Wesley Quillin, Hannah Morris, Hunter Clayton
Frosty Factory
Josh Wheat, Senior Engineer @ Frosty Factory
John Garrison, Instructor @ Louisiana Delta Community College
Dr. Jun-Ing Ker
This project evaluates the economic and operational feasibility of transitioning selected
injection-molded components at Frosty Factory from outsourced suppliers to in-house
production. The study focuses on a defined set of plastic parts and examines whether
purchasing an injection molding machine and required tooling can be justified under
realistic production conditions. A bottom-up cost model was developed due to limited
and inconsistent vendor pricing. The model incorporates material usage, estimated
cycle times, cooling requirements, machine utilization, labor costs, and maintenance
assumptions to estimate cost per part and break-even performance. Both new and used
equipment scenarios are evaluated under batch-based production conditions. In addition
to financial performance, the analysis considers operational impacts including staffing
requirements, training, facility integration, and production flow. Sensitivity analyses
were conducted to assess the effects of uncertainty in key assumptions such as utilization
rates and labor costs. The results provide Frosty Factory with a data-driven framework
to support a decision on whether in-house injection molding is viable.
Claire Howard, Kailie Carrigee, Tomás Jiménez
DIS-TRAN Steel
Clayton Eagles
Maddox Taunton
Dr. Jason Howell
DIS-TRAN Steel, a leader in high voltage-infrastructure faces extended process times
driven by bottlenecks at their manufacturing facility in Pineville, LA. This project
employs the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) framework
to mitigate process inefficiencies within Plant 3, specifically focusing on the plasma
cutter, press brake, and seam welder operations. The team addressed these inefficiencies
by developing a digital twin, using a simulation software by Autodesk, called FlexSim.
The simulation integrates AutoCAD layouts and time-study data to create a 3D and logical
process flow. Powered by empirical distributions, the
simulation simulates the process flow, identifies bottlenecks, outputs key metrics,
and allows variable manipulation to track system behavior. Through “what-if” iterative
analysis within the model, the team identified optimal combinations of factors like
batch size, staffing levels, and resource allocations without interrupting production.
The final implementation plan aims to increase throughput, reduce process time, and
improve utilization. Beyond immediate improvement suggestions, the team will provide
DIS-TRAN Steel with the functional FlexSim model to serve as a permanent decision-support
tool. This enables the facility the ability to test future variables, like introducing
new machinery, to see how changes impact the process before making physical or financial
commitments.
Kari Crumley, Brandon Franks and Dawson Miller
LA DOTD
John Holley
Dr. Jun-Ing Ker
The record-breaking icing conditions experienced across North Louisiana in early 2026
emphasized the critical need for advanced winter weather logistics. This study addresses
that need through optimized salt and brine distribution routes for the Louisiana Department
of Transportation and Development (DOTD) District 04. Covering seven parishes and
over 2,500 miles of state-maintained roadway, District 04 serves as a vital corridor
for regional transit. While the DOTD’s pre-existing preparedness plan utilizes a five-tier
response system, this project establishes the logistical foundation for a newly proposed
sixth level of emergency response.
By leveraging ArcGIS and its Vehicle Routing Problem (VRP) solver, the study identifies
efficient deployment paths by accounting for vehicle capacities, depot locations,
and the geographic distribution of essential routes. The resulting models provide
a data-driven framework to improve service delivery and public safety while minimizing
resource waste. This work demonstrates the practical application of geospatial logistics
in public sector emergency management and provides a scalable model for other districts
within the state.