program in integrated sustainable manufacturing prism—the program for integrated, sustainable...

Program in Integrated Sustainable Manufacturing

PrISM—The Program for Integrated, Sustainable Manufacturing

Marvin McKimpsonMichigan Technological University

Houghton, MI 49931

August 12, 2002


Percent of New Hires Performing Below or Well-Below Employers Expectations

Professional Areas

Business Knowledge/Skills 55%

International Perspective 46%

Project Management 40%

Written Communication 38%

Oral Communication 30%

Technical Areas

Supply Chain Management 45%

Manufacturing Processes 42%

Manufacturing Process Control 34%

Manufacturing Systems 31%

Quality 29%Manufacturing Education Plan: 1999 Critical Competency Gaps, SME 1999.


PrISM

A learning experience designed to: Provide hands-on exposure to manufacturing

operations, Improve understanding of the engineering and

human factors essential for successful manufacturing,

Expand awareness of environmental issues associated with manufacturing, and

Increase appreciation for the business elements of commercial manufacturing activities

Structured around year-long, hands-on IPPD project


Program History

Initiated July 1, 1998 Support from SME-MEP and industrial partners:

C. Thorrez Industries, GM Powertrain,Johnson Controls, Inc, NCMS, John Deere Product Engineering Center☻DaimlerChrysler (2000-2002 academic years)

Involves personnel from five Michigan Tech units:

Mechanical Engineering, School of Bus. & Econ.Materials Science & Eng., College of Engineering,Institute of Material Processing


PrISM—A Michigan Tech Enterprise

Enterprise—A College-wide initiative to develop student-run “companies” working on real-world problems Open to both engineering and non-engineering majors Program involves a mixture of “hands-on” project work and

instructional modules Students participate for up to 3 years Can earn minor in Enterprise studies (20 credits)

Funding provided by corporate partners PrISM—A Manufacturing Enterprise

Activities developed jointly by industrial and academic personnel

Students interact regularly with corporate partners through videoconferences and on-site visits

Corporate partners help assess presentations and reports


PrISM / Enterprise Coursework

Year Fall Semester Spring Semester

Sopho-more

TeamingOrien-tation

OpenCommu-nication I

PrISM Project

JuniorElective

Module

Product/Process Design I

PrISM Project

Commu-nication

II

Product/ Process Design II

PrISM Project

SeniorElective

ModulePrISM Project

Elective

ModulePrISM Project

Each block represents one semester credit of academic work


Currently-Available Elective Modules

Econ. Decision Analysis I, II, III Ethics in Engineering

Enterprise Market Principles Global Competition

Eng. for the Environment Project Management

Concept Design-Probl. Solving Material Flow – Ind. Society

Industrial Health and Safety Design for Manufacturing

Entrepreneurship Manufacturing Proc./Simulation

Budgeting-Entrepreneurial Eng. Design Impl./ Project Phases

Writing Eng in Societal Context Concurrent Engineering

7 Habits of Highly Effect, People Complex Communication Pract.

Manufacturing Proc. & Simul. Enterprise Strategic Leadership

Product/Process Design I Product/Process Design II


Product/Process Design I and II

1st Semester Product Realization Process Drawings (GD & T Overview) Manufacturing Process

Selection Failure Modes & Effects

Analysis 2nd Semester

Lean Manufacturing Statistical Process Control Design of Experiments


PrISM Project Organization

Current Structure “Team of Teams” with student Product Manager Defined Milestone reports and presentations Project management plan/timeline developed at

beginning of the year. Tracked during year Class Mechanics

Currently meet once/week for 2 hours Students keep engineering notebooks and provide

weekly progress reports Grading based on individual performance (30%),

team performance (40%) and class performance (30%)


Prior PrISM Projects

Husky Coaster (Sp. ’99)

Designed in IDEAS® and converted to N/C code

Pattern used to cast over 60 coasters

Coasters finished and sold in 10 weeks

UP Keyrack (1999-2000 ) Maple cut using N/C-

controlled abrasive water jet

Approx. 70 keyracks produced and sold


Bicycle Pump (2000-2001 Academic Year)

Product Specification Weight — < 95 g Max Pressure — 160 psi Efficiency — 175 strokes

(26x2.0 MTB Tire @50 psi) Max. Pumping Force — 108 lbs Temperature — 0 - 150oF Valve — Presta and Shrader Durability — 54 lbs side force Price — < $25.00


Enhanced PCV Valve (2001-2002 Acad. Year)

Objective Develop PCV system for

enhanced reliability at sub-zero temperatures.

Up to 180,000 vehicles/yr <$5.00/unit added cost

Class Structure Design Team Manufacturing Process

Planning Verification Testing


Some Observations

Effective communication and decision-making are challenging for a “team of teams” Weekly team updates “Executive committee” of team leaders

Unrealistic to expect students to do both IPPD and product manufacturing in one year Successful IPPD requires familiarity with product design,

process design and business issues Some incoming engineering students have little familiarity

with process design, and almost no exposure to business issues

PrISM → Manufacturing and process design Business issues currently being addressed in

modules


Some Observations—Con’t

PrISM does appear to provide students with an improved appreciation for industry perspectives on manufacturing and the importance of: Good drawings Hands-on fabrication experience Concurrent engineering Prototype testing Business issues

For more information about the program, check out the web at http://prism.mtu.edu

program in integrated sustainable manufacturing prism—the program for integrated, sustainable...

Documents

manufacturing processes42

successful manufacturing

manufacturing systems31

manufacturing operations

college of engineering

mechanical engineering

nonengineering majorsprogram

industrial partners