Manufacturing Process Improvement
A very common area for capstone projects is focusing on improving existing manufacturing processes. Students can analyze current processes using tools like work study, time studies, motion economy analysis and suggest improvements. Some examples include reducing set-up times, balancing assembly lines, reducing bottlenecks, improving material flow etc. Proposed improvements are estimated to reduce costs and improve productivity. Testing and implementing suggestions on a trial basis helps prove the benefits.
Supply Chain Optimization
As supply chains involve coordination between different entities like suppliers, plants, warehouses and customers, there is scope for optimization. Capstone projects can evaluate current supply chain design and practices. Areas like supplier selection, inventory management, transportation planning, demand forecasting, packaging etc. can be optimized. Modeling tools like linear programming are used to design improved supply chain networks that reduce costs and bullwhip effect. Collaboration with industry helps test proposed changes.
Ergonomic Workplace Design
Many occupational health issues arise due to improperly designed workplaces and tools. Capstone projects focus on ergonomic evaluation and redesign of existing workstations and tools. Students conduct time-motion studies, posture analysis and apply anthropometric data to select optimal workplace and tool dimensions. They propose changes to reduce fatigue, increase productivity and prevent musculoskeletal disorders. Implementation and effect of changes are studied on trial groups.
Quality Management Systems
Designing and establishing quality management systems helps organizations meet customer needs and standards. Capstone projects involve studying quality practices at organizations and proposing quality systems based on frameworks like Lean Six Sigma, ISO9001, Toyota Production System etc. Projects include developing documentation templates, standard operating procedures, control plans, inspection checklists, auditing processes etc. Implementation plans and training modules are suggested to embed the system in the organization.
Facility Layout Planning
Capstone projects analyze existing facility layouts and traffic patterns to identify improvement opportunities. Areas of focus include departmental layout, material/product flow analysis, space requirements for current and future operations, ergonomic considerations, flexibility/expandability of layout. Computer aided layout planning tools are used to develop alternative layout designs meeting objectives. Cost-benefit analysis helps select optimal layout and implementation plan.
Project Management
Capstone projects give hands-on experience of coordinating and leading projects. Students work with organizations to plan, schedule and control medium-sized projects within given constraints of time, cost, scope and quality. Activities include creating project charter, developing WBS, scheduling tasks/resources using project management software, monitoring progress, change control, risk management, reporting, closing projects. Valuable lessons in team leadership, communication, documentation, stakeholder management are gained.
Lean Implementation
Implementing lean manufacturing principles helps eliminate wastes to improve flow and productivity. Capstone projects work with companies lacking formal lean programs. Students study current procedures, conduct value stream mapping to identify non-value adding activities. They suggest specific lean tools tailored for the organization/process like 5S, SMED, kanban, poka yoke, TPM, pitch, point production etc. Implementation is via pilot projects and development of lean training and guidelines. Metrics track impact and continuous improvement opportunities.
This covers only some of the broad areas within industrial and systems engineering domain where fruitful capstone projects can be undertaken. The key is to select problems/opportunities of value to partner organizations, adhere to academic rigors of problem definition, data collection, analysis, alternative evaluation, recommendation, implementation planning and documentation of results. Students gain practical experience of applying theoretical concepts to real world industrial settings and solving organizational challenges via these projects.