Case study in six sigma methadology : manufacturing quality improvement and guidence for managers

This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define–measure–analyse–improve–control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities

Surface engineering by titanium particulate injection mounding

In a recent study a structural hold down component was designed and produced using the particulate injection moulding (PIM) process. The material of choice was titanium due not only to the material properties but also due to the desire to create custom made components for a state-of-the-art marine vessel. On removal from the mould the green parts were seen to have an irregular surface on the top face. The irregular surface presented no through part defects and although the surface irregularities were caused by separation of the two-phases the effect was restricted to the outer surface of the parts. In a more historic study by the author the surface properties of titanium dental implants were modified by the use of adaptive mould inserts during the moulding phase of PIM. These two contrasting studies are considered and have become the basis of a current investigation looking to engineer surface irregularities in an ordered fashion. The application of meso-machining, and additive manufacture are considered and the functionality which may arise are presented

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low-cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the mesoscale features, small cross-sections and complex geometries were considered the main problems. For both processing methods, fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed

Education Workforce Initiative: Initial Research

The purpose of this initial research is to offer evidenced possibilities in the key areas of education workforce roles, recruitment, training, deployment and leadership, along with suggested areas for further research to inform innovation in the design and strengthening of the public sector education workforce. The examples described were identified through the process outlined in the methodology section of this report, whilst we recognise that separation of examples from their context is problematic – effective innovations are highly sensitive to context and uncritical transfer of initiatives is rarely successful. The research aims to support the Education Workforce Initiative (EWI) in moving forward with engaging education leaders and other key actors in radical thinking around the design and strengthening of the education workforce to meet the demands of the 21st century. EWI policy recommendations will be drawn from a number of country level workforce reform activities and research activity associated with the production of an Education Workforce Report (EWR). This research has informed the key questions, approach and structure of the EWR as outlined in the Education Workforce Report Proposal. Issues pertaining to teaching and learning in primary and secondary education are at the centre of the research reported here; the focus is on moving towards schools as safe places where all children/ young people are able to engage in meaningful activity. The majority of the evidence shared here relates to teachers and school leaders; evidence on learning support staff, district officials and the wider education workforce is scant. Many of the issues examined are also pertinent to the early childhood care and education sector but these are being examined in depth by the Early Childhood Workforce Initiative. Resourcing for the Education Workforce was out of scope of this initial research but the EC recognises, as outlined in the Learning Generation Report, that provision of additional finance is a critical factor in achieving a sustainable, strong and well-motivated education workforce, particularly but not exclusively, in low and middle income countries. The next stage of EWI work will consider the relative costs of current initiatives and modelling of the cost implications of proposed reforms. EWI aims to complement the work on teacher policy design and teacher career frameworks (including salary structures) being undertaken by other bodies and institutions such as Education International, the International Task Force on Teachers for 2030 and the Teachers’ Alliance, most particularly by bringing a focus on school and district leadership, the role of Education Support Professionals (ESPs) and inter-agency working

Development of innovative cross-disciplinary engineering showcase

The development of engineering education relies substantially on interactive showcases and practical knowledge. The cross-disciplinary engineering showcase is designed to be fully interactive by having user input, producing a tangible output, and to understand distinct elements from each of the engineering disciplines such as, civil, mechanical and electrical (CME). The showcase operates from the input of mechanical rotational energy by the user pedalling the exercycle. Mechanical energy is then transferred to the pump via a gear train, which converts the user input of 30 rpm to the optimal pump operating speed of 2900 rpm. Further, it is used to pump water from the lower eservoir to the upper reservoir via one of the three flow paths, which the user can select by opening or closing flow valves. Once the water reaches a given height, it then flows back to the lower reservoir via a micro-hydro generator. As a result, it generates electrical energy stored in a power bank that can be used by the user to charge a digital device. Also, the showcase has a QR code to digital media, which will provide an additional explanation/exposition of the presented engineering principles to the user/students. The aim of this project is to develop a cross- disciplinary engineering showcase to enhance student learnings by interpreting the CME engineering principles in schools, institutes, and universities

The Effects of Participative Leadership Practices on Job Satisfaction for Highly Skilled Virtual Teams

Virtual-team professionals have reported experiencing low job satisfaction due to lack of face-to-face interaction leading to stress, miscommunication, and role-confusion. Dissatisfaction among virtual teams has increased turnover and management costs for organizations. Despite these known associations, there was a gap in the literature investigating efficient leadership practices to improve job satisfaction for highly skilled virtual teams. Participative leadership offers an effective approach to increase job satisfaction among face-to-face teams and innovative teams. This study explored the relationship between participative leadership and job satisfaction among highly skilled virtual teams within the global software industry. A quantitative study with a correlational design was utilized among 173 participants from the International Association for Software Architects. Participants took a voluntary online survey by responding to an invitation post on the group LinkedIn page. The questionnaire included participative leadership scale (Ismail, Zainuddin, & Ibrahim, 2010), job satisfaction scale (Wall, Cook, & Warr, 1979), and demographic questions. Correlation analysis indicated that there was a positive relationship between participative leadership and job satisfaction, r(172) = .67, p \u3c .001. Regression analysis revealed that job position had a control effect on job satisfaction, F(2, 170) = 89.46, p \u3c .001, R2 = .51. Higher-ranked professionals enjoyed higher job satisfaction when participative leadership was present. Study results are beneficial for global software organizations to streamline leadership practices for highly skilled virtual teams to ensure high levels of job satisfaction. Ensuring high job satisfaction among skilled global talent helps innovative organizations cut costs, increase competitive advantage, and ensure high work quality