Kettering University

A comparison of RI testing in the ALSE chamber for the frequency range of 200 - 2000 MHz between HBAS EMC Laboratory and an accredited Third-Party Laboratory was done to determine if HBAS should transition ALSE radiated immunity testing internally. Such a decision would eliminate the need for external testing, which has proven to be expensive and time consuming. This validation experiment shows that HBAS is capable of performing RI testing that meet the requirements of a the customers specification.

A tonnage monitoring process for the Lansing Regional Stamping Plant was in place before this project started. However, most plant personal were not following the recommended guidelines for the process to function correctly. This was due to a lack of understanding about the overall tonnage monitoring process, the lack of a standardized process, and the lack of training in the entire process. The process once correctly in place will help keep the presses safe from extreme tonnage situations that might cause harm to the press or die. It will help notify employees in changes in tonnage that could correlate to quality problems. The successful process will allow plant personal to understand and function inside the process without extensive knowledge not pertaining to their respective area. The process will be standardized in order to remain constant part to part and run to run. In order make this process successful a modified press curve was chosen to help protect the press and dies. Autotrak was chosen to help monitor part protection. The method of lowering the press curve was tested and validated during the test of GMX-966 B 3849 production part. Job element sheets were written to instruct plant personal in adjusting press protection curves, entering new die recipes and troubleshooting the tonnage monitors. Also general information and detailed troubleshooting guides were constructed and placed on each press line in the plant. The Autotrak test was not validated due to complications with the press ladder logic. Job element sheets were written to instruct plant personal on how to setup and use Autotrak once the logic changes have been completed. The continued implementation of the tonnage monitoring system to more production parts will help ensure any available means to protect the plants vested manufacturing assets will be correctly used.

An analysis of Woodbridge Fremont's electrical distribution using NFPA 70E Arc Flash Standards is used to combat the increasing risk of electrical accidents in the workplace. Ageing electrical systems are being pushed to their limits causing the need to work on live systems to avoid lost production. The analysis will determine the proper personal protective equipment to wear for each electrical panel.

As an industry leader, General Motors is implementing energy saving initiatives in its plants. One initiative is 'Welding in the Dark', which reduces the illumination above manufacturing cells unless a condition requires fluorescent fixtures above the cell, to turn on. This can be achieved by modifying the standard controls architecture and software, by adding a new ControlLogix module and introducing another communication protocol. Since the initiative will be employed in future plants as well, I created a simple, comprehensive tutorial to aid future users in proper setup of all nonstandard devices. The package includes all software required, as well as diagnostic tools.

As technology continues to improve and advance, wireless data acquisition systems become more reliable and cost effective for the manufacturing industry. This thesis project purposes a wireless real time run time tracker system for a fastener manufacturer to monitor production and machine utilization and provide real time reports to supervisors and managers. With this system, the manufacturer can optimized their manufacturing process and have visibility on the shop floor; and therefore become more competitive in the fastening industry.

Automated Focus Algorithm for Forward Facing Imager Products illustrates a clear understanding of a focus model for automotive imager products using Micron CMOS imagers. Subsequently, the model will be used as a guideline to develop production imaging software and hardware. A clear method of focusing a lens to an imager, optically and mechanically, for any of the automotive CMOS imager applications in development was not clearly defined in a usable mathematical solution. Several images were collected using Micron?s MI-360 CMOS imager, a custom image viewer/logger, and a linear positioning stage with one micron resolution which provided a repeatable platform in which to collect line profile data as a lens was passed through its focal range. The images were post-processed using line profile slopes to uncover the contrast between white and black targets. The results from this thesis provide a clear path by which CMOS imagers used for processing roadway images can be focused precisely and quickly in a repeatable manufacturing process.

Based on review of historical data from years of production, it had come to the attention of Magna Donnelly Electronics that elimination of voltage and current calibration on the Gen II VBC module may be feasible. The elimination of calibration is possible based on the positive results obtained from the final functional, locked rotor, and IPM tests. If the company should implement the calibration elimination, time and money would be saved in the process.

By developing a demonstration piece that shows distribution of control for an Advanced Front-lighting System, Visteon Corporation can show diversity to customers. Until now Visteon has only been able to supply a centralized system to customers, which limits the applications that AFS can be incorporated. By incorporating the system packaging, EMC, and EMI constraints can be overcome. This gives Visteon the ability to offer two control AFS systems.

Current PC controllers have run into software and hardware limitations due to age of equipment and lack of new developer updates. This leaves the systems open to viruses and hard drive crashes that could be cause severe downtime, thereby crippling production. By upgrading to newer PLC controllers, increased stability and protection from viruses ensure that production lines stay running without controller malfunction. This will also decrease losses in both maintenance and production.

DP Tool & Machine's previous method of checking DC motor frames was insufficient for the volume of frames being produced. The purchase of a shop-floor CMM and subsequent proper programming provides the ability to resolve this issue. The new methodology has proved effective in both reducing the amount of time spent inspecting frames as well as increasing the total number of frames inspected.

Design and creation of a programmable waveform generator.

Design of a safety PLC and its ancillary components.

Development of Pocket PC inspection technologies has rendered paper inspection methods obsolete. Completely replacing these methods by implementing Pocket PCs is not feasible at this time. However, these devices could be used for yearly or biyearly inspections and data collection. Due to the disconnected substation environments, the devices will be difficult to use effectively.

Due to the stamping process used, only half of the pre tin finish was wiped on to the contact point of Lear's Tuning Fork Terminal. Since a bare contact point could lead to fretting corrosion, which could result in terminal failure, post plating is necessary to market the terminal to Asian OEM's. After comparing various materials and post plating compositions, C18080 TR08 should be used as the base material and a post tin with a nickel underplate should be used as the post plating finish for the tuning fork terminal.

During custom ASIC development, it is important for suppliers and customers to thoroughly test and validate a newly designed part. ASIC development boards can provide exceptional testing capability to the design team. However, after a finalized ASIC design has been implemented, development boards may no longer provide any additional benefits over a simplified tester which only needs to communicate with a particular ASIC. In some cases, the use of a development board may even hinder a non-designer engineer?s ability to retrieve desired ASIC information, due to their lack of knowledge in the ASIC?s background or in the development board and associated tools. A development board may also begin to lose cost-effectiveness as extra testing capability becomes obsolete. In an effort to improve the ease-of-use and reduce the construction costs of a Freescale-based ASIC development board used as a programming tool, a new programmer system was designed at Autoliv Electronics America. An aim to add extra debugging functionality, which the previous programmer could not provide, also motivated the company to invest in the project. Research on the development board programmer was done to help understand the hardware requirements needed for programming this particular Freescale ASIC. The ASIC itself and its programming methods were also studied. The information helped influence the design of a new programmer system. With the new system, the programming software was completely reworked from scratch to clearly and concisely display the ASIC memory contents. Programming procedures were simplistically made so that even the most inexperienced users could operate the tool. The hardware design is based around a low-cost processor development kit, provided by USBMicro, and was tailored to include only the essential circuit sub-systems required for programming. This helped to reduce the overall part cost and the assembly time required. The overall outcome of the project supplied Autoliv with an easier means for ASIC programming at a lower price.

GM is replacing an existing self-contained fully-wired diagnostic tool with one that will function in a distributed wireless environment. The areas of concern include, but are not limited to, latency and throughput values under various wireless network conditions. The author performed tests that analyze the effects of bus and network loading on the parameters in question with and without enabled security algorithms. The typical dealership environment and the available wireless technologies, relevant to the project, will be discussed. The document provides the results of the test as well as a thorough test plan development with explanation of the software used to collect data.

General Motors - Controls Conveyors Robotics and Welding (GM-CCRW) deploys DeviceNet as a device level network with hopes to transition to an Ethernet based network by 2009. Evaluating Ethernet to replace DeviceNet with CCRW's desired functionality proves not cost effective until beyond this date. Ethernet is recommended to transition in steps where it offers advantages and overcomes DeviceNet limitations. This report provides awareness of issues and potential solutions when reevaluating Ethernet deployment.

Guage replacement of grinding application. Understanding of human to machine interface, as well as the components required to obtain the interface.

Implementing energy analyzer units were to control cycles run on an induction heat treating machine. The energy analyzers read power for a set number of time segments. The goal is to find the range of power at a specific time segment to give the print required effective case depth. The calculations to convert the energy analyzers time segments into a standard time in seconds allows me to locate the exact power inserted at any given moment during a cycle. The ability to correlate power versus case depth allows Machine Tool & Gear the option to track the necessary power during an entire cycle checking for power slumps or spikes. If the signature of a cycle runs outside the set parameters, the monitor will send a signal to the PLC to fault out at the end of the cycle identifying a bad part. With the implementation of these energy analyzers we have reduced the number cuts, the number of cut-off technicians and the supplies needed to cut the parts. The final graphs produced give a range of data to allow for specific parameters to be set on the energy analyzers themselves.

In order to reduce equipment and operating costs, vision guided robotics are a possible replacement for some expensive fixturing systems. The use of vision guided robots has the potential to allow operation designs to be simplified and the amount of hardware reduced. This also decreases equipment and maintenance costs while often increasing flexibility. Implementing vision guidance is recommended for use in appropriate situations to provide cost savings on initial installations and long-term operations.

It is very important for a design and test facility to know the measurement capabilities of its testing equipment. The acoustic bench in a previous study had shown a large variation due to GR&R. A new GR&R study was conducted along with automated data analysis of the complete frequency range. After the first two trials, the 20-300 Hz range was unacceptable according to industry standards. This problem was solved by changing the microphone spacing to 25 inches.

Lack of an official method of controlling software backups has created a potentially dangerous situation. In the event of program loss, an outdated or nonexistent backup of machine software will lead to unnecessary downtime. An in house manual backup system would save approximately $50,000 by not hiring an outside firm of purchasing expensive software.

Multiple manual entry of project BOM information and inaccesibility of order tracking information has increased increased the potential for errors and miscommunication and complicated information gathering efforts. A custom integrated database system will improve the efficiency of BOM and PO processing and inter-department communication. If the designed system were implemented, it would eliminate multiple entry inefficiencies and make all information available to all employees.

Over the process of several years, General Motors Powertrain Bay City Plant has caused several customer disruptions due to lack of chamfer on the Piston Pins that they machine. To detect Piston Pins without chamfer, vision inspection systems have been designed and installed by engineering companies for two of four lines in the Piston Pins machining department at a cost of roughly $24,000 each. The creation of a vision system similar in function but with a reduced cost to be implemented on at least one of the remaining lines will provide for improved output quality of General Motors Powertrain Piston Pins. By designing and creating the system at the plant, the company saved roughly $16,000.

Presents the results of the investigation to develop an efficient maintenance system for Saginaw Metal Casting Operations.

Product quality and costs are two of the biggest concerns in a manufacturing environment. CNC machine cutting tools are essential for product quality, and reducing scrap is essential for decreasing cost. Some applications have a history of cutting tool faults, and these faults not only reduce product quality, but increase costs due to scrap. This thesis project is about integrating a tool fault detection system into a CNC machine to detect tool faults before a large amount of parts get cut by a bad tool.

Quality control problems on the Export Veneer Clipping Line led The Freeman Corporation to contact Daqota Systems for a solution. Testing Demonstrates that machine vision along with motion control will lead to shorter cycle times, value optimization of veneer, and increased throughput upon completion.

Requirements management is becoming more important in the world of technology everyday. This is especially important in the world of safety critical electronics. Hamilton Sundstrand is on the cutting edge with aerospace controls and is currently revising their requirements management process as part of an overall process improvement initiative. Hamilton Sundstrand, along with all other United Technologies companies, use Achieving Competitive Excellence (ACE) as their process improvement framework. As a provider of complex safety critical systems, Hamilton Sundstrand recognizes the extreme importance of requirements management and is striving to have a ?best in class? process. Through benchmarking and process investigation, improvement opportunities have been documented. The investigation consists of research into best practices as well as process flow mapping.

Research different methods for wireless tilt and telescoping steering column control, as well as high speed streaming data networks for automobiles, and suggest best fit options based on research. Functional model covers wireless tilt and telescope control.

Siemens VDO needs a power source to produce enough voltage and current to supply a wireless transmitter for a wireless wheel speed sensor. The writer must design a system that is an adequate source for this application. This includes the testing of the power supplied from the VR sensor to the transmitter, and the lifetime of the system including the backup battery's assitance during low power generation.

Superior Controls is a system integrator with one area of specialty in traceability. Superior currently utilizes various technologies to mark parts with two-dimensional data matrices. The two-dimensional matrices are then used to track the part throughout its lifetime. Superior incorporates such part markers into its gage systems and integrates them into various other applications. The requirements of the marker are based on the material and matrix size. The two-dimensional data matrix best practices database allows for the user to check the applicability of a given marker to the part desired for marking or if marking it is even feasible, thus reducing research and testing time each time a new part needs to be marked. The database includes laser and indent part markers and was created using Microsoft Access.

The Air Force Research Laboratories required the development of a portable tracking system capable of measuring the static rotation of various tracking technologies. A tracking algorithm was developed capable of measuring rotation from images obtained at different positions. This algorithm was then evaluated using software and hardware tests and determined if it had sufficient accuracy to test other tracking systems.

The GNUCAP circuit simulator is not yet a feasible alternative to commercially available simulators. By adding nore functionality to GNUCAP it may become a viable alternative to commercially available simulators. Addition of a lossy transmission line model to the GNUCAP simulator will add increased function- ality. A model described by Kenneth Granzow would allow for implementation of a lossy transmission line model for the GNUCAP circuit simulator.

The General Motors Shreveport Assembly plant uses vertical lift transfer systems to maneuver jobs from zone to zone. When a transfer system breaks down, a lot of downtime is incurred. The thesis will address incorporating a preventative maintenance system that will warn tradesmen and engineers before the failure occurs. The motor current of the system will be monitored during production hours. Two methods of monitoring the current will be used. The first method will monitor for 8 consecutive increases in current. On the last increment, an alarm message will be triggered, which will notify engineers and tradesmen of the increases in current. The second method will use a maximum current as a high limit. If the current exceeds 10 percent above the maximum current monitored by the system, an alarm message will be triggered to notify tradesman and engineers of the abnormality in current. This process will allow for repairs to be scheduled before the system fails.

The Occupant Safety group of Robert Bosch, LCC requires an embedded software driver to facilitate communication between its next generation occupant classification system?s electronic control unit and its distributed digital sensor network using the LIN 2.0 protocol. The iterative design process using Universal Modeling Language standards arrived at the optimized solution that minimized processor computational load while satisfying the sampling frequency requirements. The implemented solution uses less than 5% of the processor computational resource allotment and occupies less than 10% of available memory space. The completed project uses LIN messaging to collect digital sensor data, which is used for further development and testing on the next generation product.

The Power & Free overhead conveyor control system is failing to meet production schedules. The current system was installed in 1970 and aging components are no longer supported by the manufacturer. Replacing the controls with an Allen-Bradley ControlLogix PLC provides for continued reliability and support. The addition of the PanelView Plus terminals and the HMI will aid in troubleshooting and maintaining the system. A modern system will also meet NFPA70e arc flash suppression safety guidelines.

The Thesis entitled "Machine Control System: Design and Program" documents the process of designing and building an automated industrial machine from start to finish. The thesis covers the process from the quotation stage, through the design and build, and finally the installation of the machine.

The Tool Monitoring Adaptive Control, or TMAC, system from Caron Engineering International is installed on the GEN IV Block line?s OP60-A as well as the GEN IV Crank line?s OP10-3 machines. The TMAC uses a horsepower transducer to monitor in real time the amount of horsepower it takes to cut each part. It stores the charts as well as the event log, containing the hard data. By utilizing horsepower limits to notify the operator of the condition of the tools and when they need to be changed, the TMAC is essentially eliminating the scheduled tool change. This process is extremely beneficial to the plant because by treating each tool individually, this takes into account whether or not it has been reground, or any other issues that would vary from tool to tool. The GEN IV Block line?s OP60 had caused a major warranty for the plant costing more than two million dollars in repair and scrap costs. The 709123 tool, a long, coolant-thru, gun drill cuts the high pressure oil holes in the engine block which were found to have hairline cranks inside of them allowing the coolant and oil to mix together. The TMAC system monitors the tool on this operation to ensure that they are cutting quality parts, with a large focus on the 709123 drill, which had chronic breaking issues in the past. The tool has since then stopped breaking and OP60 has had no more major warranty issues. The GEN IV Crank line?s OP10-3 machine is the bottleneck of the department. After a major coolant change, tool life extension was sought after in this department due to very high tooling costs. The 630703 two step drill showed much room for tool life extension after examining the horsepower that it was capable of safely reaching with both the old and new coolants. By safely doubling the tool life of the 630703 drill on OP10-3, it was safe to move this process to the OP10-1 and OP10-2 machines. By cutting the crank line?s 630703 drill costs in half and by preventing the 709123 drill from excessive breaking, the two departments have a gross savings of more than $4000 per month from just two tools. The TMAC system demonstrated the benefit of treating each tool individually by improving quality, decreasing costs, and increasing production.

The current "Hunt-and-Find" methods of document verification are very time-consuming and tedious. Boards can have from 50 to over 200 parts and take anywhere from 30 minutes to over 2 hours to check all the documents. Time and accuracy can be improved for engineering and manufacturing with a Module Repair Roadmap. The Repair Roadmap Generator should be implemented and the grid layout drawing completed to improve the document verification process.

The current apply algorithm of the Electric Parking Brake uses a constant current of 15 A to achieve and acceptable load. This strategy does not allow for consistent load at 0?C and below. Through the implementation of the look-up table that controls that apply current, acceptable loads can be achieved, down to -20?C. This look-up table allows the Electric Parking Brake's control algorithm to have a greater functionality.

The current data acquisition (DAQ) and analysis procedures used by AAM lack efficiency. The current DAQ system is reliant on a physical connection and takes up unnecessary space and the analysis is restricting on the engineers due to a required physical link between their laptop and DAQ. By replacing the DAQ with a device that communicates wirelessly and utilizes small-sized removable memory, engineers can store and analyze data in the field more efficiently.

The current gage management system does not meet the specifications of the company. The goal is to have globally implemented software that meets or exceeds the desired specifications. I will determine whether we can identify, purchase and implement a qualified gage management system or create a Product Quality Management System (PQMS) based gage system.

The design and testing of a custom air handling unit controller to fulfill the need of a controller that can be used as a standard when a specific control system is not specified by the customer. The system includes all the proper I/O to control a air handling unit including (8) Digital Out, (16) Digital In, (4) Analog Out, (4) Temperature In, and (4) Analog In.

The development of electronic control modules (ECMs) for automotive applications presents the need for an electrical signal monitoring device, which should be inline and independent. Electrical signal inputs and outputs to the ECM must be monitored during development and validation of the control system. If a small quantity of Observer devices were produced, accurate signal measurements would be available to the Electronic Control Systems engineers.

The gains made by the electronics industry in increased speed and decreases in size and cost have often come at the cost of component robustness and reliability. Currently NASA is mandated to renew emphasis on human and robotic interplanetary exploration, and commercial electronics components and packaging methods are often inadequate to fulfill this mandate. As part of continuing research and development efforts into electronics design and packaging, a technology called the fuzz button was proven to be an effective and reliable vertical interconnection for electrical signals. Fuzz buttons have low impedance to high frequency signals and resist thermally induced stress and mechanical shifting. Further work is planned to refine the technology for possible use to increase reliability of NASA's electronics designs, including systems in the new Ares I launch vehicle currently under development.

The i3 oven/press has the ability to adjust specifically for an IG unit?s characteristics. The oven/press is not currently operating to its potential because there is no way for the oven to accurately determine IG unit characteristics. A barcode system is a feasible approach for the oven to obtain the required information. A fully automated system is not a cost-effective solution to obtaining the information but a handheld barcode system is a feasible approach.

The laboratory technology at our facility did not allow remote monitoring capabilities for lab equipment, which can result in out-of-tolerance test issues for lengthy periods of time. A communication system was developed, taking advantage of wireless technology, to allow remote monitoring capabilities for the lab environmental chambers. It was setup as a preliminary system, and can be improved by replacing the current computer used with a dedicated computer, which can be accessed through VPN.

The methodology in this thesis was developed from a detailed analysis of the fault data collection systems used at Flint Engine South. Extensive data was collected from each system and each was individually analyzed as to its relevance to the overall goal of the project, which is to minimize machine faults in order to increase production up-time. The methodology created meets the goal of the project and can also be implemented into other departments to achieve the same goal.

The mission of this senior thesis project is to investigate current in-vehicle communication protocols; comparing them to the new SENT protocol and investigating the methodology of engineering the SENT signal to best fit the emission specifications prior to lab test time.

The need for an "intelligent" power management system in the test vehicle has been present for many years. General Dynamics Land Systems hopes to develop a new power management system that is based heavily on the technology of the reference vehicle. It is feasible to use a reference vehicle-based power management system in the test vehicle. If the vehicle loads are effectively assigned to specific Remote Switching Modules, the design would be successfully developed.

The old prototype life cycle tester was no longer sufficient to meet the testing efficiency nor the customer's test specifications. A new tester was designed and built using a servo motor and an updated PLC to enhance both testing accuracy and efficiency.

The purpose of this thesis was to discover the root causes of high and low g-force faults experienced at the sand compaction process at the General Motors Defiance Lost Foam Powertrain plant. The method of research was to use statistical engineering techniques to systematically analyze data pertinent to the process. All supporting data and the associated tests used to arrive at the conclusions in this thesis are documented within this report. In addition, preventive maintenance systems to prevent downtime attributed to g-force faults are discussed.

The thesis investigates the feasibility of implementing a special repair process that focuses on eliminating scrap and improving quality on certain parts of the truck that are prone to defects. This process will require additional manpower, facility modifications, as well as intensive training, but once complete, should move smoothly.

The topic of this thesis presents the method of coming up with a method for combining range information and images by using laser scanning system to capture data. We are interested here in finding an algorithm that will help us apply edge detection and object recognition techniques for an image. The thesis is also expected to provide methods of image segmentation with range information by having an enhanced edge detection based on range gradient, time derivative of range, and information in successive frames as we have done using different types of filters. In this thesis we were able to find the answer about the ability to combine range information and images by using laser scanning system to capture data. Also, we found an algorithm that will help us apply edge detection and object recognition techniques for an image. The second phase of the project shall include an advanced experiment with a single 3D-plane & Image Capture. This recommended mechanism would be mounted on a vehicle with the ability to gather test data and have a 3D scan.

The use of capacitive touch switch technology, OLED and EL lighting are examined to determine if they are a viable alternative to mechanical switches in an the interior setting of an automobile.

The validation of the SmartBar? would take many hours to complete each cycle of validation. It was explored to see if the automation of the validation would be cost effective and what the best ways were to automate the system. It was found that the timesavings over the short and long term would make this product desirable. Different ways of automating the system were explored. It was found that using a combination of LabVIEW with sensors and actuators would achieve the desired results. The methods used to research and built the system were explored and explained. A final system was developed and deployed.

There are currently two validation procedures for testing printed circuit boards at the TRW Auburn facility. The formats are the In Circuit Testing of boards as well as utilizing an Automated Optical Inspection system (AOI). TRW Auburn uses these systems in the manufacture of remote keyless entry circuit boards and tire pressure monitoring sensor and receiver boards. The continued utilization of this process for inspecting boards will be what is necessary for production unless significant changes are made to the packaging of ICs or chips we utilize on our surface mount process. These changes include but are not limited to BGA style solder joints, as well as stacking components on both sides of the PCB.

There exists an increased interrest of fuel cell energy as a possible replacement fuel source for automobile engines. Eaton Corporation seeks an adaptaion of one of their products, superchargers, for the purposes of being an air delivery system for a fuel cell system. This system is a first attempt at producing the air delivery system, which is also a donation system for the Mechanical Engineering Energy Systems lab with a possibility for joining with a fuel cell stack. As such, the system is controlled using National Instrument's LabVIEW graphical development software.

This project explains the development of a testing station for the electronics on an assembled Numatis valve manifold. The main focus bing that of the PLC program and construction fo the operator interface within the machine. The purpose which is to further the frowth of sales of the product line and expand on the quality of the shipped products.

This thesis covers the reserach, design, implementation, and testing of a supervisory control and data acquisition (SCADA) system over a wireless network. This system collects predefined system parameters from furnace and mix batching PLCs, and allows users to remotely view these predefined system parameters in real-time. Data is also collected from the PLCs and stored on the Globe Metallurgical network daily in a Microsoft Excel report.

This thesis documents original work done by the author to design and implement a manufacturing equipment data collection system at BD in Canaan, Connecticut. The intended purpose of the data collected supports Lean Manufacturing principles, Six Sigma initiatives, and product/batch traceability throughout the manufacturing process. The system implemented uses an Ethernet network to connect Allen Bradley PLC's (SLC, Micrologix, and ControlLogix) programmed with RSLogix 500 and RSLogix 5000. Rockwell Software RSSql was programmed to read information from machine PLC's and write into an Oracle database. Apriso Flexnet software is utilized for taking this data to report OEE and to automate transactions required by SAP R/3 software. The scope of this document includes the purpose of the data collection system, the strategy for collecting data, the creation of a network connecting 28 machines, and programming the PLC and RSSql.

This thesis explores the process of finding the best test buck for Magna Steyr?s needs. It will provide: (1) research that defines the needs that the buck should fulfill, (2) suppliers capable of providing the buck, (3) the options that each candidate supplier offered, (4) analysis of each of these options and (5) the recommendation for purchase based upon analysis of various systems

This thesis investigates the feasiblity of implementing a process that will enhance the facility engineering process. Through this process, the employer facility will become more efficient in setting temperature controls as well as using manpower more efficiently.

This thesis outlines the development of a plastic component which is used to replace a metal component. Steel stampings are inserted into the plastic to make for a fire fail-safe feature. This thesis results in a cost reduction for the employer and the employer's customer.

This thesis project addresses a common problem in the brake evacuation and fill process: the inability to achieve consistent and accurate predictions of the amount of time required for the process to completely evacuate a brake hydraulic system of air prior to filling with hydraulic fluid. The following paragraphs give a brief introduction to this problem.

This thesis provides a centralized reference guide that provides new employees with the ability to learn about new building construction. This thesis gathers organization procedures and design procedures used at Motor City Electric in a single document. Topics presented include: AutoCAD, power, lighting, and circuiting. Examples in each of these topics are presented for greater clarity. Calculations based on the National Electric Code and standards in Motor City Electric drafting provide an understanding of building/design procedures.

This thesis validates the tooling motion time listed in the General Motors Sequence Development Program (SDP). This program is used to aid in design for new automated production tools by visually listing the sequence of operation of the tool and estimating the cycle time needed to meet production rates. The time for the tooling motions have been examined by recording data from the field and comparing them to the time in the SDP.

This thesis was a design project, where a system was designed for a wastewater treatment center settling tank. The purpose of the design was to make a system that would integrate up to date technology and put the system on such a network that the information could be viewed and analyzed over a mile away at a remote station. In the end, the hardware for the system was researched and selected, and a test program was designed in order to prove the system could operate in the way that was necesssary.

To improve the shop floor production by networking drafting dept. and manufacturing equipment computers together.

To show that HBAS EMC is capable of transitioning radiated emissions internal. Such a decision will eliminate the need for continual external testing which has demonstrated to be a timely and costly endeavor. In addition it will be shown that both facilities meet the requirements set by the customer and are able to perform the test in accordance to the specification. After testing is complete and the results are reviewed and compared a final determination will be made if HBAS EMC is capable of transitioning radiated emissions internal.