College - Author 1

College of Engineering

Department - Author 1

Industrial and Manufacturing Engineering Department

Degree Name - Author 1

BS in Industrial Engineering



Primary Advisor

Reza Pouraghabagher


This report aims to aid Synergy Manufacturing (a well-recognized producer of high-performance components for off-roading vehicles) to improve in-house production capacity in wake of an expanded facility space and substantial increase in the number of current available products over the span of a few years. Current warehouse issues include struggling to meet demand, high inventory, and an unsafe overcrowding of WIP on the floor space. The steps taken to resolve these issues are to collect setup times, operational times, total process times, machine tool usage, and flow process from a selected group of five high-demand items from Synergy Manufacturing’s current product line. After manufacturing cell formation of machine tools and batch managing using a traditional and non-traditional algorithm respectively, manufacturing cells, machine tools, and material receiving stations were arranged appropriately along with a company-proposed integration of a new in-house powder coating cell. The results yielded observational improvements in both the material process flow and batch sizing. The scope of this project is only limited to the five chosen present-day products; thus, future studies include process tracking and data collecting from a wider variety of both present and future items, which will improve the designs modeled in this report.