Professor Robert G. Batson’s Automotive-related Research at The University of Alabama

1. Professor Robert G. Batson’s Automotive-related Research at The University of Alabama Robert G. Batson, Ph.D., P.E. Professor of Industrial Engineering, University of Alabama rbatson@coe.eng.ua.edu, 205-348-1609

2. Professor Batson’s Qualifications • Ph.D. Math and M.S.I.E., Alabama, 1979 • ASQ Certified Quality Engineer, 1988 • ASQ Certified Reliability Engineer, 1992 • P.E. in Quality Engineering, California, 1996 • Elected ASQ Fellow, 1996 • Full-time invited researcher in Quality Engineering • ACIPCO 1990-1991(Acting Supplier Improvement Coord.) • MBUSI 1999-2000(Acting Quality Improvement Coord.) • U.S. Army AMCOM Summers 2004 & 2005 • Study trips in Toyota Motor Company in Japan and Hyundai Motor Company in Korea

3. Automotive-related Courses Created and Taught by Dr. Batson University of Alabama Courses IE 418/518 Engineering Management IE 421/521 Reliability, Maintainability, and Total Productive Maintenance IE 425/525 Statistical Quality Control IE 426/526 Design and Analysis of Experiments IE 470/570 Supply Chain Engineering IE 622 Quality Engineering (Taguchi Methods, Six Sigma, QFD) Short Courses Quality Leadership Philosophies of Juran and Deming Juran on Quality Planning Statistical Methods for Quality Improvement Taguchi Methods for Quality Engineering

4. Full-time Coordinator of MBUSI’s 2000 Supplier Improvement Initiative • Planned training courses in Process Auditing and Performance Improvement, coordinating attendees, instructors, and facilities • Planned materials to be used in meetings with selected suppliers • Developed policies, reporting mechanisms, etc. in my role as a member of the Steering Committee of this initiative • Explained the initiative to MBUSI Management Team, including their responsibilities as the Senior Council • Provide technical assistance with performance improvement process and statistical tools • Prepared a five-year Supplier Improvement plan for Senior Council

5. Other Projects Completed 1999-2000 while on sabbatical at MBUSI • Statistical data analysis of brake-pedal force test used on each vehicle • Statistical data analysis of bolt “torque checks” performed each shift on a random basis by QC technicians • Statistical data analysis of a large Access database containing records of all defective material shipped to MBUSI by Tier 1 suppliers—Identified suppliers and supplied parts needing most attention of the supplier quality engineers or improvement teams. • Audit of interior door panel assembly, inspection, shipping, and conveyance to line-side. Followed parts into door assembly and analyzed those rejected for surface defects. Conducted a risk assessment for potential sources of cuts and scratches, and suggested changes at both MBUSI and the supplier. My suggestions were implemented and door panel defects due to these causes dropped 75% in a two month period.

6. M.S.I.E. 3M BellSouth Johnson and Johnson Seagate B.S.I.E. Fontaine Fifth Wheel Elk Mercedes-Benz ZF Industries Ogihara Rehau Saturn Delphi-Packard ZF Industries Nokia Placement of B.S.I.E./M.S.I.E. Graduates in Quality-related Positions since 1990

7. Quality and Reliability Engineering Research: Theoretical • Approaches to Assure Quality of Assembly • Constrained Multivariate Loss Function Minimization • An Algorithm for Optimal Loss Reduction in Serial Manufacturing • Defect Cause Diagnosis Methods for Job Shops • Control Charts for Monitoring Field Failure Data • Variation Reduction Strategies for Process Engineers • Maintenance Implications of Lean Manufacturing • How Equipment Maintenance helps Assure Product Quality (Japan’s “Quality Maintenance”)

8. Quality and Reliability Engineering Research: Applied • Optimal Green Sand Characteristics to Minimize Foundry Scrap • Parameter Design Experiments in Foundry Processes • Simulation of the Metal Distribution Process in an Automated Foundry • An Expert System to Diagnose and Analyze Surface Defects in Castings • Experimental Design to Quantify Gauge Gain in Steel Tube Manufacturing • Multiple Regression Models of Physical Property Changes in Steel under Cold-Working • Visual Quality Improvement Data System for Stamped Automobile Outer Door Panels • Experimental Design to Improve Material Durability Characteristics

9. Supplier Improvement and Development Research • Team-based Supplier Improvement Processes • Cross-company Supplier Improvement Initiatives (organizing, training, team creation and work processes, rewards, measuring and sharing cost savings, etc.) • Three Classes of Supplier Quality Improvement Incentives

10. Quality Engineering Outreach in the UA Department of Industrial Engineering Student Projects with Industry and Institutions • Undergraduate Senior Design Team Projects (4.5 months) • MSIE Student Non-thesis Projects (9-12 months) • MSIE Student + Faculty Member Projects under Contract Quality-Related Short Courses • Statistical Methods for Quality Improvement (Six Sigma Green Belt) • Juran on Leadership for Quality • Juran on Quality Planning • Deming Principles of Quality Leadership • Taguchi Techniques for Quality Engineering