An implementation model for digitisation of visual management to develop a smart manufacturing process

Purpose – This paper aims to introduce a model using a digital twin concept in a cold heading manufacturing and develop a digital visual management (VM) system using Lean overall equipment effectiveness (OEE) tool to enhance the process performance and establish Fourth Industrial Revolution (I4.0) platform in small and medium enterprises (SMEs). Design/methodology/approach – This work utilised plan, do, check, act Lean methodology to create a digital twin of each machine in a smart manufacturing facility by taking the Lean tool OEE and digitally transforming it in the context of I4.0. To demonstrate the effectiveness of process digitisation, a case study was carried out at a manufacturing department to provide the data to the model and later validate synergy between Lean and I4.0 platform. Findings – The OEE parameter can be increased by 10% using a proposed digital twin model with the introduction of a Level 0 into VM platform to clearly define the purpose of each data point gathered further replicate in projects across the value stream. Research limitations/implications – The findings suggest that researchers should look beyond conversion of stored data into visualisations and predictive analytics to improve the model connectivity. The development of strong big data analytics capabilities in SMEs can be achieved by shortening the time between data gathering and impact on the model performance. Originality/value – The novelty of this study is the application of OEE Lean tool in the smart manufacturing sector to allow SME organisations to introduce digitalisation on the back of structured and streamlined principles with well-defined end goals to reach the optimal OEE </p

A Systems thinking approach investigating the estimated environmental and economic benefits and limitations of industrial hemp cultivation in Ireland from 2017–2021

 There may be unrecognised environmental and economic benefits in cultivating industrial hemp for CO2 sequestration in Ireland. By using a Systems Thinking approach, this study aims to answer how industrial hemp, which can sequester between 10 tonnes (t) to 22 t of CO2 emissions per hectare, has been helpful towards carbon sequestration efforts in Ireland. A mixed-methods design combining qualitative and quantitative secondary material is used to inform Behaviour over Time Graphs (BoTGs) to illustrate the data from 2017 to 2021. In 2019 at its peak of hemp cultivation in Ireland the total CO2 emissions from agriculture was 21,156.92 kilotonnes, and the total land cultivated with hemp was 547 hectares which represented an estimated 0.0079% of total land use and 0.011% of agricultural land use. Based on a sequestration rate of between 10 t and 22 t of CO2, industrial hemp had the potential to remove between 5470 t and 24,068 t of CO2 in 2019. The total amount of estimated CO2 sequestrated between 2017 and 2021 was between 14,660 t and 64,504 t of CO2. This represents an estimated contribution in carbon tax equivalent of between €348,805 and €1,534,742, respectively. </p

Utilising a hybrid DMAIC/TAM model to optimise annual maintenance shutdown performance in the dairy industry: a case study

Purpose – Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity. Design/methodology/approach – Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season. Findings – Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in e8.9m additional value to the business and a reduction of 36% in the duration of the overhaul. Practical implications – The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls. Originality/value – To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting</p

Developing CDIO practitioners: A systematic approach to standard 10

CDIO (Conceive, Design, Implement, Operate) is a widely used framework designed to educate the next generation of engineers. CDIO adoption is supported and assessed by 12 standards. CDIO Standard 10: Enhancement of Faculty Teaching Competence remains one of the lowest reported standard compliances. The following paper proposes a systematic approach to standard 10 compliance based on the premise that current staffing models across many western universities rely heavily on postgraduate students and that these students typically have no previous formal education related to these teaching responsibilities. Based on the large contribution of these students, and their lack of relevant previous educational professional development opportunities, the development of this cohort is presented as the most logical starting point when working towards standard 10 compliance. However, this poses significant challenges for Engineering faculties that often do not have the expertise required to design such an advanced educational structure. This is compounded by the challenging timetables of postgraduate students who typically must also satisfy credit requirements in the early stages of their postgraduate studies. In order to meet these challenges a systematic approach to evidence-based pedagogical strategy selection is presented in the context of a model that adapts to context and settings which vary greatly across various STEM education environments. In addition, the overall outcome of this system would see the development of a professional development structure that could be linked to credits and by extension be formally adopted into a postgraduate student’s program of study. This formalization would increase legitimacy, provide a recognized professional opportunity and as a consequence would be net neutral for postgraduate students workloa

A Proposed VR Platform for Supporting Blended Learning Post COVID-19

The COVID-19 pandemic caused a shift in teaching practice towards blended learning for many higher education institutions. This led to the rapid adoption of certain digital technologies within existing teaching structures as a means to meet student access needs. This paper is an attempt to summarise and extend pre-COVID-19 pedagogical research to leverage digital immersive technologies for blended teaching in the post-pandemic era. This paper forms both a review of these methodologies and a case study of the I-Ulysses Virtual Learning Environment as an example of a platform that leverages such immersive digital technologies and employs instrumental use of VR. To further clarify, the purpose of the paper is to describe and propose a distance learning solution with immersive VR qualities; this is what the I-Ulysses environment represents, as the main obstacle to learners of site-specific information during the pandemic has been lack of on-site accessibility. Furthermore, this is of key importance, because Joyce’s novel takes place in historical Dublin, where access to the physical location of the story is indispensable to a reader </p

Highly selective trace ammonium removal from dairy wastewater streams by aluminosilicate materials

Water is a key solvent, fundamental to supporting life on earth. It is equally important in many industrial processes, particularly within agricultural and pharmaceutical industries, which are major drivers of the global economy. The results of water contamination by common activity in these industries is well known and EU Water Quality Directives and Associated Regulations mandate that NH4+ concentrations in effluent streams should not exceed 0.3 mg L−1, this has put immense pressure on organisations and individuals operating in these industries. As the environmental and financial costs associated with water purification begin to mount, there is a great need for novel processes and materials (particularly renewable) to transform the industry. Current solutions have evolved from combating toxic sludge to the use of membrane technology, but it is well known that the production of these membrane technologies creates a large environmental footprint. Zeolites could provide an answer; their pore size and chemistry enable efficient removal of aqueous based cations via simple ion exchange processes. Herein, we demonstrate efficient removal of NH4+ via both static and dynamic methodology for industrial application. Molecular modelling was used to determine the cation–framework interactions which will enable customisation and design of superior sorbents for NH4+ capture in wastewater