Ahad Ali, Ph.D.

Associate Professor 

Director, Bachelor of Science in Industrial Engineering (BSIE)

Director, Master of Science in Industrial Engineering (MSIE)
Director, Smart Manufacturing and Lean Systems Research Group

A. Leon Linton Department of Mechanical Engineering

Lawrence Technological University

21000 West Ten Mile Road

Southfield, MI 48075

Phone: 248-204-2531, Fax: 248-204-2576, Room-E37

Email: aali@ltu.edu 

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Smart Manufacturing and Lean Systems Research Group


Product Lifecycle Management (PLM) Workshop - October 7, 2015 at LTU Science Auditorium

Lean and Six Sigma Workshop at LTU, March 26, 2014.

Received an industry project on warehouse operations improvement.

Received $40 Million in-kind Software Grant on Production Lifecycle Management (PLM), Siemens Software, Award Date – July 10, 2013, $40,191,520.

Edge CAM in-kind software grant, Tooling Software Technology (TST), LLC, September 2013, $752,453.

Received KEEN Topical Grant of the Project on Sustainability Module Development in Product Design with collaboration with Gonzaga University, Ohio Northern University and Saint Louis University, Kern Family Foundation, September 2013 – August 2014, $47,000 as PI.

Received a Contract for the Project on Die Prep Time Reduction of Stamping Operations, New Center Stamping Inc., 2013 - 2014, $11,000 as PI.

Received a Contract for the Project on Energy Optimization Study Boiler Controller, DTE Energy, Jan 2010 – March 2011, $ 28,130.

Outstanding Leadership Award, Saudi National Day by Saudi Union at Michigan, Kalamazoo, MI, October 5, 2013

On the Picture: Dr. Mohammed Alessia, Saudi Arabia Cultural Attache'

GD&T Tolerance Stack-up Workshop on September 25, 2013 


GD&T Workshop at Lawrence Technological University of March 27, 2013 (250 people from 75 companies and organizations in attendance).



Symposium on Smart Manufacturing and Lean Systems and pre-symposium workshop on FMEA, June 5, 2013 at LTU, Southfield, Michigan.


Conference Chair: International Conference on Industrial Engineering and Operations Management (IEOM), Hyatt Regency Dubai, March 3-5, 2015.

Academic Chair: IIE Engineering Lean and Six Sigma Conference, Atlanta, USA, September 12-14, 2011.

LSS11 LSS11b

Majid Abab (Conference Industry Chair from Boeing), Ahad Ali (Conference Academic Chair) and Doug Long (Director of Strategic Alliances, IIE) before the start of the day's first keynote speaker at the IIE Engineering Lean Six Sigma Conference on Sept. 14, 2011 in Atlanta.



Chair: IIE Lean Student Technical Paper Competition sponsored by J T. and Carol S. Black, 2007, 2008, 2009, 2010, 2011, 2012, 2013


Pictured above are the award winners and representatives: Dr. Ahad Ali (Chair of the IIE Lean Student Paper Competition 2011), Rohan Sakhardanede, Dr. J T. Black (Sponsor),  Dr. Bernardo Villarreal Celestino (faculty advisor of first place winner), Carolina Guerra, Fabiola Garza, Nancy Lopez, Daniela B. Jasso Zuniga, Fernando de Jesus Martínez, Marco A. González, María Patricia Martinez and their advisor Rosa

Pictured above are the first place winning team, their faculty advisor, competition sponsor and competition chair at the IIE Annual Conference in Reno, Nevada, May 21-25, 2011 : Fabiola Garza, Dr. Ahad Ali (Chair of the IIE Lean Student Paper Competition 2011), Dr. J T. Black (Sponsor of the Competition), Carolina Guerra,  Nancy Lopez,  and Dr. Bernardo Villarreal Celestino (Faculty Advisor)



Courses Taught

EME 7303 Design for Relaibility
EME 7202 Manufacturing Systems Simulation
EME 6743 Value Engineering
EME 6673 Six Sigma Processes
EME 6663 Applied Stochastic Processes
EME 6653 Advanced Optimization Techniques

EME 6583 Enterprise Productivity 

EME 6403 Quality Control
EME 5603 Engineering Systems Simualtion
EME 3023 Manufacturing Processes
EME 2012 Mechanical Engineering Graphics

Master of Science in Industrial Engineering (MSIE) Program, apply online    ONLINE OPTION AVAILABLE

Doctor of Engineering in Manufacturing Systems (DEMS) at Lawrence Tech

CATIA V5 Fundamentals Training Certificate Course

Dual master's degree in industrial engineering & engineering management with quality, supply chain and healthcare focus areas at LTU: http://ltu.edu/engineering/ieem_dual.asp


Selected Publications 


    A. Pandian and A. Ali, Automotive Assembly Line Throughput Forecasting using ANN Modeling, Accepted for the Journal of Industrial and Systems Engineering, 2014.

  2. Ertunga C. Ozelkan, M. D. Sarder and Ahad Ali, Back to Fundamentals for a Successful Lean Six Sigma Enterprise Transformation: An Introduction to Jet Special Issue on Case Studies in Lean Enterprise Transformation, Journal of Enterprise Transformation, 4:1–4, 2014. DOI: 10.1080/19488289.2014.899837.

    Ozelkana, C., A. Ali, and M. D. Sarder, Lean Enterprise Transformation is a Business Necessity for Sustainable Growth, Journal of Enterprise Transformation, vol. 3,  no. 3, pp. 133-135, 2013.

    D. Johnson and A. Ali, Modeling and Simulation of Landmine and Improvised Explosive Device Detection with Multiple Loops, Journal of Defense Modeling and Simulation, in-press.

    A. Pandian and A. Ali, Performance measurement of an Automotive BIW robotic assembly: ARMA modeling, Measuring Business Excellence, Vol. 17, No. 1, pp.3 – 21, 2013.

    D. Shetty, L. Manzione, and A. Ali, Survey of Mechatronic Techniques in Modern Machine Design, Journal of Robotics, vol. 2012, article ID 932305, 9 pages, doi:10.1155/2012/932305. 

  3. T. Pandit and A. Ali, Simulation and reliability analysis of laser-welded blanks after metal surface finishing process, International Journal of Manufacturing, Materials, and Mechanical Engineering, vol. 2, no. 4, pp. 1-11, 2012. 

  4. A. Ali, Simulation Intelligence and Modeling for Manufacturing System Uncertainties, International Journal of Modeling, Simulation and Scientific Computing, vol. 3, no. 3, 1250013 (22 pages), 2012.

  5. S. Krstovski and A. Ali, Productivity Improvement in Subsystem of Assembly Process Utilizing Simulation, International Journal of Modeling in Operations Management, vol. 2, no. 3, pp. 227–241 , 2012.

  6.  M. Gojcaj, and A. Ali, Design, Simulation and Improvement of the End-of-Line Conveyor System for Car Rear Seatbacks Manufacturing, International Journal of Human Factors Modelling and Simulation, vol. 2, no. 3, pp. 222-235, 2011.

  7. V. Cook, and A. Ali, End-of-line inspection for annoying noises in automobiles: trends and perspectives, Applied Acoustic, vol. 73, no. 3, pp. 265-275, 2012.

  8. A. Ali, N. Santini, and M. A. Rahman, Kanban Supplier System as a Standardization Method and WIP Reduction, Special Issue of the International Journal of Industrial and Systems Engineering, vol. 11, Nos. 1/2, pp.179 - 188. 2012.

  9.  E. Hossain, M. R. Khan, and Ahad Ali, Design and Data Analysis for a Walking Support System for Visually Impaired People, International Journal of Advanced Mechatronic Systems, vol. 3, no. 5/6  pp. 384 - 397, 2011.

  10. Q.K. Hassan, K.M. Rahman, A.S. Haque, and A. Ali, Solar energy modelling over a residential community in the City of Calgary, Alberta, Canada. International Journal of Photoenergy, vol. 2011, Article ID 216519, 8 pages, 2011. Link 

  11. K. Altayib and A. Ali, Improvement for Alignment Process of Automotive Assembly Plant Using Simulation and Design of Experiments, International Journal of Experimental Design and Process Optimisation, vol. 2, No.2  pp. 145 - 160, 2011.

  12. D. Shetty, A. Ali, and J. Hill, Instrumentation for Vibration Measurement and Monitoring, International Journal of Precision Engineering and Manufacturing, vol. 12, no. 3, pp. 405-411, 2011.

  13. J. Blake, and A. Ali, Simulation analysis and performance improvement of engine assembly line, International Journal of Process Systems Engineering, vol. 1, nos. 3/4, pp.288-301, 2011.

  14. Q. K. Hassan, A. Ali, N. Sekhon, and X. Wang, Analysis of Potential Wind and Solar Energy at Selected Airport Locations in Canada, International Journal of Industrial and Systems Engineering, vol. 9, no.2  pp. 150 – 162, 2011.

  15. E. Hossain, R. Khan, R. Muhida and A. Ali, State of the Art Review on Walking Support System for Visually Impaired People, International Journal of Biomechatronics and Biomedical Robotics, vol. 1, no. 4, pp. 232–251, 2011.

  16. E. Hossain, R. Khan, R. Muhida, and A. Ali, Analysis and Implementation for a Walking Support System for Visually Impaired People, International Journal of Intelligent Mechatronics and Robotics, vol. 1, no. 3, pp. 46-62, 2011.

  17. A. Pandian and A. Ali, Automotive Robotic Body Shop Simulation for Performance Improvement using Plant Feedback, International Journal of Industrial and Systems Engineering, vol. 7, no. 3, pp. 269-291, 2011.  

  18. J. Polubinski, and Ahad Ali, Simulation Analysis of Commercial Truck Spiral Bevel Gear Process, International Journal of Modeling and Operations Management, vol. 1, no. 2, pp. 197 - 207, 2010.

  19. A. Ali, H. Seifoddini, and J. Lee, Efficient Material Allocation in High-Mix Low-Volume Manufacturing, Journal of Advanced Manufacturing Systems, vol. 9, no. 2, pp. 101-116, 2010.

  20. W. Moir, and Ahad Ali, Conveyor Stop for Quality Simulation Analysis, Journal of Modelling and Simulation of Systems, vol. 1, No. 4, 197-203, 2010. Link

  21. A. Pandian and A. Ali, A Review of Recent Trends in Machine Diagnosis and Prognosis Algorithms, International Journal of Computer Information Systems and Industrial Management Applications, vol. 2, pp. 321-329, 2010. Link

  22. D. Shetty, A. Ali, and R. Cummings, A Model to Assess Lean Thinking Manufacturing Initiatives, International Journal of Lean Six Sigma, vol. 1, No. 4, pp. 310-334, 2010.

  23. V. Cook, and A. Ali, Using net present value methods to evaluate quality improvement projects, International Journal of Quality and Reliability Management, vol. 27, no. 3,  pp. 333-350,.2010.

  24. D. Shetty, and A. Ali, A Model for the Total Productive Manufacturing Assessment and Implementation, Journal of Advanced Manufacturing Systems, vol.8, no. 2, pp. 117-136, 2009.

  25. M. Khadem, A. Ali and H. Seifoddini, Efficacy of Lean Metrics in Evaluating the Performance of Manufacturing System, International Journal of Industrial Engineering - Theory, Applications and Practice, vol. 15, no. 2, pp. 176-184, 2008.

  26. A. Ali, Z. Chen and J. Lee, Web-enabled platform for distributed and dynamic decision making systems, International Journal of Advanced Manufacturing Technology, vol. 38, no. 11, pp. 1260-1270, 2007.


Professional Activities

Doctoral Students

Name Dissertation Title
Saso Krstovski Heuristic and Simulation based Optimal Dispatching Rules for Gantry Systems in Automotive Applications
Mukdam Kena Door Forming Optimization for Reliability and Cost
Khaled Altayib Meta-Modeling and Heuristic Algorithms for Alignment Process of Automotive Assembly Plant

Doctoral Students



Gary T. Kraus Jr.

Dissertation Title: Paint Bank Sequence Optimization on Assembly in an Automotive Manufacturing Plant

Sponsor Company: Chrysler

Fall 2009


Program Manager
Light Tactical Vehicles at Navistar Defense
Detroit, MI

Valerie Cook

Dissertation Title: End-of-Line Inspection for Annoying Noises in Automobiles: A Methodology Using Spherical Beamforming

Sponsored Company: Chrysler

Spring 2010

Assistant Professor

Mechanical Engineering Technology 

School of Engineering 

Penn State - Behrend 

Erie, PA 16563

Annamalai Pandian
Dissertation Title: Robotic Manufacturing System Failure Prediction Methodology Development of an Automotive Assembly
Fall 2010
Assistant Professor
Engineering and Technology Department   
College of Science, Technology, Engineering and Mathematics
University of Wisconsin – Stout
Menomonie, WI 54751
Joe Ogundu
Dissertation Title: Developing the Direct Relationships and Effects of Waste Reduction/Elimination and Operating Performance Measures
Fall 2011


Engineering Services & Technical Group, Inc.

 Southfield, MI

Adjunct Professor, Oakland University

Dan Tesolin
Optimization of a Multi-Station, Parallel Machines Robotic Production Cell in  Automotive Interior Trim Cover Manufacturing
Fall 2011
Technical Cost Reduction Manager,
Chrysler Technical Center
Auburn Hills, MI
Edmund Ijumba
Dissertation Title: Metamodeling and Multi Axis Loss Function for Returnable Containers in an Automotive Parts Closed Loop Supply Chain System
Spring 2012
Sr. Staff Packaging Engineer - Green Belt
Armstrong Building Products – Technology
Lancaster, PA 17604




Ph.D. in Industrial Engineering, 2003

University of Wisconsin-Milwaukee

MS in Systems and Engineering Management, 2000

Nanyang Technology University, Singapore

BS in Mechanical Engineering, 1994

Khulna University of Engineering and Technology (KUET), Bangladesh


q BasicMOST Certification: H.B. Maynard & Company, Inc.

Research Interests

Manufacturing Systems

Modeling, Simulation, Optimization and Integration


Decision Support Systems

Supply Chain Management and Logistics

Lean Manufacturing

Energy Optimization, Biomass and Renewable Energy

Healthcare Systems


Scholarships and Awards

Outstanding Professor of the Year, Department of Industrial Engineering, University of Puerto Rico-Mayaguez, 2005-2006.

Chancellor Award, University of Wisconsin-Milwaukee: 2003 - 2004

Chancellor Award, University of Wisconsin-Milwaukee: 2002 - 2003

Graduate School Conference Travel Award, University of Wisconsin-Milwaukee: May 2002

Conference Travel Award (Australia), Lee Foundation, Singapore: December 1999

Research Scholarship, Nanyang Technological University, Singapore: 1997-2000

Government Merit Scholarship, Bangladesh Institute of Technology (BIT), Khulna: 1990-94

Junior School Merit Scholarship: 1985 - 1987