Applied Mechanics and Materials Vol. 899

Abstract: A type of porous resin was proposed to replace the existing plaster mould for Ceramic Slip Rotary Moulding (CSRM) system. The proposed resin is often used in high pressure casting of ceramic sanitary ware and table ware. The effect of resin mould in terms of mechanical strength (flexural properties), porosity percentage and percentage of water absorption as well as moulding process were recorded and compared with previous studies of plaster mould. Five (5) samples of porous resin were prepared according to ASTM 790 for flexural test and ASTM D570 for water absorption test. To determine the porosity percentage, mercury porosimeter test was conducted. The result shows that higher the water plaster ratio resultant in higher porosity percentage and water absorption. The result showed that, the proposed porous resin has great potential in replacing plaster mould as mould material for CSRM system. The mould has a uniform open pore to enable the filtration process to take place within the mould and the slip and has a great mechanical strength. However, porous resin is still a semi-permanent mould with definite service life.

Abstract: Bamboo is well known as the oldest structural material that possess unique anatomical structure and superior mechanical properties. It has become a subject of interest worldwide and research is being conducted for its structural applications including safety, durability and also mechanical properties. Many studies carried out previously indeed have shown superior strength of bamboo. Most of the research circulate on the mechanical properties improvement using chemical, plasma, enzyme, fungi and nanocellulose coating treatment. However, despite the conventional treatments’ advantages, but they are impractical, costly and it able to change the structure of the treated materials. This study aims to evaluate the morphological properties of untreated and treated of Semantan bamboo culm (Gigantochloa scortechinii) after subjected to a simple and cost-effective epoxy treatment. By using Alicona Infinite Focus 3D profilometer machine, the comparison between the untreated and treated surfaces of bamboo can be obtained under profile surface roughness test. Meanwhile, the depth formation of the treated surfaces also can be obtained by using the same machine under profile form management test. Next, optical microscope was used later to examine the epoxy matrix treatment formation of the untreated and treated bamboo surfaces. The result revealed that the application of epoxy treatment gave a better surface roughness and structure as it treat the bamboo strips and concurrently gave a thin layer of coating to the bamboo strips. The findings of this study suggest that epoxy treatment can be an effective and economical approach to treat natural fiber as it resulting in good surface structure which simultaneously increase the chemical and mechanical interlocking; thus, the bond between matrix and natural fiber become stronger.

Abstract: When the measurable quantities are not given a value for the amount considered or found a standard for the quantity, it requires calibra-tion. Calibration is a preparation process before starting the test. It is a process of finding the relationship between two unknown quanti-ties. If one of the quantities is known because it is made or set with another device, another measurement is made as similar way as possible with the first device using a second device. The measurable quantities may differ in two devices which are equivalent. The de-vice with the known or assigned correctness is called the standard. The second device is the unit under test, test instrument or any of several other names for the device calibrated. [1] The process can reduce the error margin of the tested measurement and that will prevent any unnecessary problems that may harm human in certain application applied.

Abstract: This paper presents a case study on a research framework of gap analysis on audit systems for a standard called IATF 16949 and Toyota Production System (TPS) in the automotive industry. A study was carried out to define the gaps that are currently being faced in this industry. A comparison and contrast for an audit process flow chart was plotted and showed that there are processes have similar audit objectives, same auditees and involved with the same documents to be audited. Meanwhile, 5M (Man, Machine, Method, Material, Measurement and) 1 E (Environment) methodology were used to study audit requirements for both IATF 16949 and TPS and showed that both systems share the same audit items. Rasch model was used to measure the level of satisfaction, difficulties, and challenges faced by the people in the industry. By reducing the few steps in implementing the internal audit, it is expected to minimize the “wastes” that occurred during the execution of both audit systems. This case study has proposed that the integration of audit system of the IATF 16949 and TPS will harmonize the systems and reduce the hassle faced by the people in the industry.

Abstract: Engineers in the communication and multimedia industries in Malaysia exposed to the risk factors of work-related musculoskeletal disorders. A comprehensive study was conducted to perform ergonomic studies for indoor spectrum measurement activity to improve productivity and occupational safety and health. The study consisted of two phases, where the participative assessments and direct observations were conducted on 17 engineers. In the first phase, the indoor spectrum measurement problem identification was performed by using the portable and handheld spectrum analyser. The questionnaire, body part assessments and archival operation records were investigated. In the second phase, the ergonomics intervention was introduced with a low-cost trolley that removed the work-related musculoskeletal disorders from the engineers. The same test subject, environments, work procedures and evaluation method in phase one were repeated in phase two. The analysis was done by comparing the findings between both phases through statistical analysis, and the significant improvements of ergonomic interventions were identified. The outcome of the study concluded that the analysis and results meet the main objective.

Abstract: Mid-Life Refurbishment (MLR) is a process conducted in many industries to improve or extend the life span of assets such as machines, infrastructures and systems. The objective of MLR works execution is to extend the life span, sustain the train performance and achieve system reliability. Typically, the refurbishment scope consists of overhaul, upgrading and rectification works. The biggest challenge is to determine) the scope of refurbishment works and to create equilibrium between the feasibility and viability of the project. Therefore, the main objective of this paper is to discuss the current practice of performing MLR maintenance through the utilization of Failure Mode and Effect Analysis (FMEA) and to transform the existing FMEA used by the automotive industry to fulfil the needs of Rolling Stock. The use of FMEA is critical in determining) the scope of train refurbishment work. It was carried out at the initial stages of the process in order to determine Risk Priority Number (RPN) to prioritize the type of refurbishment plans and scope. The design of the FMEA Worksheets, De-sign of FMEA severity Evaluation Criteria, Design of Occurrence Evaluation Criteria and Design of FMEA Prevention/Detection Criteria were adopted and adapted from the generic format so that it is coherent with Railway Industries. The results based on the transformation framework, the plan and scope of overhaul, upgrading and rectification were defined using the FMEA. Out of the 80 elements of MLR works that were analyzed using the FMEA approach, it was found that 46 elements needed overhaul, 23 elements needed upgrading and 11 elements needed rectification works. Finally, the application of the FMEA helped determine the MLR scope of work from 13 systems. The case study was taken from the Malaysia LRT Project, and currently the fleet has been in operation for more than 20 years (operated since year 1998).

Abstract: To understand the current state, health and efficiency of an organization, evaluation based on an organizational diagnostic model are vital. There have been a number of framework and models developed for this purpose which serves as a general rule, but they lack accuracy in certain industries due to its characteristics and scope. This paper critically analyzes previous models, highlighting its definition, advantages, disadvantages, applications and comparison between them. Recognizing factors that contribute to the performance of construction/engineering companies, the authors propose a new diagnostic model which is more suited to this industry. The new diagnostic model addresses issues of culture at work while redefining the scope of every pillar involved in previous diagnostic models. It is a revelation of an evaluation platform for all companies within the same industry, which allow further studies on sustainability framework to be developed on top of this platform.

Abstract: The aim of this study is to analyze the existing production line in the automotive industry and proposed a layout of improved production line in the manufacturing process and obtain the optimum rate of production time. Thus, line balancing method and Yamazumi Chart was utilized to analyze the current and proposed production line. The collection of the data of the existing production line was conducted at one of the automotive company in Malaysia. From the analysis of current production line, two improved layout were proposed and evaluated. The proposed layout was selected based on a balanced production line and ability to meet customer demand. A balanced production line will ensure smooth process and eliminate wastage during operation