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Item A hybrid structural interaction matrix approach to prioritise process wastes generated in a manufacturing organisation(Springer, 2022-10-05) Makinde, Olasumbo; Munyai, Thomas; Nesamvuni, EdgarThe productivity of a manufacturing organisation is limited by myriads of process wastes generated in this organisation. In light of this, the aim of this study is to prioritise various process wastes generated in a manufacturing organisation. In order to achieve this, on the one hand, a Hybrid Structural Interaction Matrix (HSIM), which is premised on the theory of subordination via systems thinking was deployed to carry out the process wastes pairwise ranking and weighting analysis. On the other hand, the Pareto Chart, was thereafter deployed to ascertain the vital few process wastes contributing to productivity loss experienced in a manufacturing organisation. A case study of the process wastes generated in an Electronic-Product Manufacturing organisation was used to validate the process wastes prioritisation model developed in this study. The result of the HSIM prioritisation analysis revealed that the intensity rating scores of the process wastes; overproduction, excess inventory, defect, motion, transport, waiting and over-processing limiting the productivity of an organisation are 7.53, 4.59, 6.06, 1.65, 3.12, 0.18 and 9 respectively. The result of the validation exercise revealed that transport, excess inventory and defects are the core process wastes that limit the productivity of an Electronic-Product Manufacturing organisation considered in this study. With this approach, operations managers of a manufacturing organisation would obviously reduce errors in the rating of process wastes, which is vital towards achieving continuous productivity improvement and sustainable manufacturing.Item Immersive virtualwork integrated learning: A development of an interactive learning environment for rail components manufacturing.(Springer, 2022-10-05) Dlamini, Nokulunga Zamahlubi; Mpofu, Khumbulani; Ramatsetse, Boitumelo; Makinde, OlusamboUndergraduate students pursuing their studies in the engineering discipline in higher education institutions (HEI) are expected to complete their work integrated learning (WIL) component as part of their curriculum. This is a compulsory module traditionally performed in the workplace environment over a specified time. However, with the scarcity of placement-based WIL, as well as the Covid-19 pandemic, there has been a reduction in the intake of students to accomplish their studies. This paper presents, a human centered design (HCD) model for developing an immersive virtual reality (IVR) rendered with an HTC Vive Pro head mounted display (HMDs) platform capable of training industrial engineering undergraduate students on the manufacturing procedure of rail components using a reconfigurable guillotine shear and bending press machine (RGS&BPM) as part of the set of immersive virtual work integrated learning (IVWIL) activities. The study explores current literature and the HCD approach to designing and developing the immersive interactive training platform. It highlights the important aspects of the development of the immersive virtual environment and recommends future work.Item Modelling and simulation of pump impeller produced using fused deposition modelling.(Springer, 2022-10-05) Muvunzi, Rumbidzai; Daniyan, Ilesanmi; Fameso, Festus; Mpofu, KhumbulaniAdditive Manufacturing (AM) is a key Fourth Industrial Revolution (4IR) technology in which parts are manufactured directly from 3-dimensional models through selective deposition of materials. As a digital technology, AM can be used to produce complex parts that are difficult to make using traditional methods without the need for tooling. Hence, the aim of this study is to investigate the performance of Fused Deposition Modelling (FDM) in the manufacture of pump impellers. This involves performing simulation to test the performance of pump impeller under real-life working conditions at different operating speeds and pressures. The model of the impeller as casted in the FDM process was developed in the complete Abaqus modelling environment. The model part was created as single solid homogenous part with no nodal separations or assembly ties or constraints between the base of the impeller and its blades, in relation to its as-cast manufacturing state. The results obtained showed that extreme operating speeds of up to 1000 rad/s or pressures of 0.22 MPa are not suitable conditions under which the impeller will operate without compromising its efficiency and structural integrity. The study is useful in providing guidance on the application of FDM to produce functional parts. Through the study, the capability of AM as a suitable approach for enabling local sustainable production of spare parts is demonstrated.Item A hybrid structural interaction matrix approach to prioritise processWastes generated in a manufacturing organisation.(Springer, 2022-10-05) Makinde, Olasumbo; Munyai, Thomas; Nesamvuni, EdgarThe productivity of a manufacturing organisation is limited by myriads of process wastes generated in this organisation. In light of this, the aim of this study is to prioritise various process wastes generated in a manufacturing organisation. In order to achieve this, on the one hand, a Hybrid Structural Interaction Matrix (HSIM), which is premised on the theory of subordination via systems thinking was deployed to carry out the process wastes pairwise ranking and weighting analysis. On the other hand, the Pareto Chart, was thereafter deployed to ascertain the vital few process wastes contributing to productivity loss experienced in a manufacturing organisation. A case study of the process wastes generated in an Electronic-Product Manufacturing organisation was used to validate the process wastes prioritisation model developed in this study. The result of the HSIM prioritisation analysis revealed that the intensity rating scores of the process wastes; overproduction, excess inventory, defect, motion, transport, waiting and over-processing limiting the productivity of an organisation are 7.53, 4.59, 6.06, 1.65, 3.12, 0.18 and 9 respectively. The result of the validation exercise revealed that transport, excess inventory and defects are the core process wastes that limit the productivity of an Electronic-Product Manufacturing organisation considered in this study. With this approach, operations managers of a manufacturing organisation would obviously reduce errors in the rating of process wastes, which is vital towards achieving continuous productivity improvement and sustainable manufacturing.Item Establishment of an appropriate data analytic platform for developing a wisdom manufacturing system using decision techniques(Springer, 2022-10-05) Zeferino, Emanuel Fernando; Mpofu, Khumbulani; Makinde, Olasumbo; Ramatsetse, BoitumeloIn today’s global business context, data has played a critical role in ensuring accurate and appropriate decision making in manufacturing organisations. Despite the huge pool of information (i.e. data) generated by consumers, repair or maintenance shops, manufacturing job shop, scientific society on various products, which could be deployed by manufacturers in eliciting vital information towards achieving sustainable product design and development, only few manufacturers are making use of this data to generate wisdom required for sustainable manufacturing. This act is caused by lack of appropriate systems capable of integrating the available data and make wise inferences that will result in a competitive advantage of a specific organisation over its competitors. In light of this, the aim of this study is to establish a suitable data analytic platform that could be used to sort, classify and integrate data required to generate wisdom vital for sustainable manufacturing. In order to achieve this, Analytical Hierarchy Process (AHP) was deployed to appraise various alternative data analytical platforms such as Python, Apache Spark, QlikView, Power BI, Tableau, KNIME, Excel, Talend, RapidMiner and Statistical Analysis System (SAS) using various criteria such as Data Format, Availability, Interface, Programming Intensity, Data Science Knowledge Intensity and Capabilities. The result of this decision analysis and selection exercise, revealed that KNIME data analytic platform, with the most important decision criterion; data science knowledge intensity, and a cumulative assessment score of 80.80 is the appropriate data analytic platform that manufacturers should use to generate a knowledge advisor vital for sustainable manufacturing and product development.Item Smart manufacturing systems for small medium enterprises: A conceptual data collection architecture.(Springer, 2022-10-05) Kanakana-Katumba, M.G.; Maladzi, R.W.; Oyesola, M.O.Smart manufacturing is the future of sustainable manufacturing entities with the emergence of innovative technologies readily available to foster industrial production. It becomes imperative for Small Medium-sized Enterprises (SMEs) to adopt the initiatives of the fourth industrial revolution termed Industry 4.0, to improve productivity and efficiency. SMEs are vital for the economic growth and social transformation of any nation, as such incorporating emerging technologies would generate more revenue and support sustainability. One of the major challenges facing the SMEs in a competitive and dynamic manufacturing environment is adapting the technique and implementation of smart enabled systems. The current manufacturing data information architecture for smart manufacturing is premeditated for big organisations with funding and skills to implement such systems, however SMEs struggles to cope with such advancement. This paper aims to propose a concept-based data collection architecture to aid SME using the systems of smart manufacturing for internetwork communication, prediction and analysis. This study proposes a conceptual data architecture framework, which SMEs can utilise for data collection and integrate into any type of small-scale industrial production settings to enable effective decision-making. The successful demonstration of the concept is to gear manufacturing SMEs towards smart systems with no-need for high-level implementation techniques.Item A model to balance production workload distribution in a trailer manufacturing organisation under fluctuating customer ordering condition.(Springer, 2022-10-05) Van der Walt, Gerhard; Makinde, Olasumbo; Mpofu, KhumbulaniTrailer manufacturing organisation considered in this study is currently experiencing a high volume of backlog orders due to its poor balancing of production workload distribution during capacity planning and scheduling. This issue has resulted in loss of sales orders experienced by the trailer manufacturing organisation. In light of this, this research study developed a model that could be used to balance production workload distribution that could be used to timeously meet varying customer orders as well as drastically minimise the backlog cost experienced in a trailer manufacturing organisation. To achieve this, on the one hand, a system model of the current production workload distribution used at this trailer manufacturing organisation was developed using AnyLogic software and parametrized using the manufacturing system operation operating conditions obtained via system observation for a period of three (3) months, in order to identify the bottleneck stations and inefficiencies present within this organisation. On the other hand, design of experiments, equipped with feasible workload control strategies were conducted on the model. The result of the simulated model revealed that the usage of an additional two bending machines and two primer paint workers, usage of additional three laser machines and three treatment workers, Heijunka order dispatching principle and Constant Work-In-Process (ConWIP) will increase the service level and mean machine capacity utilisation of the organisation, as well as reduce the backlog cost, opportunity cost and average order lead time.Item Africa industry 5.0: Challenges and opportunities in the future of manufacturing(Elsevier B.V., 2023-03-01) Matenga, Alice Elizabeth; Mpofu, KhumbulaniCloud manufacturing (CM) is a service-oriented business model which is being adopted for industry 4.0 (i4.0). African-based small-to-medium manufacturing enterprises (SMMEs) are yet to adopt the collaborative business manufacturing model, due to challenges associated with vagueness to new manufacturing technologies adoption. However, technological advancements have led to industry 5.0 (i5.0), which present multiple favorable opportunities for manufacturing organizations in Africa. Technology adoption was identified as a key accelerator towards sustainable manufacturing and successful implementation of sustainable development goals (SDGs). This paper aims to conscientise on the future of the manufacturing industry for an African digital economy. Adoption of new manufacturing technologies is disrupting traditional business models and creating new business models which are collaborative, and technology centered. A system of systems methodology was used to address multiple challenges affecting advancing technologies in the transport manufacturing industry in Africa. The result is a strategic system mapping for developing a cognitive manufacturing system for the transport manufacturing system.Item Multi-physical modelling and simulation of a planar translational scissor lift mechanism for maintenance of rail transmission lines.(Elsevier B.V., 2023-09-01) Ogbemhe, John; Ramatsetse, Boitumelo; Mpofu, Khumbulani; George, Oluwafemi Ayodeleassociated equipment. Nevertheless, the preservation of train power transmission lines presents noteworthy hazards as a result of the amalgamation of electrical perils and maintenance-associated risks. This study aims to present the design and simulation of a planar translational scissor lift mechanism. The objective is to assist maintenance personnel in the rail sector specifically during power transmission line maintenance. The scissor-lifting mechanism was modelled in Solid Works, a software programme known for its comprehensive 3-D modelling capabilities. Additionally, a mathematical model was constructed to analyse the behaviour of the scissor lift. The dynamic response of the system was investigated through the utilisation of MATLAB/Simulink to conduct kinematic and kinetic simulations. The research findings unveiled the comparative kinetic correlation between the hydraulic cylinder and other constituent elements, effectively capturing their dynamic behaviours throughout the operational process. In addition, the utilisation of Simscape facilitated the optimisation of the mechanism's design through simulation analysis, thereby offering valuable insights to inform and improve subsequent design iterations. The experimental findings indicate that the system design effectively raised the maintenance platform to a height of 2 metres in a time of 20 seconds while accommodating a load range of 500 to 1000 kg. The study presents a systematic and logical design approach that establishes a scientific foundation for the mechanism. This positions it as a valuable theoretical reference for future advancements in scissor lift development. The results of this study make a valuable contribution towards enhancing safety and efficiency in rail maintenance operations. Additionally, they help in reducing the risks associated with power transmission line servicing. Furthermore, these findings lay the foundation for future advancements in railway maintenance technology.