public Service Indiana, an investor-owned utility, formed a task force to formulate a preliminary plan for future data acquisition and control system upgrades at Gibson Generating Station. The mission of this task force was to "look at available technology and map out a strategy to meet current and future needs identified by all departments."1 The ensuing study provided the ground work necessary to convert a large generating station from an analog benchboard control system to a new distributive process control network. This paper describes the strategic position of Public Service Indiana, including the need to improve the operating efficiency and operating availability of Gibson Station. It then describes the formation and final recommendations of the Computer Modernization Task Force. The paper identifies important advantages of new computer technology to the electrical power industry and provides an economic justification of the first phase of the plant computer control modification project. 1Gregory L. Hauger, Gibson Data Acquisition/Control Systems Upgrade, Inter-departmental mail letter, Gibson Generating Station, Public Service Indiana, 13 July 1988.
    • Plan for increasing employee involvement in the utilities industry

      Thomas, Neil K.
      A research of current literature on the subject of employee involvement and participative management was carried out. Human resource consulting firms specializing in employee involvement programs for utilities were solicited for data and information. Telephone contacts, personal interviews, and solicitation of printed information were made to several large utilities that presently have employee involvement programs in their organizations. The result of this research was a description of the cultural change required, organizational components required for success, and various employee involvement programs available. Case studies of utilities with various programs were made from published and corporate literature. The result is an action plan that can be used by utilities to introduce employee involvement programs.
    • Implementing just-in-time manufacturing using Potter & Brumfield's printed wiring board department as a model

      Alcorn, Audrey G.
      Potter & Brumfield, due to the world class competitiveness of the electronics industry, must implement Just-In-Time (JIT) manufacturing techniques to survive. Success of a JIT program depends upon the order of JIT process implementation. Manufacturing must be recognized as the key to this success and must, therefore, take priority over quality, materials management and scheduling, in terms of implementation. Implementing JIT in manufacturing means reducing the leadtime. This can be achieved through several steps: reduce setup time {especially on bottleneck operations); analyze the flow of material through production lines and group technology and cell manufacturing concept design. When this is accomplished, the other aspects of Just-In-Time manufacturing will fall in place and their benefits will be realized. Production, inventory, scheduling, purchasing, and accounting systems need to change to facilitate JIT on the manufacturing floor. Worker involvement is a key factor throughout the implementation process. Teams should be organized in an effort to reduce setup times. Additionally, changes must occur with respect to job classification within the cell, organizational structure of the cell, training of affected employees, and the pay structure within the cell.
    • Development of an organization and management manual for the field construction phase of automotive projects for George Koch Sons, Inc.

      Neeley, Thomas S.
      This paper presents the development of an Organization and Management Manual for the field construction phase of automotive projects for George Koch Sons, Inc., manufacturers of paint finishing systems. The paper details the planning process, the situational analysis, the goals development, the plans and structure for the manual, and recommendations that were made upon completion of the project. The planning process involved identifying the resources available from within the Koch organization. The situational analysis utilized both a quantitative method and an environmental assessment to identify strengths and weaknesses of the field operation. The goals that evolved from the analysis were: I. To increase productivity and reduce customer complaints by developing procedures and guidelines to aid in the management of field projects. 2. To design the O & M document to be a quick and easy reference for employees who may not have an understanding or familiarity with the Koch organization. 3. To structure the O & M document to allow revisions, since all projects will have different requirements. The manual which evolved from this project included I 3 sections dealing with topics ranging from installation supervision to safety programs and equipment start up. Recommendations are made regarding the future use of the manual and on the management of information within the Koch organization.
    • Concept, design, and production of a new egg storage container

      Cox, Patricia Ann
      Consumer needs are explored in this project to determine how eggs may be stored for convenience and safety. Input from consumers was used to create a conceptual design. The concept was then modeled both on paper and using stereolithography to create representative samples of the design. The computer-aided design process shortened the lead time, reduced the tool cost, and increased the general understanding of the concept.
    • Aluminum rolling mill solid waste recycle system

      Hall, Timothy G.
      This project report describes in detail the process by which Commonwealth Aluminum will Incorporate two environmental projects into one. The first project is entitled landfill closure and the other is the company waste reduction plan in which each department will be required to use the on-site recycle facility which will treat and manage plant waste. It also describes the methods used to recycle each waste stream and how each method will contribute to cost savings and environmental liability reduction in order to achieve full compliance with regulatory mandates. The primary goal of the project is centered around reducing the volume of wastes being disposed of by Commonwealth. The annual waste report serves as the tracking mechanism for defining and quantifying the progress of the project (see Attachment B). This annual waste report assesses the old steady-state conditions and compares the waste volumes and costs with the new waste reduction program totals. The other primary goal of the project is to complete the capping of the old on-site landfill as required by the State Environmental Protection Agency to prevent groundwater contamination. This project helps achieve this goal. A financial benefit will result in the combining of both projects, thus promoting project management efficiency in order to minimize expense and project completion time for the Company.
    • Engineering economic analysis of a plastics compounding facility

      Zhu, Changhui
      In this project, we assumed that the pilot plant operation of the Research & Development Department of Ferro Corporation, Filled and Reinforced Plastics (F & RP) Division, is considering investing in an additional compounding line. There are two possible alternatives: a continuous mixer (e.g. a Farrell CP-23 Continuous Processor), or a twin-screw extruder (e.g. a ZSK-40 Twin-Screw Extruder). Two major techniques of economic analysis were used to evaluate the two alternatives. All other factors, i.e. the features of each alternative and human factors which affect the output of the equipment, were also evaluated quantitatively. For the present study, a target rate of return at 25% was selected. The results of present worth analysis predicted that the CP- 23 Continuous Processor Compounding Line will be the best choice, generating $57,336 net profit after 10 years of operation at a 25% rate of return. The ZSK-40 Twin-Screw Extruder Compounding Line will generate $3,013 by the same calculation. The rate of return analysis found that the CP-23 Continuous Processor Compounding Line can yield a 31% rate of return per annum which is much higher than the target, while that of the ZSK-40 Twin-Screw Extruder Compounding Line is only 25. 2%. A sensitivity analysis found that the gross margin rate of the ZSK-40 Twin-Screw Extruder Compounding Line would have to pe increased by $0.062/lb. to compete with the CP-23 Continuous Processor Compounding Line. Reducing the undesired down time on the ZSK-40 Twin-Screw Extruder Compounding Line cannot totally solve the problem. It is very important to note that the evaluation of these machines in this study was for a pilot plant facility only. The results have no bearing on a manufacturing operation in the real world.
    • Development of a plant policy and procedure for assurance of coal pulverizer performance

      Payne, Mark A.
      ln conjunction with a plant equipment upgrade at the Southern Indiana Gas and Electric Company (SIGECO), F.B. Culley Station to reduce Nitrogen Oxides (NOx) emissions, it was agreed upon by SIGECO and the equipment manufacturer that tighter control of individual pulverizer air-to-fuel ratios is critical in achieving optimum performance of the affected boiler. This paper delineates steps taken by SIGECO management to most effectively monitor and control operational parameters that affect the process. The final product of this project is a plant policy and procedure for assuring that these operational objectives are met.
    • Revitalizing the material safety data sheet index for Indiana Michigan Power Company Rockport Plant

      Campbell, Renee M.
      This paper presents the revitalization process of the Material Safety Data Sheet (MSDS) Index for the Indiana Michigan Power Company Rockport Plant. The paper details the importance of the MSDS Index and the Occupational Safety and Health Standards Title 29 CFR Sec. 1910 .1200 (g) (1) . The paper incorporates the additional background knowledge required to understand the project, situational analysis of the MSDS Index, and revitalization process. The detailed problems and solutions include the areas of inventories, MSDS acquisition, hazardous ingredients, substituting products, and disposing of products. The problems are exemplified in the appendices along with additional information. Some of the latest research in the area of MSDS preparation and understanding, the ANSI Z400.1-1993 American National Standard for Hazardous Industrial Chemicals - MSDS Preparation, is rationalized. The project results include inventory summaries, table, and an entire process flowchart. The most important future recommendation is the regulation and approval of new product purchases requiring Material Safety Data Sheets by the Environmental, Health and Safety Department.
    • Converting a MIL-I-45208A inspection system to the minimum demands of ISO 9002

      Skinner, James D.
      This project presents the conversion of a Mil-I-45208A quality system to one meeting the minimum demands of ISO 9002. This project briefly describes both quality systems and an approach in converting to ISO 9002. Three parts are contained in this report: an Overview, a Comparison of the Military and the International quality requirements, and a Case Study. The Overview and Comparison are descriptive to familiarize the reader with the subject. The Overview describes the project and the basic ideas of a quality system, and introduces the Military and International quality system standards. The Comparison discusses the Military and International quality system standards in depth and briefly describes the similarities and differences of Mil-I-45208A and ISO 9002. Part III, the Case Study, presents the actual conversion from a Mil-I-45208A system to one meeting the minimum ofISO 9002. This project assumes that the reader has a limited knowledge of quality system concepts. It is not intended to be a stand-alone guide to convert to ISO 9002 from Mil-I- 45208A, but gives an approach the author would take given a set of Mil-I-45208A procedures.
    • Modifications to the precipitator girder blower system for solving design inadequacies

      Eichenberger, Paul
      This research paper was completed as a requirement for the Master of Science Degree in Industrial Management at the University of Southern Indiana. It explains how competition in the electrical power industry forced electric utilities to enact aggressive cost controls to lower their operating costs. One method of lowering costs at the Rockport Power Plant involved forming a committee to investigate and complete projects aimed at improving the overall plant efficiency. This paper details the evaluation and final proposal for such a project on the electrostatic precipitator girder blower system. The committee believed major improvements could be made to this system to reduce maintenance costs and to improve the operating efficiency. The girder blower system produced too much air flow, entrained damaging moisture, and provided damaging cold air during winter operation. These three major problems were identified, the effects associated with the problems explained, and possible solutions were developed to solve each problem. Eventually, a final modification was recommended by combining the individual solutions to best solve all three problems.
    • Inner door panel manufacturing at Whirlpool Corporation's Evansville Division

      Deistler, Ronald Gregg
      This project evaluates the feasibility of relocating the manufacturing of plastic inner door panels used on Midline Redesign (MLR) refrigerators from American Sheet Extrusion Corporation (ASEC) to in-house manufacturing at Whirlpool Corporation's Evansville Division. Justification for this project will be based on researching ASEC's quality performance, cost differences for all MLR inner door panel part requirements, investment and manpower requirements, and a financial analysis. The research will conclude with proposed facility layouts and a project implementation schedule. The research results indicate that it would be more beneficial for the Evansville Division to produce inner door panels in-house.
    • Apex Engineering, Inc. : time card improvement for a consulting engineering firm

      Rosean, Alan B.
      Apex Engineering, Inc. uses a computerized accounting program called Win2 for processing its payroll even though each week every employee fills out a time sheet by hand. Errors on the time sheets were delaying processing. This thesis project looked at improving the time sheets. The project centered around the design and implementation of a computerized timecard to replace the handwritten time sheet. This project served two major purposes. First, the new computerized timecard improved the accuracy and completeness of the original time sheet. Second, the information in the new timecard can now be easily extracted and compiled into reports. All data is contained within a Microsoft Access 2.0 database table. Tools such as structured query language (SQL) can be used to extract information from the central database based on selected criteria such as a list of all employees hours for any given project. The new computerized timecard was designed with short-term tactical and longterm strategic goals in mind. The tactical goals included faster timecard completion; more accurate match of project numbers and descriptions; and more accurate computation of employee hours. The strategic goals covered creation of a centralized database containing all employee timecard data with provision for extraction, compilation and creation of reports using SQL. These SQL-derived reports now can be used for improving areas such as the bidding process or personnel assignments within the firm . The timecard was designed to be simple and easy to use, especially by noncomputer literate personnel. To use the timecard the employee merely starts the program in a standard Windows environment. Then the employee makes selections by use of a standard Windows pointing device such as a mouse or track ball. The only typing involved by the employee is entering the hours worked on each project. The timecard program automatically computes the hours as the employee advances from one option to the next. The service program is also easy to use. Its opening screen contains command buttons that open tables in the database for direct editing by support personnel. Any table can be edited. The service program operates from a secure computer to maintain confidentiality.
    • Implementation and justification of a robotic welding cell

      Voegerl, Blake R.
      Kimball Upholstered Products has been actively researching vendors in order to procure a robotic welding cell to reduce the manufacturing costs of its metal EVENT chair frames. Currently, the EVENT chair frames are produced at a remote Kimball International sister company, and Kimball Upholstered Products is interested in producing these frames in their facility where they would have control over the quality and manufacturing process of the welded chair frames. A cost feasibility study has been performed to justify the implementation of a robotic welding cell. The values in all spreadsheets and charts have been removed due to the proprietary and confidential nature of information for Kimball Upholstered Products.
    • Use of continuous quality improvement methodology to solve service delivery problems in a health care environment

      Forsyth, Arthur
      The Continuous Quality Improvement (CQI) process, a critical part of the Total Quality Management (TQM) philosophy, is designed to find problems in a manufacturing process and make corrections using small incremental changes. These changes are monitored closely to see if they have the desired effect on the process or if additional changes are necessary. This paper follows the actual implementation of this process in a health care service delivery system and discusses the various stages. TQM history is discussed in the introduction along with the change in the management culture necessary to establish and sustain a focused effort toward this end. The FADE or Focus, Analyze, Decide, and Execute method of CQI is being used as a basis for this process. This method is used at the hospital as their main tool for implementing the continuous process improvement. The process that is causing customer dissatisfaction and is the focus of this paper is the Patient Discharge Process. This process is initiated to end a patient's stay at the hospital. The process is used to give the patient necessary information, instruction and supplies needed for the continuation of care wherever he or she may go. The present focus is on the length of time that the discharge process takes. At the present time too many patients believe it requires too much time. The monitoring phase is what makes this process continuous. All of the changes that are implemented are monitored and adjustments are made when and where new problems are identified. The CQI process must be ongoing so it is necessary that it be supported by top level management, which must make the necessary resources and time available. Without this support, this process becomes intermittent and ineffective.
    • Machine shop layout, installation, tooling, and personnel training

      Benedict, Keith G.
      General Electric Company's Mt. Vernon operation employs a number of technicians to maintain its plastic fabricating equipment. Maintenance engineers in charge of several functional areas want these technicians to perform simple machining operations to reduce the cost and time associated with the current practice of outsourcing machine work. The author was retained as a consultant to set up a machine shop, specify and order tooling, develop a customized training program for the technicians, and teach machining skills to several groups of students. These tasks have been accomplished, with the training materials organized as a website, allowing them to be easily modified and accessed with any Web browser from a computer disk, an intranet, or the Internet. July
    • Investigation of awarding university credit to veterans for military experience

      Salee, Joseph C.
      Veterans at the University of Southern Indiana have expressed some concerns about the policy of awarding credit for their military experience. Under the current policy, veterans are awarded eight hours of academic credit, and in many cases some of that credit cannot be applied to fulfillment of graduation requirements. This report examines the University Core Curriculum (UCC), compares military experience to the intent of the UCC, and proposes a change in policy to accommodate veterans by assessing their military experience.