Manufacturing, Design and Materials Symposium Co-Chairs:

Presentations
9:30am-9:55am		MDM01	Timing Analysis for Submicron Digital Signal Processors (DSP's)
10:00am-10:25am		MDM02	The Bias Error of Weibull Parameter Estimations Using Small Data Sets with Censored Data
11:00am-11:25am		MDM04	Successful Fiberglass Reinforced Plastics (FRP) Applications
1:00pm-1:25pm			Coffee Break - Visit the Open Technical Exchange Poster Session
1:30pm-1:55pm		MDM05	Installation of Ultrahigh Purity Piping Systems at Semiconductor Manufacturing Facilities
2:00pm-2:25pm		MDM06	The Material Selection Process and Its Importance in Medicine
2:30pm-2:55pm		*MDM07	Designing Open Flow Channels Using HIVEL2D Code
Posters
		MDMP01	Emerging Trends in the Logistics Industry

Session Codes
*xxxnn		Both an oral presentation and a poster
xxxPnn		Poster Only

MDM01
Timing Analysis for Submicron Digital Signal Processors (DSP's)
Sudha Thiruvengada, MS, Senior Digital Signal Processor (DSP) Design Engineer, Texas Instruments
Friday, 9:30am–9:55am

Submicron designs need an accurate top-down constraint management and timing analysis (TA) flow to identify speed-paths very early in the design cycle. The flows need to be designed using a carefully managed constraint policing strategy and exhaustive analysis. At cycle times of 5ns or less, errors in parasitic extraction (PE), inaccuracies in transistor modeling by TA tools, inaccurate library characterization, netlisting errors and non-inclusion of coupling effects introduce significant errors in measuring maximum operating speed and have negative affects on the ability to accurate predict a design schedule. This paper will describe the TA flow implemented on the enormously successful MS320TMS320C6X megamodule which was designed using .25micron CMOS technology [gate length is .25 microns, and metal pitch is 1 micron].

MDM02
The Bias Error of Weibull Parameter Estimations Using Small Data Sets with Censored Data
Nancy C. Lipp, Industrial Engineering Graduate Student, Louisiana State University, Industrial Engineering Department
Gerald M. Knapp, PhD
Friday, 10:00am–10:25am

Preventative maintenance engineers evaluate plant equipment in order to predict future failures. This allows maintenance on the equipment to be scheduled before failure, which extends the life of the equipment. Future failures are predicted using the Weibull distribution. When the distribution is not known, it must be estimated. The Weibull distribution's scale and shape parameters are estimated using an estimation technique and failure data. A widely used estimation technique is the Maximum Likelihood (ML) method. Ideally, the ML method should be used with a large amount of data. In the maintenance field, the amount of failure data can be small and can contain censored data. Censored data is data that has not failed by the failure mode being investigated. Previous research shows a bias error occurs when ML method is used with small amounts of data containing no censored times. This research investigates the bias error that occurs while using ML technique for estimation with small data sets and censored data. The goal is to provide preventative engineers with a procedure to correct the bias error.

MDM03 - Withdrawn

MDM04
Successful Fiberglass Reinforced Plastics (FRP) Applications
Kelly Sauter, Development/Applications Engr., Dow Chemical, Epoxy Products & Intermediates
Don H. Kelley, Industrial Composites Development Leader, Dow Chemical, Epoxy Products & Intermediates
Juan L. Bustillos, Dow Chemical, Dow Design & Construction
Friday, 11:00am–11:25am

Generally, a materials science course is included in accredited Engineering degree plans. Often the construction material focus is on carbon steel with minimal attention given to fiberglass reinforced plastic (FRP). Presently, the knowledge base and experience of academia with FRP in various industrial environments is minimal. Experienced engineers and recent engineering school graduates often feel uncomfortable about implementing FRP to replace steel and metal alloy equipment in their processes. During the past 40 years, FRP has proven to be an economical material of construction in many industries that have corrosive environments. The goal of this presentation is to aid engineers by addressing the benefits of FRP and provide the basic requirements for successful FRP applications: proper design, fabricator qualification, and proper maintenance and operation .

MDM05
Installation of Ultrahigh Purity Piping Systems at Semiconductor Manufacturing Facilities
Kathryn Kinsey, PE, Principle Project Engineer, Air Products and Chemicals, Inc.
Friday, 1:30pm–1:55pm

Ultrahigh purity piping systems are being installed at today's semiconductor manufacturing facilities (called "fabs" within the industry) with less than 5 parts-per-billion (ppb) moisture and oxygen contamination. Additionally, particle contamination is less than 2 particles per standard cubic foot for particles larger than 0.1 micron. Semiconductor manufacturers dictate these strict criteria since even the smallest particle can ruin a computer chip.

Air Products and Chemicals has been involved in the semiconductor industry for almost a decade and has installed ultrahigh purity piping at many fabs worldwide. To meet customer requirements, Air Products has developed a detailed Quality Assurance (QA) specification that covers the installation of ultra high purity piping systems. This paper will explore the aspects of a ultrahigh purity piping installation at a semiconductor fab, which include material requirements, design, handling, inspections, fabrication, purging, welding, installation, testing, and final acceptance of the piping system. Using quality assurance methods and trained piping contractors, ultrahigh purity piping systems have been successfully installed for many semiconductor manufacturers. These procedures minimize the time required for testing and ensure that the piping systems routinely meet the high expectations of semiconductor manufacturers.

MDM06
The Material Selection Process and Its Importance in Medicine
Geraldie Fleurima Shannon, Mechanical Engineer, Manufacturing, Halliburton Energy Services
Friday, 2:00pm–2:25pm

A critical aspect of any product development is the material selection process, which typically takes place at the beginning of a design project. Improper material selection can compromise the design intent and the safety of the intended product. Conversely, careful consideration to material selection helps to produce a superior and ultimately safer product in a number of common industries like the automotive, to some less familiar areas such as the medical industry.

With the advancement of medical techniques which may require the development of new materials in order to heal and repair body parts and functions, the importance of the material selection process in medicine is extremely evident. The need to apply traditional engineering concepts and the difficulties encountered will be discussed with consideration to techniques which can be applied to improve the reliability of materials for medicinal use.

*MDM07
Designing Open Flow Channels Using HIVEL2D Code
Jill Roboski, Student, junior, University of Alabama, Civil Engineering Department
Friday, 2:30pm–2:55pm

In the past, physical models were constructed in order to study the behavior of the flow in high-velocity, hydraulically steep slope, man-made channels. These channels were constructed to control flooding. As time progressed, urbanization of areas surrounding these channels began to cause problems. The added structures caused an increase in run-off. Obstacles were added to the channels, such as bridge piers. Channel transitions often caused the water level to rise. These changes increased the chance of subcritical flow which may overtop the channel walls, causing flooding to occur.

An efficient and accurate method of designing new channels and re-designing existing channels was needed. HIVEL2D is a numerical flow model that uses the Petrov-Galerkin formulation finite element method to solve the Shallow Water Equations. By utilizing HIVEL2D, a safer more accurate solution to the design of channels may be found.

This project encompassed a parametric study of HIVEL2D. Three general steps governed each simulation: generating the grid via Groundwater Modeling System (GMS), obtaining a steady state solution utilizing HIVEL2D, and finally analyzing the solution using either FAST or XMGR. Simulations were selected based on their ability to evaluate the ability of HIVEL2D to obtain a steady state solution, to study the accuracy of the models returned by HIVEL2D, and to test the grid independence of HIVEL2D. The simulation geometries included in this project were both straight channels and straight wall channel contractions.

MDMP01
Emerging Trends in the Logistics Industry
Holly J. Teig, Inventory Manager, Caterpillar Logistics Services

Product logistics today is a competitive advantage in a world where quality and price mean little unless you deliver your products, parts, or materials where and when they're needed. It is a strategy for success for companies competing in the global marketplace. No longer is it as simple as getting your goods from Point A to Point B at the right time. They may be more than half a world and several time zones apart. An integrated logistics strategy that can react to the demands of a worldwide market is required to meet today's customers needs.

Integrated solutions are the next generation, and are focused on total supply chain management. Integration delivers greater returns, because it is a system wide view of logistics. It also supports the global nature of today's marketplace. Companies that have recognized the competitive advantage that integrated logistics offers also know that managing such a system is complex, often going beyond the technology and experience level they may have. These enterprises are looking for logistics experts to move their business forward.

Full service, third-party logistic providers are filling this need, offering a seamless, well-managed network of facilities, transportation strategies, inventory technologies, and information systems to achieve and maintain a marketplace advantage.