Effective data collection and analysis for efficient implement of Standardized Work (SW) / Ahmed Jaffar, Nurul Hayati Abdul Halim and Noriah Yusoff

This research paper presents an implementation of one of the Lean Manufacturing (LM) tools, known as Standardized Work (SW), at an automotive assembly line in Malaysia. The main functions of SW are to design, develop, document and visualize a set of manufacturing process with detail and proper study on it. SW is conducted to raise production efficiency and quality. Quality here referred to quality of the products to be produced and quality of the jobs to be performed. With the main objective to demonstrate a systematic and organized guideline on how data collection and analysis should be conducted with detail explanation on tools and methods used for efficient implementation of SW, a case study was conducted at an automotive components assembly line, at XYZ Manufacturing Sendirian Berhad. There are five major phases involved in the implementation of this research work; (i) observation, to understand the existing study area conditions, (ii) data collection through observation, referring to company’s production system and work study method, (iii) data analysis using SW tools, (iv) development of standardized process, and (v) results evaluation by using lean metrics to analyze the performance of the standardized assembly process. results show that, with systematic and proper implementation, SW offer a lots of benefits such as help to increase efficiency and quality and process stability in terms of productivity, quality and operator’s performance. Moreover, it also helps to achieve LM philosophies which are wastes elimination and continuous improvement during the implementation

Implementation of Just in Time Production through Kanban System

Uncertainties brought about by fluctuations in demand and customers’ requirements have led many established companies to improve their manufacturing process by adopting the Kanban system. By doing so, they are able to manufacture and supply the right product, in the right quantity, at the right place and time. Implementation of the Kanban system resulted in reduction of inventory to minimum levels besides increasing flexibility of manufacturing. Successful implementation of the Kanban system furthermore reduces operational costs, consequently increases market competitiveness. The Kanban system is basically an inventory stock control system that triggers production signals for product based on actual customers’ requirements and demand. The system is controlled by the Kanban card which dictates the optimum production parameters. It is used to authorize production of any product to replenish those already consumed by the customer or subsequent process. This study covers pre-requisite activities in establishing a Kanban system, starting from designing Kanban flow, gathering manufacturing data, calculating optimum Kanbans in the systems, establishing pull mechanism and rule and finally evaluating Kanban performance using lean parameter. This paper studied the implementation of the Kanban system at a local auto-component company in Malaysia. The scope of implementation was focused at BLM Cylinder Head Cover assembly process. This paper concludes that implementation of the Kanban system reduced lead time, minimized inventory on floor and optimized storage area. The objective of this study is to show that Kanban system improves a manufacturing system as well as achieving Just In Time practice. Keywords: Just In Time, Kanban system, Manufacturing lead time reductio

Mesh independence study on CFD for Cryo-CO2 cooling strategy

This study conducts comprehensive mesh independence tests to identify the optimum mesh independence parameters that offer the most feasible Computational Fluid Dynamic (CFD) analysis on cryo-CO2 temperature variations and its heat transfer performance under cryo-CO2 cooling strategy in metal cutting. ANSYS Fluent was used to conduct the CFD study with its mesh control parameters (relevance center and smoothing) designed using Response Surface Methodology (RSM) under Central Composite Design (CCD). An Analysis of Variance (ANOVA) was applied to analyse how the controlled factors influenced the cryo-CO2 flow temperature when it flowed from the nozzle to the tooltip. The analysis found that the relevance centre was more significant in influencing the accuracy of the response value. For optimization, the combination of medium relevance center and smoothing meshes was suggested to develop the lowest cryo-CO2 flow temperature at 256.85 K. This is crucial since most machining outputs are heat dependent. Experimental data sets were used to validate the predicted result. Distances between 3.6 to 18 mm showed an acceptable deviation of ~0.4 – 0.6% and ~0.4 – 4.2% for simulated and experimented work, respectively. This value is acceptable, and the generated quadratic model equation can be applied for prediction. The heat transfer performance of the cryo-CO2 flow at tool-chip and tool-workpiece interfaces under high-speed machining was also discussed. Moreover, further analysis using the optimal solution has led to a better understanding of heat transfer in cryogenic carbon dioxide (CO2), resulting in enhanced cooling of the cutting zone and improved machining processes

Performance of Coated Carbide Tools when Turning Inconel Alloy 718 under Cryogenic Condition using RSM / N. Badroush ...[et al.]

This paper investigates the influence of cutting parameters on different responses variables and the performance of PVD coated carbide cutting tool when turning Inconel 718 under cryogenic condition. The factors and range of parameters investigated are; cutting speed (90-150 m/min), feed rate (0.05-0.2mm/rev) and depth of cut (0.25-0.75mm). The experimental runs were established using Box-Behnken design experiment. For the responses, 2 variables were evaluated which are surface roughness (Ra) of the machined surface and tool life (TL) of the insert. Analysis of Variance (ANOVA) was used to identify factors which significantly affect the response variables. From the analysis, the cutting speed and feed rate are the most significant factors affecting the TL followed by the depth of cut. While for the Ra, the interaction of feed rate and depth of cut are the most significant, followed by the depth of cut. The prediction Ra and TL models were developed with 95% of prediction interval between the predicted and actual experiments using the optimal parameters

Prediction of cutting force for milling of inconel 718 under cryogenic condition by response surface methodology / Nurul Hayati Abdul Halim...[et al.]

In order to identify the influence of different cutting parameters on cutting force under cryogenic cooling assistance, this paper presents an experimental investigation on the influence by high-speed milling Inconel 718 using carbide coated ball nose milling inserts. For Design of Experiment (DOE), Box-Behnken Response Surface Methodology (RSM) with 29 experiments was applied to accommodate 4 factors; cutting speed: 120-140 m/min, feed rate: 0.15-0.25 mm/tooth, axial depth of cut: 0.3-0.7 mm, and radial depth of cut: 0.2-0.6 mm at three levels each. The milling process was performed under a CO2 cryogenic environment using a new design of cryogenic controlling system for consistent and efficient cooling effect at the cutting zone. The experimental results found the forces varied from as low as 112 N up to a maximum of 452 N. The analysis of variance (ANOVA) confirmed the axial depth of cut as the dominant factor influencing the cutting forces followed by the interaction between feed rate and radial depth of cut. The forces were significantly increased with the axial depth of cut due to the increase of the size of cut by the insert. Meanwhile, the developed statistical equation model reported an average error of 4.72% between the predicted and actual cutting forces. With 95.28% of confidence level, this confirms the adequacy of the predictive model to be used within the range of the investigated parameters. Thereby, the numerical optimization suggested parameters of Vc: 140 m/min, fz: 0.25 mm/tooth, ap: 0.3 mm, and ae: 0.21 mm to be applied to achieve a cutting force as low as 117.72 N. The correlation between the cutting forces along with tool wear progress and pattern was also discussed

Abstracts of the International Halal Science Conference 2023

This book presents the extended abstracts of the selected contributions to the International Halal Science Conference, held on 22-23 August 2023 by the International Institute for Halal Research and Training (INHART), IIUM, Malaysia in collaboration with Halalan Thayyiban Research Centre, University Islam Sultan Sharif (UNISSA), Brunei Darussalam. With the increasing global interest in halal products and services, this conference is timely. Conference Title:  International Halal Science ConferenceConference Acronym: IHASC23Conference Theme: Halal Industry Sustainability Through ScienceConference Date: 22-23 August 2023Conference Venue: International Islamic University (IIUM), MalaysiaConference Organizer: International Institute for Halal Research and Training (INHART), International Islamic University (IIUM), Malaysi