{"id":120015,"date":"2023-04-18T14:23:09","date_gmt":"2023-04-18T19:23:09","guid":{"rendered":"https:\/\/uwm.edu\/news\/?p=120015"},"modified":"2023-04-21T09:35:45","modified_gmt":"2023-04-21T14:35:45","slug":"uwm-engineering-students-create-solution-that-saves-company-840000-per-year","status":"publish","type":"post","link":"https:\/\/uwm.edu\/news\/uwm-engineering-students-create-solution-that-saves-company-840000-per-year\/","title":{"rendered":"51ÁÔÆæ engineering students create solution that saves company $840,000 per year"},"content":{"rendered":"

The three 51ÁÔÆæ senior engineering students stood on the workroom floor of a Wisconsin manufacturing company, about to tell 70 older, experienced machinists how to improve their inventory system.<\/p>\n

Easton Dobson, Colin Haagensen and Ryan O\u2019Day promised their audience that the idea they were about to hear \u2014 an idea that originated with management and was engineered by the students \u2014 would make their jobs easier.<\/p>\n

\"\"
Ryan O\u2019Day<\/figcaption><\/figure>\n

\u201cWe had made sure along the way to get the perspective of the machinists,\u201d said O\u2019Day, who graduated in December 2022 with an undergraduate degree in industrial engineering. \u201cWe wanted to hear what was really happening on the floor.\u201d<\/p>\n

It went well. So well that the company \u2014 Oak Creek-based AAA Sales & Engineering (AAASE) \u2014 adopted the students\u2019 proposed solution: a bar-coding system they simply called the Inventory Traceability Project.<\/p>\n

Steve Coolidge, AAASE\u2019s general manager, estimates the Inventory Traceability Project will save the company $840,000 annually. As promised by the 51ÁÔÆæ students, it has already made the machinists\u2019 jobs easier by significantly reducing the time it takes them to locate parts in the 80,000-square-foot building.<\/p>\n

62-minute search for parts<\/h3>\n

AAASE provides precision machined castings and forgings for 13 clients \u2013 including Caterpillar and Eaton \u2013 and maintains about 400 active part numbers at any time. Hundreds of times daily, machinists must locate these parts, searches that had ranged from one to 62 minutes.<\/p>\n

Sometimes, Coolidge said, machinists just gave up the search and sought out a supervisor.<\/p>\n

\u201cWe had no formal inventory system,\u201d he said. \u201cThe only system we had was institutional knowledge. This worked for the tenured workforce, but as new employees joined us, it became a problem.\u201d<\/p>\n

Which is why Coolidge sought help from 51ÁÔÆæ\u2019s Department of Industrial & Manufacturing Engineering, housed in the College of Engineering & Applied Science. It was the first time AAASE worked with 51ÁÔÆæ.<\/p>\n

\u2018Applying what you learn\u2019<\/h3>\n

Through a senior design class for industrial and manufacturing engineering students, AAASE challenged the team of Dobson, Haagensen and O\u2019Day to create a method to record and maintain the physical location of $2 million worth of parts that ranged in price from $17 to $1,400 each. In this mandatory class, students work on teams as they transfer their classroom knowledge to real-world industrial problems.<\/p>\n

\u201c51ÁÔÆæ are important, but applying what you learn in the classroom to business is fundamental,\u201d said O\u2019Day, who will pursue a master\u2019s degree in data science in fall 2023 at the University of Denver. \u201cWe were tasked with a sizeable project from an actual client, and it was very valuable.\u201d<\/p>\n

Coolidge mentored the student team over the three-month project. They were advised by Dah-Chuan Gong, a 51ÁÔÆæ visiting scientist who is a supply chain and logistics expert, and Wilkistar Otieno, associate professor and chair, industrial and manufacturing engineering.<\/p>\n

Industrial engineering students learn how to make things better in any industry by analyzing and optimizing the integration of people, machines, materials, time and other resources.<\/p>\n

\u201cIndustry-driven, senior design projects give our students an incomparable way to learn and grow,\u201d Gong said. \u201cIn the process, they face current, real-world industrial problems. To succeed, they must learn more carefully how to define scope, how to apply appropriate methodology, and how to measure and justify their results.\u201d<\/p>\n

Benefits accrue as company rolls out students\u2019 system<\/h3>\n

Today on the workroom floor at AAASE, machinists are using the Inventory Traceability Project to easily locate parts. The average search time for a part has decreased from 11 minutes to less than three, which means the company\u2019s 46 machines are idling 3,500 fewer hours each year. Human error from manual data entry has been reduced, and the process of identifying parts and transferring information has been streamlined.<\/p>\n

There will be more to come. The students set up the system so the company could roll it out incrementally.<\/p>\n

\u201cThe student team did an amazing job of working with our employees,\u201d Coolidge said. \u201cThey brought a passion for making their work easier and more efficient, and our team immediately respected them for that.\u201d<\/p>\n

Previous project<\/h3>\n

This isn’t the first time that engineering students helped a company solve a problem. Last year, another group of students created a system<\/a> that saved a Saukville specialty steel manufacturer more than $40,000.<\/p>\n

\u201cThe students knocked it out of the park,\u201d said Ted Fitzpatrick, a process metallurgist at Charter Steel and the team\u2019s contact at the company. \u201cThe entire reason we changed the heat-treatment cycle was because of the work the student group did. They took it above and beyond.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"

An Oak Creek manufacturing company had a major problem tracking inventory. 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