Papers by Author: Mohd Nizam Ab. Rahman

Abstract: Stiff competitions, fluctuation in demand and changes in customer preferences have prompted the automotive component manufacturers worldwide to enhance their manufacturing system. Lean Production System (LPS) is a proven method used by many automotive component manufacturers to maintain their competitiveness. Although research on lean implementation has been conducted extensively, there is still a limited number of studies on the LPS implementation from the employees’ point of view. Thus, the main purpose of this study is to investigate the LPS implementation from the employees’ perspectives in an automotive component manufacturer in Malaysia. Both quantitative and qualitative methods were employed in this study. A survey questionnaire was developed from previous literature and distributed to 50 middle and lower level employees. The questionnaire was pilot-tested by the employees and also verified by the industry experts. Structured interviews with 25 employees were conducted to determine their perceptions and problems encountered during the LPS implementation. The result of the study revealed that majority of the employees in this company were only aware of 5S and Kaizen although there are many other LPS tools which are also useful to them. However, the employees agreed that the LPS give many benefits in the workplace. Another finding was Employee Involvement (EI) in the LPS was mostly in the form of sharing responsibility with their co-workers. Problems were due to the lack of knowledge and training in the LPS among the employees. Greater effort should be taken by the company to ensure successful LPS implementation and its sustainability over time.

Abstract: The interests of various economies in improving and expanding the growth of small and medium enterprises (SMEs) have thrived for a few years, particularly in the automotive sector. Although there are several supporting programs, SMEs face a large number of issues in their operation and performance. One of the successful techniques towards achieving collaborative relationships and problem solving in SMEs is through supply chain integration. Many enterprises have realized the benefits of integration among supply chain members. Supply chain management has become an effective strategy for boosting competitiveness. However, there are a few reasons that put off automobile SMEs from completely performing supply chain management. This study combines literature and findings of a questionnaire analysis to urge facts and knowledge regarding the importance of supply chain management and challenges of automotive SMEs in enhancing their collaborative relationships and effectiveness through SCM. In addition, this study observed that top management, work culture and attitudes of staffs and technologies being traded are among the significant impediments to well-integrated relationship between SMEs. Finally, the study concludes that SMEs need to fully adopt SCM to meet potential advantages and control their performance.

Abstract: The influence of a binder system to the rheological behavior of a Metal Injection Molding (MIM) feedstock is presented in the paper. The binder systems used are: a) PEG & PMMA b) Palm stearin & LLDPE and, c) Tapioca starch & LLDPE. The viscosity and shear rate of the feedstocks were measured at various range of temperature and shear rate across the L/D = 10 capillary rheometer. The flow behavior index, n and activation energy, E of each feedstock were measured to show its significance as MIM feedstock. Generally, the result indicates all feedstock exhibits a shear thinning behavior and the binders are suitable as MIM binder. Additionally, the present paper has discovered that the binder system does not have much influence to the activation energy. In order to show the relevance of the rheological behavior to the actual injection molding performance, green parts has been injection molded and the result shows an agreement with the rheological behavior result.

Abstract: Sintering is a key step in the metal injection moulding (MIM) process, which affects the mechanical properties of the sintered part. The mechanical property of the sintered compact is resulted from tremendous sintered part densification. The paper presents an optimisation of the sintering parameter for the best flexure strength of the fine SS316L water atomised powder compact. The L9 (34) orthogonal array is used in the study and four replication of the flexure strength has been recorded at each experiment trial. The analysis of variance (ANOVA) signifies the sintering variables are highly significant to the flexure strength, α = 0.005. The study demonstrates that the cooling rate is the most influential variable that contributes to the best flexure strength, followed by heating rate, dwell time and sintering temperature.

Abstract: This paper analyses the importance of embedding the importance of commercialisation of University’s research in the Engineering education in Malaysia. By conducting courses or program about this commercialization aspects by the engineering faculty, the commercialization process for the university will be sustained in future. The literature so far reviewed shows that engineering education processes have been extensively studied to study the best mechanism and model for engineering education in Malaysia. Aiming to contribute to such literature, we look at the current practice of Engineering Faculties under the Malaysian Research Universities in order to see to what extent aspects of commercialization of university’s research are incorporated in their syllabus. We found that the aspect of the commercialization of university‘s innovation are less exposed to engineering students in Malaysia. This paper suggests that it is vital to incorporate the commercialization of university’s research aspects into the engineering syllabus to develop the culture of entrepreneurship among engineering students which eventually assists the university to commercialize its’research.

Abstract: Although management of organizations are faced with a number of problems which come up during implementing SCM projects, intense competition force them to overcome these difficulties on order to be successful in the fierce global market . In Developing countries, such as Iran and Malaysia, this matter is still considered as a major challenge due to facing several troubles for implementing SCM across their organizations. This paper presented several problems which have occurred when SCM were implemented across Iranian and Malaysian organizations and also suggested a proper framework for cutting down the most important of those difficulties. A survey questionnaire was used to gather the data needed and the review of literature leads authors to propose two frameworks. The survey reveals that both Iranian and Malaysian companies suffer from the “lack of information” as a major difficulty in implementing SCM. Framework A and B were suggested for sharing point of sale (POS) data across the SCM to overcome the lack of information across the chain. The findings of this research would give invaluable information to all managements who investigate for the proper method to conquer the SCM problems.

Abstract: Quality improvements are implemented through various systems, techniques and tools in a company. The implementation of quality initiatives are commonplace in large companies rather than the smaller ones. Small and medium-sized enterprises (SMEs) are usually constrained by their size, expertise and financial resources. Nevertheless, it is important for them to improve their quality of physical work setting and working environment to sustain a competitive advantage. 5S is one of the most widely adopted techniques for industrial housekeeping and, in improving the quality of workplace environment. Since the cost of the development and implementation is one of the main constraints for 5S program at workplace in SMEs, the sustainable design concept shall be adopted. As the main part of the research work, a conceptual model of continuous improvement initiative for quality working environment within small and medium-sized manufacturing companies was developed and proposed. The focus of this research study is on the aspect of how to implement the 5S practices by incorporating sustainable design for improving a quality workplace environment and reducing the environmental impacts through a comprehensive approach. Finally, conclusions are drawn and suggestions made for further research in SME companies.

Abstract: This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the I-Kaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases as the tool wear increases. This method can be used for real time tool wear monitoring.

Abstract: The Grey-Taguchi method was adopted in this study to optimize the injection molding parameters for the MIM green compacts with multiple quality performance. A Grey relational grade obtained from the Grey relational analysis is used as the quality performance in the Taguchi method. Then, the optimum injection molding parameters are determined using the parameter design proposed by the Taguchi method. The result concluded that the mold temperature (D) is very significant, by the fact that the ANOVA shows its contribution to excellent surface appearance as well as strong and dense green compacts is 38.82%.

Abstract: This paper presents the rheological properties of SS316L water atomized MIM feedstock. Coarse and fine SS316L water atomized powder is mixed with a composite binder consisting of PMMA and PEG to form a homogenous paste, termed as feedstock. The feedstock is loaded with SS316L water atomized powder ranging 62 v/o, 62.5 v/o, 63 v/o, 63.5 v/o and 64 v/o. However, due to the morphology of the water atomized powder which is not spherical compared to the gas atomized ones, fine powder feedstock is unable to produce any significant rheological result due to the powder loading being more than 63.5 v/o. Results show that the fine powder feedstock demonstrates a higher viscosity if compared to the coarse powder feedstock. It can be established that binder separations are likely to occur in the coarse powder feedstock, especially, at high temperatures. The investigation concludes that the fine powder feedstock has its best rheological properties at 62 v/o while the coarse powder feedstock lies between 63 v/o and 63.5 v/o.