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- Creators: Barrett, The Honors College
Description
Company X is one of the world's largest semiconductor companies in the world, having a current market capitalization of 177.44 Billion USD, an enterprise value of 173.6 Billion USD, and generated 52.7 billion USD in revenue in fiscal year 2013. Recently, Company X has been looking to expand its Foundry business. The Foundry business in the semiconductor business is the actual process of making the chips. This process can be approached in several different ways by companies who need their chips built. A company, like TSMC, can be considered a pure-play company and only makes chips for other companies. A fabless company, like Apple, creates its own chip design and then allows another company to build them. It also uses other chip designs for its products, but outsources the building to another company. Lastly, the integrated device manufacturing companies like Samsung or Company X both design and build the chip. The foundry industry is a rather novel market for Company X because it owns less than 1 percent of the market. However, the industry itself is rather large, generating a total of 40 billion dollars in revenue annually, with expectations to have increasing year over year growth into the foreseeable future. The industry is fairly concentrated with TSMC being the top competitor, owning roughly 50 percent of the market with Samsung and Global Foundries lagging behind as notable competitors. It is a young industry and there is potential opportunity for companies that want to get into the business. For Company X, it is not only another market to get into, but also an added business segment to supplant their business segments that are forecasted to do poorly in the near future. This thesis will analyze the financial opportunity for Company X in the foundry space. Our final product is a series of P&L's which illustrate our findings. The results of our analysis were presented and defended in front of a panel of Company X managers and executives.
ContributorsJones, Trevor (Author) / Matiski, Matthew (Co-author) / Green, Alex (Co-author) / Simonson, Mark (Thesis director) / Hertzel, Michael (Committee member) / Department of Finance (Contributor) / W. P. Carey School of Business (Contributor) / Barrett, The Honors College (Contributor)
Created2015-05
Description
Upon investigating the current state of the high scrap problem at Niagara Bottling's Phoenix manufacturing facility, it was found that 49% of the scrap was being generated at the bottling lines in the form of plastic bottles, and 39% of scrap took the form of preforms accumulated at either the bottling lines or the injection molding machines. The scope of this project includes all forms of polyethylene terephthalate (PET), but the large accumulation of scrap in these areas suggests a primary focus on the bottling lines and the injection molding machines. Further analysis of the bottling lines found that the filler at each line as well as the blower on line X1 were the biggest contributors to the scrap accumulation problem. Each of these machines was seeing over 0.4% of bottles rejected at the visual inspection units. Due to the underlying status and quality issues of the injection molding machines that were beyond the scope of this project, this process was only investigated for solutions involving the overall processes and people. Based on the data and process flow analysis there were several solutions proposed including a root-cause analysis of the highest faulting machines, the repair of the injection molding overhead conveyor systems, the creation of a low waste environment, and the implementation a scrap tracking and analysis process. Based on the current high variability in the scrap experience across all machines, it is recommended that Niagara Phoenix pursue the scrap tracking and analysis alternative. After the implementing the scrap tracking and analysis process, the initial results were encouraging and could potentially warrant the investment in a software platform that could automate the collection of data necessary for this process. Based on the initial results of the manual collection and analysis process, each individual line show signs of potential reduction in the scrap rate of over 50%. According to this improvement, purchasing the software platform would see a payoff period of only 36 days.
ContributorsSanchez, Thomas Camden (Author) / Kellso, James (Thesis director) / Lupe, Munoz (Committee member) / Barrett, The Honors College (Contributor) / School of International Letters and Cultures (Contributor) / Department of Supply Chain Management (Contributor)
Created2015-05
Description
Over the course of six months, we have worked in partnership with Arizona State University and a leading producer of semiconductor chips in the United States market (referred to as the "Company"), lending our skills in finance, statistics, model building, and external insight. We attempt to design models that help predict how much time it takes to implement a cost-saving project. These projects had previously been considered only on the merit of cost savings, but with an added dimension of time, we hope to forecast time according to a number of variables. With such a forecast, we can then apply it to an expense project prioritization model which relates time and cost savings together, compares many different projects simultaneously, and returns a series of present value calculations over different ranges of time. The goal is twofold: assist with an accurate prediction of a project's time to implementation, and provide a basis to compare different projects based on their present values, ultimately helping to reduce the Company's manufacturing costs and improve gross margins. We believe this approach, and the research found toward this goal, is most valuable for the Company. Two coaches from the Company have provided assistance and clarified our questions when necessary throughout our research. In this paper, we begin by defining the problem, setting an objective, and establishing a checklist to monitor our progress. Next, our attention shifts to the data: making observations, trimming the dataset, framing and scoping the variables to be used for the analysis portion of the paper. Before creating a hypothesis, we perform a preliminary statistical analysis of certain individual variables to enrich our variable selection process. After the hypothesis, we run multiple linear regressions with project duration as the dependent variable. After regression analysis and a test for robustness, we shift our focus to an intuitive model based on rules of thumb. We relate these models to an expense project prioritization tool developed using Microsoft Excel software. Our deliverables to the Company come in the form of (1) a rules of thumb intuitive model and (2) an expense project prioritization tool.
ContributorsAl-Assi, Hashim (Co-author) / Chiang, Robert (Co-author) / Liu, Andrew (Co-author) / Ludwick, David (Co-author) / Simonson, Mark (Thesis director) / Hertzel, Michael (Committee member) / Barrett, The Honors College (Contributor) / Department of Information Systems (Contributor) / Department of Finance (Contributor) / Department of Economics (Contributor) / Department of Supply Chain Management (Contributor) / School of Accountancy (Contributor) / School of Mathematical and Statistical Sciences (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / WPC Graduate Programs (Contributor)
Created2015-05
Description
Modern manufacturing has allowed society to make giant leaps and bounds within the sphere of building. But how much are we sacrificing for this to occur? There is a fine line between a quality product and its counterpart- the quantity product. Who is responsible for maintaining this balance? How can we ensure that the responsible parties are aware of how something will be produced? Designers must be educated in manufacturing processes so that they can act as a quality control buffer and make informed decisions about the product specified. The responsibility of maintaining a balance between quality and quantity (or cost) is a joint one. In some cases, it may fall on the craftsman, who pushes out more product in order to compete in the market today. In others, it may be on the manufacturer, who uses particular methods of building in order to ensure a quality product. However, in most scenarios, furniture is produced to spec, per the intent of a designer. Whether the craftsman or the manufacturer makes the product, some sort of design minded person is behind the order and has the final say on how a piece that they have commissioned will look. A purchase order is issued to a manufacturer or craftsman based on a provided quote. Shop drawings are reviewed by a designer to ensure that the proper materials are used, the proper dimensions are met, and that the aesthetic of the piece matches the designer's vision. In recognizing that a portion of responsibility for the manufacture of product falls onto the designer, who submits a specification to a manufacturer, and approves or denies shop drawings, we can recognize a missing piece of their fundamental education. Newly graduated designers lack basic knowledge about the way things that are used every day are built, how they want them built, and what materials are used to build them. Extensive engineering and labor processes are required to fabricate products; processes that a designer may know nothing about, thereby forfeiting their involvement in quality control. This first section of this paper will strive to address issues of quality versus quantity, and the role of the designer in maintaining a balance between the two. In addition, it will focus on implementing methods to educate designers on manufacturing techniques, essentially creating a quality control mechanism in terms of furniture specification. The second section will consist of a developing course outline addressing the basic knowledge and application of manufacturing techniques for interior designers.
ContributorsMunoz, Olivia Lauren (Author) / Brandt, Beverly (Thesis director) / Rosso, Rachel (Committee member) / Tassell, Toni (Committee member) / Barrett, The Honors College (Contributor) / The Design School (Contributor)
Created2014-05
Description
The following document addresses two grand challenges posed to engineers: to make solar energy economically viable and to restore and improve urban infrastructure. Design solutions to these problems consist of the preliminary designs of two energy systems: a Packaged Photovoltaic (PPV) energy system and a natural gas based Modular Micro Combined Cycle (MMCC) with 3D renderings. Defining requirements and problem-solving approach methodology for generating complex design solutions required iterative design and a thorough understanding of industry practices and market trends. This paper briefly discusses design specifics; however, the major emphasis is on aspects pertaining to economical manufacture, deployment, and subsequent suitability to address the aforementioned challenges. The selection of these systems is based on the steady reduction of PV installation costs in recent years (average among utility, commercial, and residential down 27% from Q4 2012 to Q4 2013) and the dramatic decline in natural gas prices to $5.61 per thousand cubic feet. In addition, a large number of utility scale coal-based power plants will be retired in 2014, many due to progressive emission criteria, creating a demand for additional power systems to offset the capacity loss and to increase generating capacity in order to facilitate the ever-expanding world population. The proposed energy systems are not designed to provide power to the masses through a central location. Rather, they are intended to provide economical, reliable, and high quality power to remote locations and decentralized power to community-based grids. These energy systems are designed as a means of transforming and supporting the current infrastructure through distributed electricity generation.
ContributorsSandoval, Benjamin Mark (Author) / Bryan, Harvey (Thesis director) / Fonseca, Ernesto (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2014-05
Description
The basis of this project was to analyze the potential cost savings derived from the implementation of an ultrasonic flaw detector for gas pipes in factories. The group began by researching the market of the Industrial Internet of Things. IIoT is a very attractive market for investment, as connected technologies are become both more advanced and more affordable. Factory automation also saves costs of human capital, maintenance, and bad product cost as well as safety. After doing this preliminary research, the group continued by identifying potential solutions to current shortcomings of the manufacturing status quo. After narrowing down the options, the ultrasonic flaw detector appeared to have the highest potential for success in Company X's factories. The group began doing research on what physical components would go into this solution. They found pricing for all of the various parts of such a device as well as estimated labor, maintenance, and implementation costs. After estimating these costs, the team began the construction of a detailed financial model to generate the hypothetical net present value of such a tool. After presenting two times to a panel of Company X employees, the group decided to focus only on cost savings for Company X, and not the potential revenues of selling the whole solution. They ran a sensitivity analysis on all of the factors that contributed to the NPV of the project, and discovered that the estimated percentage of scrapped product resulting from gas leaks and the percentage of gas lost to leaks contributed the most to the NPV.
ContributorsFlick, Jacob (Co-author) / Alam, Mustafa (Co-author) / Nguyen, Mong (Co-author) / Zhang, Zihan (Co-author) / Simonson, Mark (Thesis director) / Hertzel, Michael (Committee member) / Department of Finance (Contributor) / Department of Information Systems (Contributor) / WPC Graduate Programs (Contributor) / School of International Letters and Culture (Contributor) / School of Mathematical and Statistical Sciences (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05
Description
The purpose of this creative project was to investigate the process a start-up or small business must complete to have a sell-able apparel product manufactured. The initial goal of the project was to experience the manufacturing process from start to finish and complete a full production run from a professional manufacturer. The conclusion found was that start-ups and small businesses will have to begin production within the United States.
ContributorsBour, Melissa (Author) / Sewell, Dennita (Thesis director) / Rogers, Dale (Committee member) / Ellis, Naomi (Committee member) / Dean, Herberger Institute for Design and the Arts (Contributor) / Department of Supply Chain Management (Contributor) / Dean, W.P. Carey School of Business (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
Curtiss-Wright Corporation is a global company that manufactures and provides services for the commercial, industrial, defense, and energy departments. The Curtiss-Wright facility that was the focus of this research is part of the Sensors and Controls Division and focuses on manufacturing and assembling aircraft components. Visual Factory, an electronic work instructions software, was implemented for a trial run for two products on the assembly floor. Data collected from several workstations and operators was analyzed to determine if there were impacts to product quality or changes in assembly completion times when using Visual Factory. After analyzing data from six operators and six workstations, it was found that operators could complete processes in less time than was previously believed. Timing data also helped to create standardized learning curves and improvement percentages for specific workstations and processes. This data allows management and supervisors to more adequately allocate time for training and extrapolate post-training completion times based on initial completion times. Part quality data was less abundant, but there were fewer major issues with part quality when using Visual Factory. Visual Factory also allowed for more in-depth collection of quality issues on specific units. It is recommended that Curtiss-Wright continues with implementation of Visual Factory across the entire assembly floor and all product lines.
ContributorsNelson, Jade Hunter (Author) / Coursen, Jerry (Thesis director) / Rossiter, John (Committee member) / Harrington Bioengineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05
Description
Rotary drums are commonly used for their high heat and mass transfer rates in the manufacture of pharmaceuticals, cement, food, and other particulate products. These processes are difficult to model because the particulate behavior is governed by the process conditions such as particle size, particle size distribution, shape, composition, and operating parameters, such as fill level and rotation rate. More research on heat transfer in rotary drums will increase operating efficiency, leading to tremendous energy savings on a global scale. This study investigates the effects of drum fill level and rotation rate on the steady-state average particle bed temperature. 3 mm silica beads and a stainless steel rotary drum were used at fill levels ranging from 10 \u2014 25 % and rotation rates from 2 \u2014 10 rpm. Four heat guns were used to heat the system via conduction and convection, and an infrared camera was used to record temperature data. A three-level, two-factor, full-factorial design of experiments was employed to determine the effects of each factor on the steady-state average bed temperature. Low fill level and high rotation rate resulted in higher steady-state average bed temperatures. A quantitative model showed that rotation rate had a larger impact on the steady-state bed temperature than fill level.
ContributorsBoepple, Brandon Richard (Author) / Emady, Heather (Thesis director) / Adepu, Manogna (Committee member) / W.P. Carey School of Business (Contributor) / Chemical Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
Statistical process control (SPC) is an important quality application that is used throughout industry and is composed of control charts. Most often, it is applied in the final stages of product manufacturing. However it would be beneficial to apply SPC throughout all stages of the manufacturing process such as the beginning stages. This report explores the fundamentals of SPC, applicable programs, important aspects of implementation, and specific examples of where SPC was beneficial. Important programs for SPC are general statistical software such as JMP and Minitab, and some programs are made specifically for SPC such as SPACE: statistical process and control environment. Advanced programs like SPACE are beneficial because they can easily assist with creating control charts and setting up rules, alarms and notifications, and reaction mechanisms. After the charts are set up it is important to apply rules to the charts to see when a system is running off target which indicates the need to troubleshoot and investigate. This makes the notification part an integral aspect as well because attention and awareness must be brought to out of control situations. The next important aspect is ensuring there is a reaction mechanism or plan on what to do in the event of an out of control situation and what to do to get the system running back on target. Setting up an SPC system takes time and practice and requires a lot of collaboration with experts who know more about the system or the quality side. Some of the more difficult parts of implementation is getting everyone on board and creating trainings and getting the appropriate personnel trained.
ContributorsSennavongsa, Christy (Author) / Raupp, Gregory (Thesis director) / Dai, Lenore (Committee member) / Materials Science and Engineering Program (Contributor) / Chemical Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12