This spring, the ISE 498 (senior design) teams were joined by the ISE 521 (healthcare systems) teams to showcase their hard work and creative, problem-solving skills. The program allows seniors and graduate students to collaborate with local companies to solve real-world problems by creating innovative solutions. This experience is their final opportunity before graduation to apply the knowledge and skills they obtained throughout their studies, while experiencing the challenges of teamwork and tight deadlines.

Senior Design (Service Systems)

1st Place | Team NC State College of Engineering

Student Team: Lucas Barbu, Nick Harvey, Brett Olson and Curt Verchick

As NC State’s College of Engineering tried to boost sponsored funding, it became clear the current process needed review. The Research Administration department couldn’t keep up with the rising number of submitted grant proposals. To fix this issue, the senior design team stepped in to improve how things worked. Their main goal was to build tools to help staff review and finish proposals before sending them to funding agencies. Along the way, the team used new artificial intelligence methods to cut down on delays and extra steps. As a result, they gained the ability to handle and complete more grant proposals than in past years.

To fix this issue, the senior design team stepped in to improve how things worked. Their main goal was to build tools to help staff review and finish proposals before sending them to funding agencies. Along the way, the team used new artificial intelligence methods to cut down on delays and extra steps. As a result, they gained the ability to handle and complete more grant proposals than in past years.

2nd Place | Team Hitachi Energy (Waste)

Student Team: Maddie Billings, Sophia Lloyd, Grace Newman and Audrey Westlund

Hitachi Energy’s plant in South Boston, Virginia, aims to send zero waste to landfills by 2030. To reach this goal, the plant is improving how it sorts waste and lowering its environmental impact. As part of this effort, a senior design team created a strategy to reduce waste contamination. Specifically, they focused on cutting down cardboard contamination, which often prevents recycling. To solve this problem, the team looked at processes that created the most cardboard. Then, they suggested several changes. For example, they designed a better layout for trash and recycling bins. They also added clearer signs and did a cost study using a cardboard compactor. As a result, these ideas may help improve recycling and could spread to other parts of the plant.

Senior Design (Traditional)

Student Team: Lanai Adams, Parker Dotson, Ty Frankosky and Shiv Hira

1st Place | Team Union Special

Union Special Bread, a wholesale and retail bakery planning to expand into a new facility, faces rising labor costs and process delays in its prep and packaging room. To solve these issues, a senior design team carefully studied the room’s layout, work patterns and equipment use. As a result, they introduced new breadbaskets, clear standard procedures and a better room setup. These changes quickly reduced wasted time, improved how tools were organized and lowered costs. Overall, these updates support future growth, improve efficiency and reduce wasted materials and time.

2nd Place | Team Novo Nordisk (Material Handling)

Student Team: Juan Balderas, Stanley Haviland, Zachary Jones, Danielle Lewis and Meredith Padgett

In early 2025, Novo Nordisk’s Durham, NC, facility expanded to add production capabilities, which brought new inventory challenges. Poor storage, random ordering and weak tracking caused delays and crowded the warehouse.

To fix these problems, a senior design team created a three-part plan. They introduced an ordering system linked to SAP, improved vertical storage and built a smart tracking tool. By using data analysis, clear workflows and risk prevention, the team supports the July 2025 production launch. This effort also helps Novo Nordisk save money, work more efficiently and keep production on track.

Healthcare Services

1st Place | Team UNC Health (Scheduling)

Student Team: Emily Bothwell, Kristine Huynh, Katie Leonard and Lydia Lloyd

UNC Hospitals wants to shorten surgery scheduling lead time and make better use of its services by improving the Operating Room (OR) Block Schedule. To help with this, a senior design team created a Python tool that predicts lead times and service use based on changes to block assignments. With this tool, the team can make smart suggestions for dividing OR time. In addition, the tool supports ongoing improvements by helping staff adjust schedules using real data. As a result, the hospital can boost efficiency and respond better to patient needs.

Fan Favorite

Team Engineered Controls International (ECI)

Student Team: Emily Berg, Matthew Madren, Nicholas Norris, and Elizabeth Putelo

Engineered Controls International (ECI) makes flow control devices for propane, natural gas and other industrial gases. With over 100 machines on-site, poor layout and weak material flow have slowed production.

To solve this, a senior design team built a better layout using a math model, considering space and machine locations. They also improved material handling by adding a staging area and an Andon light system. As a result, these updates reduce machine downtime, improve workflow and create a setup that can adapt as ECI grows.