Date of Award
2026-05-01
Degree Name
Master of Science
Department
Industrial Engineering
Advisor(s)
Amit J. Lopes
Abstract
Additive Manufacturing (AM), particularly Direct Energy Deposition (DED), has gained increasing relevance in industrial and research environments due to its capability to manufacture complex geometries and repair high-value components. However, despite its technological advantages, DED processes often lack standardization, clear documentation, and structured workflows, especially in academic laboratories. This research aims to optimize and standardize DED processes through the application of Lean Manufacturing principles using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. The study was conducted at the Keck Center for 3D Innovation, focusing on pre-printing and printing activities. Key issues were identified. Improvement actions included the implementation of 5S methodology, development of 25 Standard Operating Procedures (SOPs), workspace reorganization, visual management techniques, use of RACI chart, and training sessions. The results demonstrate significant improvements in process performance. Task completion times were reduced by up to 80% in some operations, operator movements decreased substantially, and user confidence increased from average values near 5 to above 8 on a 10-point scale. Additionally, the number of questions raised during task execution was drastically reduced, and 5S audit scores improved from an average of 2.36 to 4.72. These results confirm that Lean Manufacturing tools can be effectively applied to additive manufacturing environments to enhance efficiency, reduce variability, and improve process reliability. This work establishes a foundation for the integration of Lean principles in additive manufacturing and provides a structured framework that can be extended to other AM processes and research environments.
Language
en
Provenance
Received from ProQuest
Copyright Date
2026-05
File Size
87 p.
File Format
application/pdf
Rights Holder
Erick Gerardo Molina Castaneda
Recommended Citation
Molina Castaneda, Erick Gerardo, "Process Optimization Of Directed Energy Deposition Via Dmaic Methodology And Lean Manufacturing Principles" (2026). Open Access Theses & Dissertations. 4736.
https://scholarworks.utep.edu/open_etd/4736