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Open Access Knowledge and Scholarship

Date of Award


Culminating Project Type

Starred Paper

Degree Name

Engineering: M.E.M


Mechanical and Manufacturing Engineering


College of Science and Engineering

First Advisor

Ben Baliga

Second Advisor

Hiral Shah

Third Advisor

Balasubramanian Kasi

Creative Commons License

Creative Commons License
This work is licensed under a Creative Commons Attribution-Noncommercial-No Derivative Works 4.0 License.

Keywords and Subject Headings

Material handling, Lean Manufacturing,Kanban,Two Bin ,Bill of Material


Material handling has become critically important because of improvement in the industry automation and the scale of production. US based ABC Refrigerator Company was also suffering from unreasonable material handling design in the past few years which caused the delivery delay and material wastage. The goal of this project was to reduce waste from the material handling system and improve the efficiency of the whole production. This project redesigned the new replenishment system called Material Excellence Program (MEP) which was made up of three sub-systems: Min max, Kanban, and Two Bin systems by applying, just-in-time and pull principles into the material handling process. Based on the selection criteria such as quality, usage frequency, part cost, and others. The materials in the warehouse were mainly divided into two categories: common parts and specific parts. MEP mainly focused on the common parts delivery. Time studies were conducted to record the cycle time of new replenishment system after implementation of the lean principles. The results of the project of Material Excellence Program were used at ABC. The new replenishment system was first implemented to ABC and improved the material handling system by solving problem of the smaller quantity deliveries delay and reducing waste through transportation and double handling at changeovers.


I would like to express my great appreciation to Dr. Ben Baliga and Dr. Shah Hiral, my capstone project advisor, for their great patient guidance, enthusiastic encouragement, and critical advice of this project work. I would like to thank Dr. Balasubramanian Kasi as well, for his out-of-the-box thinking which inspired me a lot during this project. I would like to extend my grateful thanks to Mr. Anthony Haugen, my project supervisor of the company, for his professional guideline and valuable support in keeping my progress on schedule.

Finally, I would like to thank my parents for their self- giving support and encouragement throughout my study.



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