Dr. Clay Walden
Director, CAVS Extension
Mississippi State University
Session: “Building Partnerships with Industry and the Community”
ENGINEERING ENGAGEMENT WITH
REGIONAL INDUSTRIES
Our Campus …
Our Challenge as an Engineering
Outreach Center
“Wide variety of companies
expressing a variety of needs
… requires a flexible approach
to achieve business value
(economic impact).”
Variety of Companies …
• Large OEM’s (e.g., automotive
assembly plants).
• Branch plants (e.g., suppliers).
• Locally owned family businesses
• Automotive, shipbuilding,
medical devices, aerospace, and
hospitals
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Variety of Needs …
“Problem solving skills of our people is lacking …”
“Excessive overtime required to support rapid business growth …”
“Not sure how to make changes to meet a major new business opportunity …”
“Need advanced planning tools to support new model launch …”
“Do not have the resources to competitively develop a new products …”
“Automatic data collection has resulted in information overload …”
“Need to validate results, a new invention which will change the world …”
“Problems with developing the right test instruments”
“Problem job overseas as well as difficulty in configuring engineered jobs”
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… Flexible Approaches
Listen and Learn first!
Difference between Important and Urgent
Solutions (“First Order” and “Full Orbed”)
On-Site Teams; Best Practices / Technical Assistance
Engage Faculty; Students
Blended teams with seasoned professionals working alongside faculty
and students as “pulled” by the client’s project.
• Workshops (standard and custom)
• Coaching and Mentoring of Projects
CITE Armored (Holly Springs, MS)
CITE Armored: R&D Project “Idle Reduction”
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Client: CITE Armored – small manufacturer (~100
employees) in Holly Springs, MS without an R&D
capability.
Background: Initial relationship started with lean and six
sigma type engagements …
Project Description: Idle reduction technology allows
operators to refrain from long duration idling of the engine
by providing vehicle utilities (e.g., electricity, heat, A/C)
through an alternative energy system.
Results: installation complete on pilot vehicles (Dodge and
Navistar) … pilot vehicles in testing.
Team: Glenn Dennis (CAVS-E), Mike Mazolla, Matthew
Doude (CAVS) graduate students (ME, EE).
Nautic Star (Amory, MS)
Toyota (Blue Springs, MS)
Nissan (Canton, MS)
“Clear Vision” Student Project
Real World – Undergraduate …
Student Engineering Design Projects …
resulting in increased testing
capability … increasing vehicle quality.
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Transferred technology to
Nissan
Integrated measurements
from vehicle (e.g., VIN),
test results into plant
wireless network
Support of New Model Launch …
Using Simulation
Navistar Defense (West Point, MS)
Publication of “First Ever” MEP
“National Case Study”
MSU played a major role in the launch of Navistar Defense’s
armored vehicle plant in West Point, MS. Key activities
included design and implementation of the manufacturing
processes and overall production system. Major vehicle
launches have included the KBR armored cab, multiple
MRAP versions, and TACOM vehicle. Supplier development
involving over 12 Mississippi Small manufacturers.
From prototype to full-scale production peak employment
1,050 at the plant. … average employment over 500
employees across 5 years.
Total Impact from all of CAVS Extension’s work … over $4B in
economic impact (3rd party survey reported by MEP).
Documented savings of dozens of lives in Iraq due to
increased protection from the threat of IED’s
Winner: 2010 University Economic
Development Association’s National
Award for Excellence.
Quality Manufacturing (Columbia, MS)
Quality Manufacturing Group (Columbia, MS)
Manufacture
QMG, a small family owned business, is located in Columbia,
MS is nominated for the Excellence in Innovation Award on the
strength of the following accomplishments:
• QMG added a new product line, which required the doubling
of their existing workforce from 30 to 60 employees, while
increasing sales by $7 million and reducing costs by $2
million.
• Significant growth results within a remarkably short time
frame (i.e., 3 months).
• Illustrates workplace-workforce synergies that MEP
practitioners can exploit nationally on behalf of small and
medium size manufacturers (SME’s).
AZZ Calvert (Richland, MS)
Modeling hot spots at an isolated phase bus termination and determining Forced
requirements for cooling …. (images provided by AZZ/Calvert).
Hol-Mac (Bay Springs, MS)
Company Background: Hol-Mac in Bay Springs, MS has several plants
and over 300 employees . It is one of the largest manufacturers of refuse
and recycling equipment in the US.
Project Objective: MSU CAVS Extension, an MEP.ms Affiliate Center,
working with the CAVS Research team, assisted Hol-Mac engineers in
designing a new rear bumper based on DOT guidelines. Hol-Mac realized
that none of the existing vehicles in the market contained a rear bumper
that met the current U.S. Department of Transportation (DOT) guidelines.
This was a challenging technical problem because the bumper had to be
designed to minimize the effect of a rear end collision.
Project Results: Project team CAVS and CAVS Extension
working with Hol-Mac engineers modified and analyzed
the design in virtual space using advanced finite element
analysis (FEA). The resulting new design was then
physically tested at the CAVS laboratory to verify the
bumper performance under actual loading conditions. This
entire project was completed within a two month
timeframe. Hol-Mac has already incorporated the new
bumper design into their product line and is the only
company in its market with a ‘DOT’ bumper. This has
provided Hol-Mac with a significant competitive
advantage.
New Bumper: Working as Designed
Potentially saving lives … Picture received 2013
Professional Development
• Six Sigma Green Belt, Black Belt
• Lean Certificate Class (Mfging & Healthcare)
• Lean 101, 5S, VSM, …
• Measurement Systems Analysis (Gage R&R)
• Introduction to Minitab
• Experimental Design
• Statistical Process Control
• Problem Solving; 8D
• Process FMEA – Control Plans
• Financial Fundamentals
• Environmental & Safety
• Reliability Center Maintenance
• Simulation Modeling and Analysis w/ Flexsim
• Ergonomic Essentials
• Fundamentals of Welding for Engineers
• Introduction to Solid Modeling; AutoCAD
• Introduction to Metrology
• Geometric Dimensioning and Tolerancing
• ASQ Exam Prep: Certified Quality Engineer
• Maintainability & Reliability (TPM, …)
• Innovation Acceleration
Accelerating Jobs and Innovation Through Community
and Economic Development in Rural Mississippi
Accelerating Jobs &
Innovation
Strengthening
Communities
Developing
Entrepreneurs
Growing
Companies
Expanding
Clusters
Projected
Impact
• $30 million
in private
investment
• Create /
Retain 500
jobs
Federal Agency Heads and Governor Bryant …
hosted by MSU during RJA Project Kick-off
Rural Jobs Accelerator (RJA)
Federal Award: $1,065,000 (3 years)
Project Team : MSU: CAVS-E (Lead-PI),
nSPARC, SRDC, OETT, FFI, SRDC,
Agricultural Economics , Mississippi
Development Authority (MDA); Innovate
Mississippi
RJA Advisory Board
Planning & Development Districts (Three
Rivers, South Delta, Central Miss., South
Miss., North Central), State Agencies
(MDA, MDES), Regional Economic
Development (CREATE, Community
Development Foundation, Delta Council,
Bolivar, Part Gibson, Natchez, Itawamba
County) Private Sector (Nissan, Southern
Motion, Jimmy Sanders, Inc., Butler Snow,
Stone Adams), Community Colleges (State
Community & Jr. College Board, ICC,
EMCC, MDCC, Holmes CC), Utility
Companies (Miss. Power, Entergy, EPA of
Mississippi), Institutes of Higher Learning
(MSU Extension Service, IHL, Delta State
University, Alcorn State University); Statewide Associations (MAMA, MMA, Miss.
Minority Business Alliance.
Mississippi’s Rural Jobs Accelerator led by MSU’s CAVS
Extension … Invited to speak at the White House Forum on
Regional Innovation in Rural America.
Mississippi’s Make it in America
• Developing More Competitive Supply Chains …
Insourcing, reshoring, supplier development
– Events, training, resource development
– “Tiger team” projects
– Technical assistance
• Enhancing Skills …
– Six Sigma Green Belt
– Lean Certificate Classes
– CC Internships
Making a Difference
 Economic Impact: $5.8 Billion
 3,800 jobs created or retained
Through …
On site Projects and Professional
Development Workshops (e.g., Lean Six Sigma,
Problem Solving, Kaizen Events, Simulation
Modeling, Solid Modeling, Plant Master
Planning …)
Successes
Simulation Modeling: Plant Start-Ups
Prototype to Full Scale production (9 mo.)
80% Improvement in Plant Quality
400% Increase in Plant Throughput (3 mo.)
… Achieving Business Value
Economic Impact: $5,804,892,852*
(Reported from January 1, 2006 to March 31, 2014;
Number of companies surveyed… 262
Jobs Saved:
1,784
Jobs Created:
2,025
Cost Savings:
$27,539,701
Increased Sales:
CAVS Extension Center
Canton, MS
$5,327,791,521
Retained Sales:
$272,805,031
Investment Created:
$169,380,399
*Economic Impacts collected through third party surveys of completed
projects. These surveys are conducted on behalf of the U.S. Department
of Commerce.
Questions?
For Further Information, ….
Dr. Clay Walden
Director of CAVS Extension, Mississippi State
University
walden@cavse.msstate.edu
(601) 407-2713