Industrial & Manufacturing Engineering Masters Theses

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Intelligent Cold Supply Chain Management System with Radio Frequency Identification, Global Positioning System, and Wireless Sensor Network
(North Dakota State University, 2009) Yang, Xiaomin
This thesis establishes an intelligent cold supply chain management system which consists of two parts: one is the intelligent tracking system integrated with Radio Frequency Identification (RFID), Global Positioning System (GPS), and Wireless Sensor Network (WSN); the other is the cold supply chain model. This tracking system is mainly designed to monitor the food products during the transport, including two parts, a data terminal and a data server. The data terminal is installed inside a container, comprised of GPS, Bluetooth, industrial computer, WSN, RFID reader, RFID antenna, and Code Division Multiple Access (CDMA) modem. The data server is a computer which is able to access internet and has one Structured Query Language (SQL) database. Related application programs are developed with JAVA language. The whole system is successfully tested and meets the expectations we desired at the beginning. In this study, a refrigerator is used to simulate the environment of the container. The data terminal collects all information, including temperature inside the container, GPS location, Product's Identification, and current time in five minute intervals (customers will be asked to set this time interval at the beginning). CDMA cellular network provides the communication between the data server and the data terminal. The data server receives all information and saves the information in the SQL database, which can be used to predict the food safety. Advantages of this tracking system include the ability: 1) to trace and track the products starting from the suppliers to retailers; 2) to monitor and store important parameters during the processing and distribution of food products, such as temperature; 3) to communicate in real time for prompt response; and 4) to quantify food safety prediction. The objective of the model developed in this study is to maximize the profit of the cold supply chain. There are one distribution center, multiple retailers and suppliers involved in the cold supply chain. Since the real-time quality situations of products are available even during the transport, retailers can set prices of products based on the real quality situation. The company is able to dynamically plan the quantity of distribution from the distribution or suppliers' site. In addition, retailers are able to manage the inventory based on the real shelf life of products. This thesis also concludes all different inventory results for retailers under different scenarios which can help retailers to predict and manage the inventory. The optimization software, Lindo, is used to demonstrate that this model is capable to dynamically plan the distribution quantity. The sensitivity analysis for prices, transportation costs, and holding costs is discussed to simulate different situations during the transportation and distribution.
Adaptive Production Planning and Scheduling for the Make-to-order DNA Manufacturing System
(North Dakota State University, 2010) Song, Dan
This thesis develops an adaptive production planning and scheduling system for the make-to-order plasmid (DNA) manufacturing system. The system, which has stochastic nature and random demand, was represented by a mathematical programming model first. Then in order to solve it, discrete-event simulation models were developed to generate a feasible schedule that maximizes the production throughput in the planning horizon in a mix-product type environment. A special heuristic order selecting and splitting procedure was designed to aid the production planning and scheduling process. Experiments were conducted to evaluate the algorithm and results are compared with those obtained by using four classic dispatching rules, such as first come first served (FCFS) and shortest processing time (SPT). To take advantage of simulation results, a rule-based expert system was created with pre-defined scheduling rules. Rules regarding production planning and scheduling can be used by human schedulers easily and the system is very flexible in further extension.
Winter Road Maintenance System Design for Snow Plowing
(North Dakota State University, 2010) Kayabas, Poyraz
Winter road maintenance is critical to ensuring safety and mobility of transportation systems in regions with heavy snowfall. Winter road maintenance system design involves several inter-related decision making problems for different operations that are often performed with expensive and limited resources. This study involves developing an integrated solution methodology for depot location selection, district design, and vehicle routing problems for winter road maintenance system design in the context of snow plowing. The methodology allows decision makers to evaluate and compare different system alternatives based on a number of service level related system design criteria. The solution methodology is illustrated using the example of the road network of the Fargo District of North Dakota's transportation system. Results indicate that the methodology can be used as a decision making support tool for planning winter road maintenance operations.
Multiresponse Optimization Methodology Considering Related Quality Characteristics
(North Dakota State University, 2011) Thambidorai, Ganesh
Engineering problems often involve many conflicting quality characteristics that must be optimized simultaneously. Engineers are required to select suitable design parameter values which provide better trade-off among all quality characteristics. Multiresponse optimization is one of the most essential tools for solving engineering problems involving multiple quality characteristics. Optimizing several quality characteristics when the quality characteristics are correlated makes the optimization process more complex. The aim of this research is to evaluate the performance of several existing multiresponse optimization methods and investigate their capabilities in dealing with correlated quality characteristics. This study also investigates the impact of uncertainty in terms of input parameter selection. A new multi-response optimization approach has been proposed for solving correlated quality characteristics. The proposed approach is compared with the existing methods and found more robust in terms dealing with uncertainty in target selection. The comparative study and application of the proposed approach is demonstrated by considering two examples from the literature having correlated quality characteristics.
CFD Heat Transfer Simulation of the Human Upper Respiratory Tract for Oronasal Breathing Condition
(North Dakota State University, 2011) Srinivasan, Raghavan
In this thesis. a three dimensional heat transfer model of heated airflow through the upper human respiratory tract consisting of nasal, oral, trachea, and the first two generations of bronchi is developed using computational fluid dynamics simulation software. Various studies have been carried out in the literature investigating the heat and mass transfer characteristics in the upper human respiratory tract, and the study focuses on assessing the injury taking place in the upper human respiratory tract and identifying acute tissue damage based on level of exposure. The model considered is for the simultaneous oronasal breathing during the inspiration phase with high volumetric flow rate of 90/liters minute and a surrounding air temperature of 100 degrees centigrade. The study of the heat and mass transfer, aerosol deposition and flow characteristics in the upper human respiratory tract using computational fluid mechanics simulation requires access to a two dimensional or three dimensional model for the human respiratory tract. Depicting an exact model is a complex task since it involves the prolonged use of imaging devices on the human body. Hence a three dimensional geometric representation of the human upper respiratory tract is developed consisting of nasal cavity, oral cavity, nasopharynx, pharynx, oropharynx, trachea and first two generations of the bronchi. The respiratory tract is modeled circular in cross-section and varying diameter for various portions as identified in this study. The dimensions are referenced from the literature herein. Based on the dimensions, a simplified model representing the human upper respiratory tract is generated.This model will be useful in studying the flow characteristics and could assist in treatment of injuries to the human respiratory tract as well as help optimize drug delivery mechanism and dosages. Also a methodology is proposed to measure the characteristic dimension of the human nasal and oral cavity at the inlet/outlet points which are classified as internal measurements.
Integration of Simulation and DEA to Determine the Most Efficient Patient Appointment Scheduling Model for a Specific Clinic Setting
(North Dakota State University, 2011) Aslani, Nazanin
This study develops a method to determine the most efficient scheduling model for a specific clinic setting. The appointment scheduling system assigns clinics' timeslots to incoming requests. There are three major scheduling models: centralized scheduling model (CSM), decentralized scheduling model (DSM) and hybrid scheduling model (HSM). In order to schedule multiple appointments, CSM involves one scheduler, DSM involves all the schedulers of individual clinics and HSM combines CSM and DSM. Clinic settings are different in terms of important factors such as randomness of appointment arrival and proportion of multiple appointments. Scheduling systems operate inefficiently if there is not an appropriate match between scheduling models and clinic settings to provide balance between indicators of efficiency. A procedure is developed to determine the most efficient scheduling model by the integrated contribution of simulation and Data Envelopment Analysis (DEA). A case study serves as a guide to use and as proof for the validity of the developed procedure.
Economic Analysis of Packaging Systems
(North Dakota State University, 2011) Biradar, Vaibhav Mahadev
Packaging has a significant impact on the efficiency and effectiveness of the supply chain, where improvement can be achieved through the development and selection of an appropriate packaging system. One way to explore this is through the development and use of mathematical models that facilitate economic analysis of packaging systems. Recently, one of the most remarkable trends in logistics is the extensive use of returnable or reusable containers. Returnable container systems have increasingly been introduced in various industries to take advantages of cost savings, but it is very crucial to ensure that a reusable packaging system is an economical packaging choice. In this thesis, an extensive study of an economic analysis of disposable, recyclable, and reusable packaging systems is conducted. This includes identification of significant cost factors and variables involved in the management of disposable, recyclable and reusable packaging systems, and formulation of a mathematical model to compare total cost of packaging systems. The developed mathematical model can be used to choose the most economical packaging system for industries. The linear programming (LP) method is used to develop the mathematical model. The various new factors such as the collapsible ratio of recyclable, disposable and reusable packages have been introduced for the first time in the economic analysis of the packaging systems. The developed mathematical model can be used for a range of industries and for different industry scenarios. The packaging system information of Toyota assembly plant is used for the validation of a mathematical model. The obtained results are compared with previous research based on the same data set and results found in concert with the finding of previous research which validate the model.
Transparent and Crack-Free Silica Aerogels
(North Dakota State University, 2012) Athmuri, Kalyan Ram
The process of making silica aerogels has been studied in detail over the past two decades due to its usage in a wide range of low end applications such as thermal insulators, supercapacitors etc., as well as high end applications like particle physics, space explorations. These applications call for control over the properties of aerogels, such as their transparency, density, porosity, pore size, and integrity. However, despite all the past research, controlling properties of aerogels is still not a fully developed science, a lot more research needs to be done. The literature on silica aerogels does not cover the study of the relation between transparency and cracks in aerogels – which can be a key factor in making aerogels for many applications. Hence, optimization of the transparency and integrity of the aerogels in order to obtain high transparency and low cracks was attempted in this thesis.
A Study on the Impact of Patient Centered Medical Home (PCMH) Implementation on Nursing Work Practice
(North Dakota State University, 2012) Shinde, Nikhil Vijay
Primary care and nursing are important components of the U.S. healthcare system and are facing challenges of quality, access, cost, time spent and inefficiencies of clinical activities. Patient Centered Medical Home (PCMH) is a newly developed care model which has the potential to overcome these challenges. The present study uses a questionnaire approach to find the impact PCMH implementation may have on nursing practice and subsequently primary care. Analysis of the data collected from the questionnaire revealed some surprising results about the nursing practice. For example nurses spend less time on direct care and more time on indirect care and documentation. The nursing demand in terms of Full Time Equivalent (FTE) for nurses decreases. The future demand for nurses (not in FTE) shows an increase after PCMH implementation. The satisfaction level and overall health of patients, patient readmission, job satisfaction of nurses and department productivity shows improvement after PCMH implementation.
Impact of Integrating Zone Bypass Conveyor on the Performance of a Pick-To-Light Order Picking System
(North Dakota State University, 2012) Xu, Xia
This thesis investigates the impact of integrating Zone Bypass (ZBP) conveyor to a Pick-To-Light (PTL) order picking system. This integration results in a new system (PTL+Z), which could be helpful to achieve higher levels of productivity in warehousing operations. Two options have been proposed to improve the current PTL system productivity. One is to adapt the ZBP conveyor, which will help each order to bypass unnecessary zones with nothing to pick. Another one is to better plan stock keeping units (SKU) assignment by applying level loading assignment. Mathematical models are developed to evaluate system throughput of PTL system with random assignment (PTL/R), PTL system with level loading assignment (PTL/L), PTL+Z system with random assignment (PTL+Z/R), and PTL+Z system with level loading assignment (PTL+Z/L). Simulation models are validated to test the reliability of mathematical models. Also, economic analysis is developed in term of payback period for decision purpose.
Study and Analysis of Automated Order Picking Systems
(North Dakota State University, 2012) Ambati, Akhilesh Chandra
Order picking is an essential part of order processing in warehousing and distribution operations and can be performed using manual, automated, or semi-automated systems. This thesis analyzes two automated systems, which include carousel and AS/RS (automated storage and retrieval system). The main goal of this research is to develop mathematical models to compare the performance of both systems under random and class-based storage assignments. Simulation models are used to validate the reliability of mathematical models. The outputs of mathematical and simulation models are consistent indicating carousel system with class-based assignment has the highest throughput. Economic analysis is used to estimate the payback periods required to convert from manual to AS/RS and carousel systems. The economic analysis shows that converting from manual to AS/RS with class-based assignment has the shortest payback period.
Applying Simulation and Genetic Algorithm for Patient Appointment Scheduling Optimization
(North Dakota State University, 2013) Peng, Yidong
In this study, we discuss the implementation of integrated simulation and genetic algorithm for patient scheduling optimization under two different settings, namely the "traditional" scheduling system and the "open access" scheduling system. Under the "traditional" setting, we propose a two-phase approach for designing a weekly scheduling template for outpatient clinics providing multiple types of services. Our results demonstrate that the two-phase approach can efficiently find the promising weekly appointment scheduling templates for outpatient clinics. Under the "open access" setting, we propose a discrete event simulation and genetic algorithm (DES-GA) approach to find the heuristic optimal scheduling template for the clinic allowing both open access and walk-in patients. The solution provides scheduling templates consisting of not only the optimal number of reservations for open access appointments and walk-ins, but also the optimized allocation of these reserved slots, by minimizing the average cost per admission of open access or walk-in patient.
Challenges and Barriers Affecting the Success of Total Quality Management
(North Dakota State University, 2013) Rokke, Connie
This thesis is a compilation of two papers. The first provides an overview of TQM from its beginnings through today's business climate. The fundamental principles of TQM are explored and the benefits identified. A review of the challenges and barriers that prohibit most companies from achieving these successes is conducted to understand why well intentioned companies are not always able to sustain this management technique. The second paper analyzes these challenges and barriers of TQM attempting to quantify their impact on the success of a TQM program. This study analyzes survey data using Structural Equation Modeling. The findings indicate the challenges associated with some of the TQM Principles are correlated and a few of them have an impact on the success of a TQM program. This research is unique in its attempt to apply quantifiable measures to the challenges faced by organizations that endeavor to implement TQM programs.
Reliability Estimation Considering Customer Usage Rate Profile and Warranty Claims
(North Dakota State University, 2014) Limon, Shah Mohammad
Providing more realistic reliability prediction based on small proportion of failed population or test data has always been a challenging task. Manufacturers rely heavily on reliability prediction for designing warranty plan. Further, to predict warranty claims for the remaining warranty period, it is important to have more realistic reliability assessment by considering a larger proportion of the population or the maximum possible information on the remaining population. However, generally this information is not readily available and is very difficult to gather on the scattered population. In this work, we propose to use customer usage rate profile to generate censored usage data on the remaining population that do not have any failure and warranty claim yet. We intend to use field data available such as warranty claims, field failures, recall data, and maintenance data to develop usage rate profile and subsequently estimate censored usage time. Finally, reliability estimation methodology is developed considering both censored data and field failure data to provide more reasonable reliability prediction for the remaining warranty period. The proposed methodology is demonstrated considering real life data from a big manufacturing company.
Molecular Dynamics Simulation of Nano-Indentation Process of Silicon: Effects of Initial Temperature and Grain Size
(North Dakota State University, 2014) Wang, Yachao
In this study, a comprehensive investigation on nano-scale indentation of monocrystal and polycrystalline silicon is carried out by adopting molecular dynamic (MD) simulation. Five levels of initial temperature (30K, 100K, 300K, 500K and 700K) are configured in this study and the simulation results reveal the amount of bct-5 silicon atoms at the maximum indentation position is not significantly affected by the initial temperature, substantially less ß-silicon atoms are observed with higher temperatures. The temperature effect on the unloading process is also discussed. Meanwhile, indentation force curves for polycrystalline silicon (grain size ranging from 6.45 nm to 20.48 nm) and single crystalline silicon is compared. The result shows that the normal Hall-Petch effect is not seen in the nano-indentation process of silicon. The grain boundary increases local stress during the indentation process and results in less formation of ß-silicon phase, but it hardly affects the formation of bct-5 silicon.
Dynamic Pricing in Supply Chains Bringing the Perishable Approach to Dynamic Car Market
(North Dakota State University, 2014) Tripathi, Prateek
In a business environment, using dynamic pricing is a standard practice, especially in the management of revenue. Given the availability of online information concerning inventory and pricing, customers are in a position to understand pricing strategies that sellers employ, and at the same time to be able to develop a possible response strategy. In this thesis, Dynamic Pricing in the Supply Chain: Bringing the Perishable Approach to Dynamic Car Market is investigated and evaluated. This study incorporates strategic consumer response to dynamic prices, particularly for perishable goods, using a number of variables, such as income, demand and price. The main factors that influence stochastic behavior of prices in car market supply chains are the focus of the analysis. It also includes the appropriate parameters to include in a dynamic optimization-pricing supply chain problem and a discussion of how businesses can efficiently optimize the pricing problem in a stochastic market situation.
Solder Joint Reliability: A Unified Thermo-Mechanical Model Approach
(North Dakota State University, 2014) Advani, Gurmukh Hiro
Due to an unprecedented pervasiveness of electronics in high performance applications, the dependability of mission critical equipment and systems, often solely depends on the reliability of underlying embedded electronic sub-systems. This includes reliability of the solder joints which are subject to fatigue failure over time in harsh operating environments replete with thermo-mechanical stresses. Fatigue behavior of the solder joints has been previously studied under the separate domains of microstructure evolution and non-linear plastic deformations. The proposed study captures the underlying physics of failure mechanisms to model the failure initiation and degradation phases to obtain a unified model characterizing the overall fatigue behavior over the two phases. The model development is followed by reliability analysis which takes into account the individual phases to establish the conditional relationship for a unified reliability model. The reliability analysis has been attempted using both the failure time and the damage accumulation approaches.
A New Reliability Assessment Model for Power Electronic Modules Considering Failure Mechanism Interaction
(North Dakota State University, 2015) Zhuang, Xing
A reliability prediction method is proposed to determine the lifetime of IGBTs (Insulated Gate Bipolar Transistors) under power cycling test based on the performance of solder joint and wire bond. The failure characteristics of solder joint and wire bond are captured via selected PoF model respectively. To provide precise reliability prediction, PoF models are converted into probabilistic models. In addition, the failure interaction between wire bond and solder joint is studied. Wire bond lift-off is treated as the predominant failure mode based upon experiments from literature and solder joint degradation process is triggered by wire bond degradation process. Increased junction temperature is captured as it is affected by the degradation process of both components. In the end, the system reliability is computed in a series system configuration.
Two Data Mining Applications for Predicting Pre-Diabetes
(North Dakota State University, 2015) You, Guangjing
In this study, the performance of Logistic Regression and Decision Tree modeling is compared by using SAS Enterprise Miner for predicting pre-diabetes in US population by using several of the common factors from the type 2 diabetes screening criteria. From 17 variables of NHANES’ three sets of dataset, a total of 13 risk factors were selected as predictors of pre-diabetes. A comparison of two data mining methodology showed that Decision Tree has a higher ROC index than Logistic Regression modeling. All ROC indexes for two models were greater than 77% indicating both methods present a good prediction for pre-diabetes. The predictive accuracy of the two models was greater than 72% on the whole dataset. Decision tree modeling also resulted in higher accuracy and sensitivity values than Logistic Regression modeling. Taken as a whole, the results of comparison indicated Decision Tree modeling is a better indicator to predict pre-diabetes.
A Quality Management System Implementation Framework for Small-Sized Companies
(North Dakota State University, 2016) Sawant, Manish Avinash
A detailed framework is essential to facilitate quality system implementation. In this study, we have offered a cost effective do-it-yourself approach to quality management. We have proposed a quality system implementation framework for small-medium sized organizations to enable their transition from a no-quality system to an ISO 9001 quality management system. The proposed framework is validated using a case study of a small door manufacturing company. The findings reveal several setbacks experienced during quality system implementation and suggests means to overcome them using a proposed seven step framework. This study also advises an effective maintenance tool to facilitate continuous improvement in organizations after implementing a quality management system. The study results will be useful for quality practitioners, managers, consultants and engineers, especially in small companies and discloses several benefits that can be achieved by employing the proposed framework in any organization irrespective of its size and nature.

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