• 3rd party perspective : Professional Consultant, Inc. management of Rexam automation line upgrade

      Hagedorn, Julie A.
      This case study will review an Automation Control upgrade at Rexam in Princeton completed by Professional Consultants, Inc. (PCI). This case study is presented from a third party perspective, as the writer was a programmer on this project. Primary focus was given to major issues that directly impacted the overall success of the project, with special emphasis on management and their decisions throughout the project. Then some time will be spent summarizing best practices learned from relevant journal articles which are summarized in Appendix J. Discussion on which particular best practices that the author feels PCI should consider adapting as company practices can be found in the Discussion section. Lastly, a review of major issues in the project will be presented with predictions of how they could have turned out differently had these practices already been in place. Suggestions to avoid making the same mistakes on future projects will also be explored, as well as discussions on what elements of the project went well and should be repeated in the future. A literature review section which highlighted numerous articles pertaining to various project management practices that the writer felt was relevant to this project are located in the Appendix. This report is meant to provide an insight into how project management practices at PCI can be altered for improved efficiency and financial success in the future.
    • 442 McAdam

      Boulangger-Gimenez, Dalia
      The McAdam Company has recently moved its headquarters to Toronto, Ontario, and is predicting a major increase in demand of its unique handbags. Sarah Shell, business owner, has realized she can no longer produce the handbags herself and she is exploring whether to outsource production with either a domestic or an international manufacturer. Shell needs to take production costs, minimum order requirements, and volume designs into consideration in order to make the best profitable decision for her business. After analyzing the possibilities of outsourcing, Shell determines that using an international manufacturer will improve the profitability of the company. The cost of production is $80 per handbag if produced by an international manufacturer vs. $120 per handbag if produced by a domestic manufacturer. However, residual inventory levels at the end of the season will likely be higher if an international manufacturer is selected and this excess inventory may end up being sold at a discounted price and possibly a loss. Residual inventory levels at the end of the season will likely be lower by using a domestic manufacturer, and this alternative provides the convenience of having the production onsite and easier to monitor by Shell. Finally, a local manufacturer will also save McAdam shipping costs.
    • Additional fly ash storage : dewatering bins conversion project at Indianapolis Power & Light Petersburg Generating Station

      Brooks, Christopher Joseph
      The objective of this thesis is to complete a project in order to create additional ash storage capacity and system reliability for our Petersburg Generating Facility. Specifically, an economical solution for fly ash storage and disposal is required in order to meet evolving environmental emissions regulations required at the coal fired power plant. First, the additional storage space required will allow both outage maintenance on existing fly ash storage locations and add extra capacity for use during full capacity generation. Second, creating this additional place for disposal will allow for operations to continue generation during any issues with the existing disposal locations. Operational and financial impacts determined that a project centered on the conversion of existing bottom ash handling tanks provides the greatest benefit. Current and future operations is impacted and internal planning and coordination helps change once open topped dewatering bins to closed fly ash handling tanks.
    • Administrative, behavioral, and work process changes for reliability imporvements in pelletizer rubber pull rollers used in manufacturing of engineere

      George, Nicholas Andrew
      This project focuses on improving work practice around pelletizer equipment for the purpose of reducing business impact from maintenance costs. There is a particular emphasis on the human behavior factor influencing the resistance to change. This issue has parallel application to a variety of change management efforts in manufacturing or process improvement environments. The study introduces pelletizer equipment and the standard approaches taken by three units - or "plants" - within one particular chemical manufacturing facility (which remains nameless for anonymity), for pelletizer pull roll maintenance. The impact of poor practices results in significant business impact, especially over the life of the facility. The focus of the study is implementing best practice changes in each of the three units to alter human behavior around rubber pull roll maintenance, and introduce sustainable changes that will result in a recovery of the expense of the pull rolls. Each unit has its own set of unique challenges that must be overcome to have a positive impact. As part of this study, trials were conducted and documented with positive results. Administrative and behavioral changes were an integral part of the change management process. At the conclusion of the project, each unit has a solid foundation for a path forward to sustainable and meaningful change that improves business cost and efficiency long term.
    • 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.
    • Analysis of a Returnable Packaging System : Refrigeration and Air Control Group of Whirlpool Corporation

      Bloodworth, Dennis S.
      True supply chain management requires that every step of the material flow process be examined to determine if the best possible cost has been achieved. A different perspective is sometimes needed to view additional savings opportunities that will help a company create and maintain a competitive position in the global marketplace. As circumstances frequently change in the business world, it is essential that even the management of materials once considered disposable be evaluated for long term use. It is in the proper management of these materials and associated processes that new opportunities arise to achieve best in class performance. Whirlpool Corporation has made a concerted effort to leverage its many years of manufacturing experience in the continued operation of its returnable packaging program. However, in a fiercely cost constrained environment, Whirlpool Corporation has reached a decision point for future planning and operation of this program. The maintenance of business cost for one of the three divisions has exceeded the contribution level at which the division financially supports the returnable packaging program. This disparity of cost versus benefits received has temporarily been covered by cost improvements achieved by the group. However, this practice cannot continue indefinitely This paper has focused on the existing operations involved in managing the program for these three manufacturing divisions located in the United States of America. Costs and benefits have been documented. These divisions have realized significant savings through pooling their resources to achieve standardized robust designs, leveraged buying, and an effective material flow process. This team effort has enabled them to drive down the manufacturing conversion cost for individual divisions while allowing them the opportunity to use the savings to create value for the company, the employees, and the shareholders. It is important that every company examine opportunities for improvement. While validating the value creation this program currently provides for Whirlpool Corporation, this paper considered the following program improvement options: 1.) Do nothing; maintain status quo of materials primarily owned by Whirlpool Corporation achieving incremental improvement as opportunities present themselves. 2.) Supplier owned packaging where this cost is buried in the piece price of the part cost. 3.) Expanded regional, systematic, synergetic process of the current system described in option number one above. Whirlpool Corporation has traditionally taken the path of ownership of the majority of the materials comprising the returnable packaging program. Benefits including lower purchase order cost, lower inbound freight costs, improved quality, and lower indirect labor costs have been realized. Ownership of the materials allows Whirlpool Corporation to better control the variability of these cost elements. This paper has shown that additional opportunities for improvement exist for those who choose to be good stewards of every part of their material flow process. Therefore, with proper process ownership, option number three, as noted above, is the best future option for Whirlpool Corporation.
    • 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.
    • Assessing efficiency opportunities for metabolic products

      Coulter, Julia
      This project is focused on Mead Johnson's metabolic product family. The team will document the current cost of goods structure and the charges which are incurred at the third party manufacturer. Based on this infonnation, we will identify opportunities to reduce costs associated with product sampling, label order processes, production equipment cleanups, and material carrying costs. We will also assess qualitatiye issues. These will include Plant 2's safety record as compared to the perfonnance of Plant 1 's and quality systems versus Mead Johnson's internal quality standard. Based on the information gleaned from these assessments, we will identify savings opportunities, make recommendations on how best to capture the savings and offer suggestions to improve qualitative systems.
    • Automation & network disaster recovery planning (ANDRP)

      Wolfe, Rockie S.
      Automation has evolved into many levels of complexity and points of failure. In this research paper the focus is on automation disaster recovery methods and examples. Also, extra effort was put into the growing interdependency of automation and Information Technology (IT) in the modem manufacturing facilities of today. Disaster recovery plans under the business continuity model is briefly discussed as research and articles in this area have been in print for decades if not centuries. Some discussion is covered in the benefit-cost analysis section. This short discussion is not meant to take away from the importance of benefit-cost analysis to artfully sell needed projects to procurement and upper management. The research is broken down into five different yet related disciplines: Automation, Disaster Recovery Plans, Information Technology, the new Hybrid, and Benefit Cost Analysis. After covering the five different disciplines there is a follow up with an example application for Automation / IT Disaster Recovery Plan. The intent of this paper is to create guidance for starting a disaster recovery plan in a manufacturing setting. Unfortunately no '"one size fits all" and the many challenges of natural and intellectual negative effects on business continuity will demand a lifelong commitment to investment, education, and awareness.
    • Benefiting from the advancement in gas tungsten ARC welding technology in a welding fabrication facility

      Hammen, Gregory Joesph
      A&B Process Systems is a manufacturing facility of various product lines supporting industries including food, dairy, and pharmaceutical. These fabricated products have a requirement to be high in purity and utilize various grades of stainless steel due to their ability to inhibit corrosion. Historically the business make up has been to customize every order to suit the needs of the buyer. However, times have changed and A&B has recognized that they are in an ever-growing competitive industry. In fact, consultants and employees have been assigned to seek ways to maximize throughput and minimize costs. Practices such as lean six sigma and theory of constraints are being communicated to create a culture that constantly looks for ways to improve the entire fabrication process. From the design to delivery, there are many opportunities to improve upon inefficiencies. In an effort to reduce lead time and costs, a proposal was made by senior management for standardization implementation. The proposed plan was to have a finite number of tank designs that the company has to offer at a set price. This would ultimately speed up the design process and the ability to batch orders and promote repeatability and consistency through the standardization process. In order to increase productivity and maintain the quality and safety during the fabrication of these tanks, a time study was performed over a period of two weeks to review the current welding practices associated with welding circumferential welds. On average, A&B produces a quantity of four hundred 10-foot diameter tanks per year. This amounts to 1,275 in. of weld seam per tank. After introducing the new and improved welding process, 3,060 hours of labor have been saved amassing over $275,394.00 and allowing the ability to fulfill additional work orders each year.
    • BWX Technologies' reentry into the commercial nuclear market

      Hines, Matthew A.
      This thesis investigates the potential for BWX Technologies (BWXT) to reenter the commercial nuclear market. Information is presented on the current nuclear energy initiatives taking place around the globe. These discussions focus on the growing need for nuclear power worldwide. The current state of the company is examined in order to determine what is required for BWXT to make the switch from defense work to commercial work. Thorough discussion on how the company will manufacture both types of products simultaneously is also included. Historical evidence from past commercial ventures will aid in deciding how BWXT should approach future commercial initiatives. Many facets of doing business are analyzed to guide BWXT in making the most effective business decisions related to future commercial nuclear projects. These facets include areas such as customer impact, quality management, financial information, and new technologies. There are opportunities in each of these areas for BWXT to make improvements in an effort to achieve optimal profit from future contracts. The reintroduction of commercial nuclear work will bring with it many role changes for BWXT personnel. Management, office employees, and shop hands will all be required to learn new responsibilities. The effectiveness of personnel assignments and training will be critical at the beginning of any new commercial project. The findings of this thesis will be presented to BWXT management in hopes of gaining support to move forward with the implementation of the ideas discussed within this report.
    • Capable associates perform strongly : an in-depth look at training, development, recognition and involvement

      Eagan, Julie
      This project will focus on the importance of associate training, development, recognition and involvement within an organization. Initially, the associate involvement and developmental tools currently being utilized at Rexam Closures and Containers will be examined. Once this assessment has been completed, the developmental needs of the current workforce will be examined in order to determine what areas are not being addressed and to gage effectiveness of the existing processes and programs. New tools will then be developed while current tools are redefined in order to meet the demands of the associate base. Actions will then be taken to gain support from management and develop implementation procedures in order to implement the new tools and filter them throughout the organization successfully. This step will involve detailed communication to the management team and the development of smaller focus groups to drive the programs throughout the departments, shifts, individual facilities and the organization as a whole. After implementation takes place, there will be ongoing evaluation to ensure that the desired results are being achieved. As the associate population changes, updates and revisions will be made in order to improve performance. These follow-up actions will be developed and performed by Human Resources and management team members throughout the organization.
    • Closing the gap from strategy to performance : utilizing the strategic planning process in small business entities

      DePillo, Karla Sue
      This paper examined the strategic planning components and processes for a small business enterprise seeking to grow its firm through sales volume and revenue. The purpose of the paper is to fill the gap in research related to the application of strategic planning tools in small to mid-sized businesses and to provide a case study that outlines a 'how-to' approach to applying formal strategic planning tools to an existing small organization. The review of the literature was presented in two categories: Strategic Planning and Performance Measurement Systems. The research methodology utilized two key components: I) books and articles focused on strategic planning and performance measurement systems of small to medium-sized business enterprises known as SME's and 2) an adaption of another organization�s approach to strategic planning and implementation. The strategic planning tool implemented during the case study was a framework called the 'situation audit', which pulls together the external and internal factors affecting the organization. The situation audit performed included a detailed SWOT's analysis. The Balanced Scorecard approach was used as the framework for identifying a system of metrics based upon the results of the situation audit. The research conducted indicates that successful organizations use some level of business planning. Mature, larger organizations tend to apply formal planning practices whereas; small to medium-sized organizations may be less formal. The application of the situation audit and balanced scorecard approach during the case study resulted in valuable insights and recommendations for the subject SME and suggests that strategic planning can help this company and similar organizations become more sophisticated in identifying and achieving its targets and objectives.
    • Cogeneration: a sustainability project

      McClellan, Daryl S.
      Qualitative and anecdotal evidence demonstrates that reducing waste and conserving resources promote corporate sustainability both economically and environmentally. Developing and applying new ideas to achieve higher performance and excellence have lead to the re-emergence of a past application at Mead Johnson Nutritionals (MJN). A turbine/generator project will focus on the importance of sustainability with respect to energy conservation and maximization of utility inputs. An existing turbine/generator removed from service in 1997 will be redesigned and reinstated to supplement present as well as, future energy utilization. Once an assessment of the feasibility is completed, an implementation plan for execution will be presented for capital funding. The project scope will achieve the customer's desired automated operational requirements. Facility Management (the customer) at MJN will be responsible for determining the turbine operating parameters. Ultimately, this project will make a considerable recurring contribution towards Bristol-Myers Squibb's (BMS) global sustainability goals.
    • Commercial packaging process improvement

      Elrod, Nathaniel C.
      The primary focus for improvement is the tray load and unload operations within the Commercial pack lines at the AmeriQual Foods plant. It looks at two different options that combines the position of tray loader and tray unloader on one manual pack line. The improvements had to have a short payback less than a year and be universal that could be installed on any line within the department. It also had to have potential to be incorporated into future projects to improve efficiency.
    • 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.
    • Conversion of Green Station lime scrubbing system to limestone

      Shaw, Thomas L.
      This paper investigates the costs associated with the current operation using a lime scrubber and compares those costs with the conversion to a limestone scrubber. The conversion to limestone impacts several key costs that affect the cost to generate a megawatt-hour of electricity. Replacement costs for equipment and expected savings in disposal and operational costs are compared to the existing operational costs. Additionally, a typical business case was developed to project the expected cost savings and the expected internal rate of return on the capital expenditure.
    • 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.
    • Cost reduction proposal for a tamper-indicating closures manufacturing cell

      Fromm, Brad
      Rexam Closures & Containers manufactures the tamper-indicating cJosure (CGI) product Jine to compete in the automotive after-market. Due to extreme price pressure in the market, Rexam Closures & Containers found it desirable to reduce the cost to manufacture the CGI closure. In order to identify potential cost savings, lean manufacturing techniques were researched and utilized where appropriate. In particular, the value stream associated with the manufacturing process used for the CGl was mapped and analyzed to identify non-value-added operations. The value stream mapping process generated several opportunities to reduce waste and, therefore, cost. Product testing was conducted in order to verify that the cost savings alternatives did not negatively affect product function. As a result of the analysis, a recommendation that documents potential cost savings of $24,000 annually was forwarded to Rexam CJosures & Containers' senior management.
    • Creation of an education supervisor's handbook for ITT Technical Institute

      Cotner, Jerry W.
      When an employee is promoted to an Education Supervisor or when a new hire is placed in this position there is a period of confusion as to what job responsibilities are and the correct procedures for implementing these responsibilities. There are many questions and duties that are required but with little or no written information on how to perform them. This project is to ascertain the requirements and create a manual to make this process a smooth transition with minimal outside help. This process will require an in depth review of the current policy manuals as well as conferring with several department heads. Through this consultation it was determined that a manual over the following areas could affect a smoother transition. These areas include, the classroom environment, scheduling, safety and security, instructor motivation and training, and hiring and firing. This report will examine these areas and how the Education Supervisor Manual was put together.