Examples of Past Projects

Spring 2020 

 1  Modineer 

 Plant Consolidation

 2

 Modineer 

 Plant Layout
 3

 Wabash National

 Supply Chain / Warehouse Manpower Utilization
 4

 GC3

 Design and Develop an Automated Manufacturing Cell
 5

 AlgoBank

 Financial Engineering of Tradable Instruments
 6

 3D STONE

 Planer SMED and Change Over Productivity
 7

 Aerofab

 Shared Serviced and Product Flow
 8

 Fratco

 Scrap Reduction
 9

 Southwire

 Automate and Provide a Cost Analysis
 10

 United States Cold Storage

 Schedule / Work Allocation Optimization
 11

 United States Cold Storage

 Product Flow / Facility Layout Analysis
 12

 Purdue Dining

 Central Culinary
 13

 Purdue Dining

 Centralize Hiring of Students
 14

 Purdue Dining

 Mobile Ordering
 15

 Viasat

 Viasat Discrete Event Simulation Tool
 16

 Purdue Orientation

 Boiler Gold Rush Centralized Check-in
 17

 Indianapolis Bar Association

 Workflow Manual and Improvement
 18

 East-Terra Plastics

 Car Seat Recycling
 19

 CLASS of America

 Parts Distribution Warehouse Enhancement
 20

 DRS Land Systems West Plains

 Production Line Optimization *
 21

 Purdue Weldon School of Biomedical Engineeing

 AI-augmented Happiness Monitoring and Intervention
 22

 Endress+Hauser

 Corrugated Storage
 23

 Fiat Chrysler Automobiles

 8-Speed Transmission CL2 Machining Performance
 24

 Fiat Chrysler Automobiles

 6-Speed Transmission CL2 Machining Performance
 25

 Tesla

 Gigafactory NV Warehouse Design
 26

 IU Health Ball Memorial Hospital

 Elective Surgery Block Schedule Improvement
 27

 Northrup Grumman

 Production Scheduling *
 28

 North Central Nursing Clinics

 Improving Process of Ordering and Stocking Medication Samples and Direct Relief Medication
 29

 Oakley

 Frame Molding Schedule Optimization-Automation
 30

 TVS Motor

 Integrated Project Management for PED with Queuing Theory
 31

 Frito-Lay

 Optimize and Integrate Racking  Methods in Warehouse Expansion
 32

 IVY Tech

 Optimize Academic Advising Process Statewide
 33

 Purdue IE Gateway

 Design Build to Scale Lab
 34

 Purdue IE Gateway

 Design and Develop Idea, Analysis, Syntheses Learn it Lab
 35

 Purdue IE Gateway

 Design and Develop the Human Integration Learn It Lab
 36

 Purdue IE Procurement 

 Optimize Spend Categories and Develop an Estimation Model
 37 

Buchanan Group

 Blast Production Line Efficiency
 38  

 IU Health Arnett Hospital

 Improve OR Central Sterile Efficiencies and Workflow

*US Citizenship Required

Fall 2019

1

Modineer

Optimize material flow and capacity at plant X

2

Modineer

Optimize layout and operations at plant X

3

Endress+Hauser

Production cart design

4

Tesla Motors Optimize days on hand raw material
5

Tesla Motors

Optimize warehouse racking for maximum utility
6

FCA (Fiat Chrysler Automotive)

Introduce single minute exchange of dies to reduce maintenance time 
7

Purdue Dining and Culinary

Evaluate flow and recommend layout for the All-American Dining Room
8

Purdue School of Nursing, North Central Nursing Clinic

Improve document management
9

Purdue School of Nursing, Riggs Clinic

Improving vaccination process
10

Trinity Horizons

Thrift store optimization
11

Trinity Horizons

Create improvements of office network and database administration
12

Jesuit High School

Develop an alumni survey and create associated database

13

St. Vincent's Hospital

Improve the surgical instrument sterilization process
14 Leonardo DRS Land Systems

Production line optimization

15

Northrup Grumman

Develop a room/space allocation tool
 16 

Telamon Industrial Solutions

Optimize and standardize air intake and valve cover assembly
 17  Biomedical Engineering & Industrial Engineering, Purdue

Develop app for tracking mobile use patterns

 18 

Purdue RecWell (CoRec)

Improve CoRec program registration processes
 19  Minority Perspective Services Start-up

Creation for a cutting edge review service, a formal business plan, & database

 20 

The Twisted Hammer

Improve customer flow, minimize bottlenecks

Spring 2019

 1

 Almost Home Humane Society

 Optimize Facility Layout, Capacity, Flow and Communications

 2

 Marketing for Purdue Dining and Catering Services

 Simplify and Optimize the work order process

 3

 College Consulting Group

 Create a non-profit national college consulting organization 

 4

 Purdue Black Cultural Center

 Create Purdue Black Cultural Center GIS Mapping 

 5

 Purdue Dining and Catering Services

 Refrigerator/Freezer/Dry Goods Storage-North End- ADR, Ford, Wiley

 6

 Purdue Dining and Catering Services

 Refrigerator/Freezer/Dry Goods Storage-South End- Windsor, Earhart, Hillenbrand

 7

 Purdue Dining and Catering Services

 Improve work flow of Villa Pizza/ Green Leaf's

 8

 Janus Developmental Services, Inc

 Implementation of Hydroponics Program

 9

 Premier Auto Detailing and Wash

 Optimize Mobile Wash Service 

10

 Warren County, Purdue Extension

 Optimize Routes to Grocery Source

11

 Creative Flooring, Inc.

 Propose improved supply and tooling inventory methods and procedures

12

 Monsanto BioTech, Bayer

 Vegetables Seed Production Optimization

13

 TVS Motors

 Evaluation of capacity, cost and suggesting model 

14

 TVS Motors

 Optimize the flexibility and balancing in production lines

15

 TVS Motors

 Integrated project management for PED with queuing theory

16

 TVS Motors

 Digital twin 3-D layouts for factory and warehouses

17

 Jeco Plastic Products

 Create a simulation that will determine Cost of Goods Sold (COGS) and increase machinery capacity

18

 Pregis LLC

 Optimize Pregis Converting Operations 

19

 Eli Lilly

 Improve Inspection Operations 

20

 Shindigz

 Optimize manufacturing processes and inventory management

21

 FroYo Xpress

 FroYo Xpress Continuous Process Improvement

22

 Caterpillar

 Improve Safety for Headline Inspection  

23

 Caterpillar

 Minimize turbocharger lifting devices 

24

 Wabash National

 Streamline operations and lean subassemblies 

25

 Wabash National

 Dry Van Trailer Labor Analysis

26

 FCA Group Fiat Chrysler Automotive

 Optimize 9 Speed Dock 

27

 FCA Group Fiat Chrysler Automotive

 Analysis of 8 speed buffer data 

28

 FCA Group Fiat Chrysler Automotive

 Run pattern (work schedule) analysis 

29

 FBi Buildings, Inc.

 Optimize Future Material Flow though Manufacturing Site 

30

 Faurecia Seating

 Advance innovation in technology at Faurecia 

31

 Endress + Hauser Automation

 Develop Facility Design for growth beyond 2024

32

 Southwire Company

 Optimize planning and inventory in the Compounding Department

33

 East-Terra Plastics

 Increase Operational Space Efficiency 

34

 Pitney Bowes

 Redesign layout and optimize process for handling exceptions (QA) packages 

35

Commercial Vehicle Group (CVG)

 Benchmark Best Worldwide Practices in Industry 4.0 within the Discrete Manufacturing Industry 

36

Sprague Devices, Commercial Vehicle Group, Inc.

 Evaluate and recommend a lean assembly solution for Commercial Wiper Motor Link Assembly

37

 Community Health Network

 Neonatal Intensive Care Unit (NICU) Bed Planning

 38

 IU Health - Frankfort Hospital

 Data analysis on surgery procedure times to optimize staffing and patient response

39

 Purdue School of Nursing & IU Health - Arnett

 Reduce the rate and optimize the sterilization process for operating room equipment

40 

 Department of Veteran Affairs Medical Center 

 Barrier Analysis – African American Employment

41 

 IN3/Crane/Naval Strategic Warfare Center

 Lifecycle Stage Risk Analysis regarding supply of different integrated circuit brands 

42 

 IN3/Crane/Naval Strategic Warfare Center

 Lifecycle Stage Risk Analysis regarding supply of different integrated circuit manufacturers

43 

 Veterans Administration Medical Center

 Analyze and Optimize Emergency Department Wound Care Processes 

Fall 2018

1

Washy Wash

Optimize Facility Layout and Material Flow Throughout the Facility

2

Bonnell Aluminum - Packing off of Anodizing      

Anodizing Carrier Redesign and optimization of packing operations

3

Bonnell Aluminum - Packing Department

Increase Packing Capacity and improve throughput

4

Harrison Castings

Apply Human Factors to Safe Casting Manipulation throughout the facility

5

Discount Filters

Streamline Material Flow

6

Richardson Strategy Group

Maximize Grain Silo/Bag Storage and Analytics

7

Faurecia Seating

Technology Development Company Wide - Vision Systems

8

Buchanan Group

Optimize Laser Etching Operations

9

Endress + Hauser Process Automation

Maximize Inventory Storage and Streamline Layout Flow

10

Endress + Hauser Workbench Design

Introduce Innovative Production Workbench Design

11

Purdue Dining & Catering – Au Bon Pain

Optimize Line Queuing at Au Bon Pain

12

Purdue Dining & Catering – Daily Delivery

Optimize Daily Truck Dining & Catering Deliveries Campus-wide

13

Purdue Dining & Catering - Allergies Purple Diamond

Determine Process to Implement Purple Diamond Concept for Allergies

14

Wabash National Dry Van Production

Supply Chain Analysis of the Wabash Refrigerated Vans

15

FCA

Improve Throughput of Aluminum Transmission Cases

Spring 2018

1

Home Depot

Increase efficiency, improve workflow and streamline processes

2

Endress + Hauser                

Assembly operation waste reduction, including: cycle time, total lead time, cost and savings estimate

3

Endress + Hauser

Optimize delivery, storage and ergonomics in storage 

4

Meyers Spring

Optimize ergonomics and throughput for new station

5

Indianapolis Veterans Hospital Eye Clinic

Recommend methods that maximize resources and patient satisfaction

6

Indianapolis Veterans Hospital Transportation

Optimize the transportation services to provide easy, safe, and supportive transportation for Veterans' appointments

7

Indianapolis Veterans Hospital - Scheduling System

Integrate four systems for increased reporting optimization and process work flow

8

Purdue Dining & Catering – Storage

Develop optimal storage layout

9

Purdue Dining & Catering – Set and Strike

Analyze and optimize event setup and tear down process

10

Purdue Dining & Catering 

Make proposal for optimized kitchen plan, include costs

11

Purdue Dining & Catering – Wiley Dishroom

Optimize operation design, flow of resources, and placement of work related materials

12

Purdue Dining & Catering – Allergies Purple Diamond

Develop marketing and process for notifying the dining courts of special meals for food allergy sufferers

13

Purdue Dining & Catering – Cosi

Redesign the front line to improve efficiency and work flow

 14

Premier Detailing and Wash

Maximize efficiency in each bay with new technology; study trials to quantify waste elimination

 15

Fine Hygienic Holding

Design and develop a product entry into the global feminine protection category 

 16

Retail Grocer

Develop a more efficient method in collecting facility profile and applying profile data using estimations verses manual collections

 17

Retail Grocer

Identify opportunities and measure current state of how retail grocery employees are allocating their time in the department in relation to customer curbside activity

18

Cameron Hospital - Angola, IN

Increase efficiency within the Medical Surgical Staff 

19

United Bulk 

Use data analytics to develop Activity Based Costing Model with interest in expanding terminal capacity 

20

Wabash National  

Develop labor standards for a high-option newly-launched production line 

21

Newgistics

Provide recommendations on optimal facility layout, volume balancing & a staffing plan of a new Midwest Supercenter

22

CVS Pharmacy

Analyze factory physics, workload, workflow and staffing during the two-shift (16-hour) operation

23

IU Health-Riley Hospital for Children            

Develop a tool to coordinate Child Behavioral Health Care across multiple resources

24

ZF - Commercial Steering             

Improve process flow in steering column assembly lines 

25

B. Walter Company

Improve process flow and changeover in welding and stamping areas 

26

Flotec

Improve Quality Management System documentation in preparation for an upcoming audit

27

Purdue University Student Health (PUSH)

Redesign and re-layout the Extended Care Area of the PU Health Center 

28

Caterpillar DOC Assembly

Improve efficiency in assembling and installation of the DOC in the final assembly 

29

Caterpillar Transformation VSM

Transform process of connecting rod manufacturing through the use of value streams; recommend improvements

30

Reindeer Shuttle

Conduct analytical projects to sustainably respond to the continuous growth in demand on services; recommend ways to meet growth in demand

31 

Sacoma

Redesign plant layout of both existing and new equipment into a new adjacent factory based on demand forecast


Fall 2017

1 Purdue Univ. School of Nursing Develop a user interface is to aid in scheduling the varying courses in the simulation lab
2 Meijer, Inc.  Evaluate the task work in new inventory coordinator roles in stores to better align to daily responsibilities and improve the flow of product from "door to floor"
3 Caterpillar #1 Design New Light Weight Universal 3500 Engine Support Stands
4 Caterpillar #2 Evaluate and recommend process improvements that will increase capacity, reduce lead times and improve cost efficiencies in the 3600 Engine area
5 FCA (Fiat Chrysler Automotive) Use preventive maintenance equipment procedures to develop manpower requirements for the 5 skilled trades within KTP
6 Deloitte Consulting LLP Evaluate and provide cost analysis of investment opportunity in an IoT (Internet of Things) platform through which performance metrics can be monitored and plant equipment performance and denigration may be captured and analyzed.
7 Lafayette Steel & Aluminum Division of Oscar Winski Co. Streamline material flow, minimize required warehouse space and reduce wasted operator motion. Provide plan as to how this additional production volume can be housed with our existing facility
8 Endress+Hauser Analyze the transport carts in the Pressure department. The team will present a detailed analysis outlining cart inventory, storage and flow-through time. The team should provide recommendations based on their findings regarding increase in productivity, use of lean principles, and implementation of process improvements, data analysis and design.
9 Purdue Univ. Dining & Catering Located on the lower level of Armstrong Hall of Engineering. Amelia’s is home to fresh sandwiches, soups and salads. Made in house daily along with variety made- to- order beverages. The goal of this project is to research the efficiency behind the counter and make recommendations based on increased efficiency of line queuing/service and set up/clean up.
10 Purdue Univ. Dining & Catering The catering department serves groups as small as three up to groups of 5,000, from coffee and donuts to four-course meals. The goal of this project is to look at efficiency: of set up/tear down and clean up.  Present costs associated with recommendations.
11 Sacoma Involved with a new plant expansion define the scope and present process mapping, simulation (Arena) of material flow, design of workstations and overall plant layout involved with new equipment installations
12 Sero Colombia Solve immediate and future capacity challenges conducting a remote project, study and understand the current lines and provide recommendations for a new relocated facility
13 U.S. State Department Determine the validity of an Act and its original intent with impact on today’s industry

Spring 2017

1 Lafayette Steel & Aluminum Engineer a single-piece flow, automated extrusion bending work cell
2 Aurora Parts & Accessories LLC - Lebanon                            Review all aspects of our existing quality assurance program and recommend both for the implementation of new measurements/programs and for value-added improvements to existing programs
3 Veterans Hospital Indy Pharmacy 1: Optimize medication routes utilizing Omnicell
4 Veterans Hospital Indy Engineering Purchase Process Improvement
5 Veterans Hospital Indy Develop technology to empower veterans to navigate VA healthcare system
6 Veterans Hospital Indy Improve on-line ordering system of expendable items
7 Veterans Hospital Indy Develop resource allocation models for the following use-cases of healthcare available only in the emergency care setting
8 Endress+Hauser Central Stores Optimization
9 Premier Detailing and Wash Further develop Scanning systems on smart devices
10 Endress+Hauser Improve layout of the "Combi" (three level measurement devices)
11 Purdue IE Develop for the International Council on Systems Engineering (INCOSE) a professional development capability for systems engineers
12 IU Simon Cancer Center/ Purdue University   Use data analytics to study and recommend improvements for patient experience
13 Purdue Dining & Catering Recommend the most efficient set up to allow for all three brands (Harrison Grille, Pete's Za and the Daily Bite) to continue functioning in the same production area
14 Purdue Dining & Catering Recommend best layout for outside patio area for Ford Dining Court Outdoor Seating
15 Purdue Dining & Catering Improve processes of the PMU dish room
16 Purdue Dining & Catering Improve the accessibility and utility of the space and efficiency of the PMU kitchen area
17 Evonik For the Rotary Vacuum Drying Operation, creating a scraping tool and cleaning station for the tool that addresses the ergonomic issues with handling this tool
18 Airline research/Purdue University Conduct an ergonomics assessment at maintenance facility
19 IU Health  Study workload requirements, analyze demand patterns, and design a new staffing model for a clinical or support area
20 IU Health  Develop a care model for Riley
21 IU Health  Study the volume of fast track patients, the provider/ED staff staffing model, and national best practices for design and throughput
22 IU Health  Reduce clinician burnout and input time regarding electronic medical records activities; study data, spend time with clinicians and recommend ways to reduce input burden
23 Janus Developmental Services                    Initiate a newly purchased hydroponic growth system, layout the area, and assess efficient and effective work flow design
24 Montgomery County Health Dept.                Develop a grant management tool that would keep all grant contract requirements and information together; indicate deliverable, funding, timeline status and allow for easy 
25 ConAgra Foods Reduce yield loss and environmental impact for our Reddi Wip production lines; process flow, ID loss points, quantify, prioritize losses, root cause, plan, implement, est savings
26 Newgistics Train on and apply MOST (Maynard Operation Sequence Technique) and use MOST to develop & validate engineered labor standards for the Fishers; recommend improvements to processes or facility layout
27 Phoenix Closures One project would help us understand the cost and labor for color changes on our production lines; second project to develop a process flow or value stream map for our warehouse operations when it becomes finished goods
28 Fiat Chrysler Automotive Multiple transmission parts are processed through a high pressure de-burr machine, which must have the grippers changed based on which product is being processed. Due to increased demand, the need to reduce cycle time is required.
29 Marion Manufacturing Develop a production scheduling/reporting system that will produce detailed production plans from either their existing MRP system, or from some other process
30 Grocery Retailer Retail Store Work Process Efficiency Improvement Opportunities:  Front-End Operations
31  Grocery Retailer Retail Store Work Process Efficiency Improvement Opportunities:  Deli Operations

Fall 2016

Grocery Retailer Work Sampling Study
2 Lafayette Police Dept Process Improvement of Dispatched Calls
3 RecycleForce Improve facility process flow 
4 Triumph Group Improve safety and ergonomics
5 Hillenbrand Dining Court Optimizing the "Take Back" program
6 Montgomery Health Dept. Improve management system/create dashboard
7 VA Hospital Improve efficiency in medical/surgical inventory
8 Janus Developmental Services Increase work floor space utilization and organization
9 Fiat-Chrysler Automotive Improve SI-EVT production schedule
10 Caito Foods Services Improve warehouse layout
11 Grocery Retailer Improve efficiency in retail store work processes
12 Premier Auto Detailing and Wash Introduce new technology in reorganized space
13 Purdue IE Develop web-based database for past senior design projects
14 Purdue Dining Courts Optimize line set-up for five different dining courts
15 Fewell Monument Streamline production in monument manufacturing
16 Buchanan Group Improve production scheduling to increase throughput
17 Marble Products International Implement a new inventory tracking system
18 Lemongrass Optimize efficiency of service and customer flow
19 Benton County Health Dept. Design a performance management system
20 Endress+Hauser Design and prototype a product handling cart

Spring 2016

1 IU Health Physician Area redesign
2 Eaton 1 Reduce waste in returnable packaging
3 Eaton 2 Decanting/Metering
4 E&H Wetzer Ergonomic Evaluation
5 Jeco Plastics Improve Sensor Collection System
6 Meyers Spring Company Assembly design of Hay Rake Wheels and Will-Rich Springs
7 Premier Wash and Detail New Premier Detailing Operations
8 Fiat Chrysler Automotive Using WCM (World Class Manufacturing) methodology and TOC (Theory of Constraints) identify
issues for the 9-Speed Transmission machining process.  Determine top issues as related to
efficiency, availability and quality with focus being the process bottleneck.  
9 Intel LoRA-based applications for Industrial Internet of Things
10 Purdue Dining and Catering 1 Cueing of the line and efficient set up in the current space of the retail operation in MSEE
11 Purdue Dining and Catering 2 Increase process efficiency used for producing products for On-the Go! and Retail
12 Purdue Dining and Catering 3 Hillenbrand Dining Court Line Cueing and Salad Bar
13 Purdue Dining and Catering 4 Increase process efficiency in the meat tumbling process currently at Wiley Dining Court
14 Purdue Dining and Catering 5 Windsor Dining Court On-the-Go
15 Wabash Center Balance workload and schedule 30-vehicle fleet
16 Zimmer Biomet  Use collected data to determine proper machine allowances
17 Lowes At RDC, Design ergonomic and effective picking cart for doors and windows
18 CNO Financial Group 1 Claims Production Standards (work measurement)
19 CNO Financial Group 2 Claims Forecasting Model (forecasting and production scheduling)
20 CNO Financial Group 3 Operations Workstation Analysis (human factors/ergonomics)
21 Tru-Flex After Market Business Unit Error-proof the kitting validation procedure (incorrect labeling of shipping boxes)
22 Kimball Hospitality Machine Flow Scheduling Project (Batch Size Determination, Scheduling Tool Development)
23 Best Home Furnishings Ergonomic Enhancements to Upholstered Furniture Assembly
24 Wabash National  Final Mile Facility (FMF) Value Stream Map
25 Newgistics 1 Indianapolis Sort Balancing
26 Newgistics 2 Inbound Process Overhaul and Redesign
27 Holland Colours America  Small Batch Holcoprill Manufacturing Process
28 GM Ft. Wayne Assembly Lean Material Strategy, Kit Cell Design

Fall 2015

1 General Motors Fort Wayne Assemble (FWA) Final Process Manpower Utilization
2 General Motors Marion Metal Center Elimination of waste with handling and storing of blanks between the blanking operations and press lines
3 Newgistics (Fishers, IN) Incentive Pay Design (Pay for Performance)
4 Newgistics (Cincinnati, OH) Staffing Plan Design for Large Continuity Program
5 Fairfield Manufacturing (Lafayette, IN) Tooling Location Project
6 Aurora Parts (Lebanon, IN) Shift Workflow Planning
7 Caterpillar (Lafayette, IN) Assembly Line Load Balancing Tool
8 Crossroads Industrial Services (Indianapolis, IN) Polystyrene Recycling Process Sound Reduction
9 Premier Auto Detailing and Wash (Lafayette, IN) Streamline all office processes
10 Zimmer Biomet (Warsaw, IN) Machine Allowances
11 Fiat Chrysler Automobile (FCA) (Kokomo, IN) 948TE Machining Project - 9 Speed Transmission
12 Fiat Chrysler Automobile (FCA) (Kokomo, IN) 845RE Machining Project - 8 Speed Transmission
13 Purdue University Dining and Catering Central Production Kitchen Product Transportation 
14 Purdue University Dining and Catering Living Wall or Roof Top Garden
15 Purdue University Dining and Catering CBORD (Food Management System) efficiencies 
16 Purdue University Dining and Catering Windsor Dining Court Dish Room
17 Wabash National (Lafayette, IN) Axle Bogie Validation of Current Cycle Times and Costing
18 Wabash National (Lafayette, IN) Metal Fab  Aftermarket Validation of Current Cycle Times and Costing
19 Wabash National (Lafayette, IN) Comprehensive Material Usage Value Stream Map
20 Wabash National (Lafayette, IN) Lafayette Manufacturing Campus Optimization 
21 Wabash National (Lafayette, IN) Rear Frame Validation of Current Cycle Times and Costing
22 IU Health   (Lafayette, IN) RN staffing according to patient arrivals