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Vol. 10, Issue 11, PP. 93-106, November 2023
The garment manufacturing industries faces significant challenges to stay competitive and survive in the global market due to the highly flexible and dynamic customer demand for top-quality products at lower prices. Thus, the product quality and product cost both are very critical concerns for garment manufacturers. The variations in sewing process are not acceptable and variations are mainly responsible for defects, which leads to increasing overall production costs, lowers profits and customer dissatisfaction, among others. Therefore, due to the competition of today’s business climate in textile sector, many garments manufactures are working to find the ways for improving quality of the products and reducing defects percentage to a minimum level. On one hand Lean technique can help to eliminate the production waste and convert the system into highly adaptive production system in order to meet the customers demand. On the other hand, Six Sigma intend to reduce process variability, improving quality of the product. Aiming to provide applicable improvement proposals for the sewing process in apparel industry, this research is conducted in which Lean and Six Sigma is implemented through DMAIC (Define, Measure, Analyze, Improve, and Control) approach. The methodology developed in this study has increased the sigma level from 3.9198 to 4.3546 which dropped the defect rate by 26%. Moreover, the preventive & Proactive actions proposed in this study helped to reduce the thread wastage by 30% & 36% on Lock-Stitch and Over-Lock machines, respectively and saved 1,29636 Rs. per month which can further be improved in the near future by reducing defects percentage, reducing variations in process, and improving overall quality of the product.
© The authors retain all copyrights
This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 11, PP. 83-91, November 2023
Risks are any deviations of processes from their normal behavior that can cause economic, physical or emotional harm. Based on the nature of its job, the steel mills are the industries that are prone to a high number of risks. Also, the high number of applications of its product makes it a must to maintain a healthy working environment. However, it is quite difficult to neutralize those risks while keeping the cost constant. This research addresses those risks by applying scientific methods and providing a systematic way of prioritizing and analyzing the failure risks. It consists of two risk analysis methods. First is the Failure mode and effect analysis (FMEA). It helps identify the risks, shows the cause of each failure and shows the impact of each failure on the production system of the steel mill. The second method is the Boston Rectangular matrix, it helps prioritize the risks to be addressed. These are the most recommended methods to ensure a good production system. These methods use the statistics of Risk priority number (RPN) to prioritize the problems. They identify, evaluate, monitor and handle those risks in the best possible way. The data collected in this research is from the activities performed on the production side of a local Steel industry in Pakistan. This research shows the combined application of the FMEA and Boston matrix and proves that a high number of hazards can be identified and neutralized by properly implementing them more than any other method.
[1] Mehrzad Ebrahemzadih1, G. H. Halvani, Behzad Shahmoradi, Omid Giahi. (2014). Assessment and Risk Management of Potential Hazards by Failure Modes and Effect Analysis (FMEA) Method in Yazd Steel Complex. Open Journal of Safety Science and Technology Vol.04 No.03. 127-135.
[2] Dudek-Burlikowska M. Monitoring of the Production Processing in a Metallurgical Company Using FMEA Method. Institute of Metallurgy and Materials Science of the Polish Academy of Sciences.
[3] Ji-Won Song 1, Jung-Ho Yu and Chang-Duk Kim. Construction Safety management using FMEA technique: Focusing on the cases of steel frame work. Department of Construction Engineering, University of Kwang-woon, Wallgyedong 447-1, Nowongu, Seoul, Korea
[4] R. Suresh , M. Sathyanathan , K. Visagavel, M. Rajesh Kumar. Risk assessment for blast furnaces using FMEA. International Journal of Research in Engineering and Technology. eISSN: 2319-1163 | pISSN: 2321-7308.
[5] Shahin, A., Labib, A., Emami, S. and Karbasian, M. (2019), "Improving Decision-Making Grid based on interdependence among failures with a case study in the steel industry", The TQM Journal, Vol. 31 No. 2, pp. 167-182.
[6] Dharu Dewi, Imam Bastori, Arief Tris Yuliyanto, Karina Stankevica and Arnold Soetrisnanto. September (2020). Manufacturing Risk Identification in the Steel Industry. Volume 190. 1st International Conference on Renewable Energy Research and Challenge.
[7] U D Widianti, T Harihayati, S Sufaatin. (2018) Risk project management analysis. IOP Conf. Series: Materials Science and Engineering 407012087
[8] S.Vivek , N.Karthikeyan , A.V.Balan. (2015) Risk Assessment and Control Measures for Cold Rolling Mill in Steel Industry. International Journal of Mechanical Engineering and Research, ISSN 0973-4562 Vol. 5 No.1
[9] Mehdi Ahmadi, Seyyed Mohammad Hadji Molana and Sayed Mojtaba Sajadi, (2017). A hybrid FMEA-TOPSIS method for risk management, case study: Esfahan Mobarakeh Steel Company. International Journal of Process Management and Benchmarking Vol. 7, No. 3
[10] David VYKYDAL, Richard FABÍK, Michaela KELBLEROVÁ. (2011). Cost oriented FMEA of hot rolled wire production. Regional Materials Science and Technology Centre. Brno, Czech Republic, EU.
[11] Arash Shahin, Ashraf Labib, Ali Haj Shirmohammadi, Hadi Balouei Jamkhaneh (2020). Developing a 3D decision-making grid based on failure modes and effects analysis with a case study in the steel industry. International Journal of Quality & Reliability Management ISSN: 0265-671X
[12] Aulia Ishak, Khawarita Siregar, Rosnani Ginting and Afrianti Manik (2020). The Fuzzy Failure Mode and Effect Analysis (FMEA) Method to Improve Roofing Product’s Quality (case study : XYZ Company). IOP Conference Series: Materials Science and Engineering, Volume 1003, 2nd International Conference on Industrial and Manufacturing Engineering (ICI&ME 2020) 3, Medan, Indonesia
[13] M S Ishak et al. (2021). Defining-Measuring-Analysing-ImprovingControlling (DMAIC): Process and Improve Stability in Carbon Steel Industry. Journal of Physics: Conference Series2129 012029.
[14] ODLANICKA-POCZOBUTT Monika1, KULIŃSKA Ewa h. (2016). The application of the FMEA method to Failure analysis in the production process in a selected company of the metallurgical secondary manufacturing industry. Silesian University of Technology, Gliwice, Poland, EU.
[15] Jagdeep Singh, Harwinder Singh, Bhupinder Singh. (May 2020). Prioritization of Failure Modes in Manufacturing Processes, ISBN: 978-1-83982-143-1
[16] B. GAJDZIK, J. SITKO (2016). Steel mill products analysis using qualities methods METALURGIJA 55 (2016) 4, 807-810.
[17] Ioannis S. Arvanitoyannis & Theodoros H. Varzakas. (Jul 2009). Application of Failure Mode and Effect Analysis (FMEA) and Cause and Effect Analysis in Conjunction with ISO 22000 to a Snails (Helix aspersa) Processing Plant; A Case Study.
[18] Rony Prabowo, Mochamad Bagus Setiyawan, Rusman Rusman. Quality control product with using the Failure Mode and Effect Analysis method and Fault Tree Analysis (FTA) at Pt. Agung Seel Makmur Sidoarjo.
[19] Hyo Suk Gwon a, Muhammad Israr Khan a, Muhammad Ashraful Alam a, Suvendu Das. (July 2018). Environmental risk assessment of steel-making slags and the potential use of LD slag in mitigating methane emissions and the grain arsenic level in rice. Journal of Hazardous Materials. Volume 353.
[20] Xi Liang a, Katharina Kaesehage a, Francisco Ascui a, Jeffrey Wilson c. (September 2021). Opportunities and challenges for decarbonizing steel production by creating markets for ‘green steel’ products. Journal of Cleaner Production. Volume 315
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Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 10, PP. 74-82, October 2023
Prior to six Sigma introduction, manufacturing industries used to follow their production procedures without taking an interests in improving the quality of products by meeting customer specifications, which resulted in huge time- consuming and wasteful production. Modern manufacturing industries are trying their best to make their products defects- free, i.e., of good quality,and producing less of waste by improving the processes using various techniques. Six Sigma has made its name in the modern competitive world, competing with each other in the quality field. Six-Sigma is basically a statistical-based processes used to check the deviation of process from standard. Mohsin Matchbox Industry has increased production through six sigma DMAIC methodologies. The DMAIC methodology helped workers do their tasks with less effort by improving the processes. The installation of steel racks helped the targeted industry reduce waste, which increased profit. The rejection rate was reduced to almost 30%. The execution of the six-sigma DMAIC methodology also improved the quality of the product.
© The authors retain all copyrights
This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 08, PP. 69-73, August 2023
Climate Change, an inevitable phenomenon, is impacting weather patterns and results in extreme climatic events. Pakistan is the 5th most affected country by climate change. Globally, Pakistan is highly susceptible to temperature rise, due to its geographic location. This study explores the effects of climate change on the seasonal flows of Budni Nullah. In order to, investigate the effect of changing climate, bias-corrected data of five General Circulation Models (GCMs) of “Coupled Intercomparison Project-6” (CMIP6), under Shared Socioeconomic Pathway (SSP2-4.5) have been used. The hydrologic model, Soil and water assessment Tool, (SWAT) was calibrated and Validated for a period of six years (2002-2008) and four years (2009-2013) respectively with statistical functions: R-squared, 0.78 & 0.58, Nash–Sutcliffe efficiency, 0.75 & 0.80. Three future time periods: (2011-2040), (2041-2070) and (2071-2100) of each 30 years were selected and accordingly. The average monthly flow was modeled for SSP245. A comparison of the results reveal that for majority of the time increas in flows were witnessed during monsoon season. Higher flows were observed during time period of 2011-2040.
Sajadullah, Dr. Asif Khan, Naila Ahmad
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Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 06, PP. 64-68, June 2023
This study investigates the optimization of the Selig (S1223-il) airfoil to improve the performance of vertical axis wind turbines (VAWTs) using the QBlade software. The efficiency of wind turbines heavily relies on the design of their airfoils, as they play a critical role in capturing energy from the wind. Parametric optimization methods are employed to simultaneously reduce the thickness and camber of the airfoil. Specifically, the airfoil thickness is reduced from 12.14% to 8.5% at the maximum thickness position of 19.80%, while the camber is decreased from 8.87% to 8.46% at the maximum camber position of 49%. These optimizations result in improved aerodynamic performance of the airfoil. Simulation results demonstrate significant enhancements in the coefficients of lift (CL), drag (CD), moment (Cm), and lift-to-drag ratio (CL/CD) at an optimal angle of attack of 10o. The optimized airfoil exhibits CL and CL/CD ratios increased from 1.988 to 2.121 and 33.370 to 55.356, respectively, while CD and Cm are reduced from 0.063 to 0.038 and -0.226 to -0.244, respectively. Thereby, the coefficient of power (CP) is improved from 23% to 34% due to these optimizations. The findings of this study suggest that employing parametric optimization methods to enhance the Selig (S1223-il) airfoil represents an effective approach to improving the performance of VAWTs. This approach contributes to the promotion of wind energy utilization as a sustainable and environmentally friendly power source.
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This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 06 PP. 55-63, June 2023
Various forms of cancer have been recognized, all sharing a common objective: the rapid destruction of healthy tissue. To enhance a patients chances of surviving cancer, it is crucial to accurately diagnose and prognose the specific type of underlying disease. Early identification and personalized treatment can potentially improve survival rates. Additionally, it is important to differentiate cancer patients based on their risk levels for disease progression. In the past, data mining and machine learning algorithms have been employed for cancer diagnosis. However, these approaches rely on manually conducted feature extraction techniques, resulting in unreliable categorization. Consequently, precise cancer identification becomes a time-consuming task fraught with the possibility of pathologist errors. In contrast, deep learning has recently gained significant traction in categorization and detection fields, owing to its powerful feature extraction capabilities. Therefore, I utilized a hybrid deep learning model to achieve better accuracy in identifying cases of lung cancer.
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This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 06, PP. 46-54, June 2023
Lithium-ion (LiFePO4) battery can give various good features, for instance, more modest volume, higher security, cut down weight, without memory influence, higher release current, longer life cycle, recyclable and greater breaking point. In the proposed system, the battery structure will recognize the crucial factors of the lithium-ion (LiFePO4) battery module, including delivering or charging current, battery voltage, and temperature. Over current protection, overvoltage protection, cut off, over temperature protection, etc., are only some of the safety features that the battery management system may provide for the battery module. The employed battery management system IC is capable of controlling the uniformity of each cell. For this study, three-series-connected lithium-ion battery pack to test the suggested control method. Proteus has unparalleled performance by doing research and replicating its results, and then using the resulting replica diagrams to validate research hypothesis. With Proteus, result of battery management system will be obtained and analyzed.
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Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 05, PP. 37-45, May 2023
Electricity has many advantages over other forms of energy, including ease of production, handling, flexibility, and efficiency, making it the most useful form of energy ever discovered. However, as the population grows, so does the electricity demand. Building new power plants requires a lot of effort, money, time, and resources. It is imperative to use the energy already available wisely. For the intelligent use of energy, a variety of approaches are used. To achieve the goals of lowering electricity costs, peak-to-average ratios (PAR), and user comfort, meta-heuristic optimization algorithms are frequently used and occasionally mathematically based optimization algorithms are employed. This concept also led to the creation of the Smart Grid (SG) and its concept. To use the energy effectively and conduct a comparison, a Synergy of Sine Cosine Algorithm (SCA) and Particle Swarm Optimization (PSO) are used in this paper.
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This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 03, PP. 30-36, March 2023
One of the most significant case studies in the world market is the analysis of the strategic management techniques in aviation industry with COVID-19 crisis. Currently, the global community has been affected severely with the Coronavirus pandemic COVID-19. Aviation is one of the industries that has been hardest hit. A strategic management approach used in this study to investigate how COVID-19 challenged this sector. The airline sector operates in a very cutthroat environment. Its target market includes people from all over the country and the world with a variety of specialties. For the management to examine the decision-making process and stabilize the uncertain conditions brought on by the environment, strategic management practices are of utmost importance. Analysis of the economic and administrative repercussions of Covid-19, which disrupted travel plans and altered budget projections, has assumed a crucial role. By implementing conventional business procedures, strategic management makes a significant contribution to addressing the challenge. The paper highlights the best management approaches, which unquestionably address the crises and support the aviation industry and compares them to analogous prior crises.
© The authors retain all copyrights
This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 03 PP. 22-29, March 2023
On Load tap changer OLTC transformer having electromechanical hybrid switch, is used to regulate voltage level by changing the taps without arcing which cause increase or decrease in voltage level in a very efficient and coherent manner depending upon the requirement of the system. Mostly mechanical type of On Load tap Changer is widely used for control voltage in distributed networks. Mechanical On Load Tap Changer has some disadvantages during tap changing process like causing arc, slow switching, high malfunction rate and require manpower. In mechanical switches wear and tear occurs due to tap changing due to the arcing phenomenon. Besides these drawbacks, there are also some advantages of mechanical OLTC such as low on-steady losses and high overload capacity. Due to fluctuations in voltage level of smart grid a hybrid power electronic assisted mechanical On Load Tap Changer transformer is designed. In this research paper a hybrid Switch is proposed using the advantages of mechanical as well as electronic bidirectional switches for automatic tap changing of OLTC transformer. The electronic OLTC uses semiconductor namely IGBT as a bidirectional switch. By using electromechanical switch the taps changing process will be arc less and there will be low On-state losses and high over load capacity. This will provide automatic, arc free tap change and long lifetime.
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Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 03 PP. 16-21, March 2023
Now a days modern power system gradually prefers renewable energy resources. Conventional energy resources involves issues related environmental pollution and its reserves are also diminishing whereas demand for energy is rising daily. Whereas share of renewable energy in power industry is increasing because they are affordable, reliable, clean and available in large quantity. Renewable energy resources are intermittent in nature. So, to make power system more reliable combination of both piezoelectric transducers and solar panel are used to generate sufficient energy. Solar panels output is first given to DC-DC Boost Converter through maximum power point tracking (MPPT) algorithm. Piezoelectric generator gives AC output so it is desired to rectify this output to get DC. Both sources are then connected in parallel which charges/discharges through a bi-directional DC-DC converter. Battery is connected with the system. The overall DC output is converted to AC through voltage source inverter (VSI) for grid connection and vice versa. The main purpose to design such kind of power system is to generate electricity from renewable energy resources which will be more reliable.
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This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 03 PP. 10-15, March 2023
Lean manufacturing has become a global trend, with companies constantly striving to achieve more with less. However, many companies, including those in Pakistans sugar industry, have yet to fully embrace this concept. With Pakistan facing electricity shortages, the countrys 85 sugar mills collectively generate less than 500 MW of electricity. A traditional Sugar Mill, which currently runs at 6000 TCD, has been identified as a primary model for this upgrade. By up gradation to 2-roller mills, instead of 4-roller or 6-roller mills, this energy production can be increased by up to 15%. After implementing this change, the mill can save up to 30% and 40-45% energy compared to 4-roller and 6-roller mills, respectively. This is due to the fewer components required with a 2-roller mill, particularly after the removal of the trash plate which consumes around 25% of the total crushing mill energy. By applying various data-gathering approaches, a model has been developed that can save over 13% of bagasse, enabling sugar mill owners to export energy to the National Grid and generate additional revenue.
© The authors retain all copyrights
This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.
Vol. 10, Issue 02, PP. 01-09, February 2023
Poor ergonomics directly affect the performance of workers and its major cause is muscle fatigue. Conventional methods of fatigue assessment are unrealistic and based on the perception of an individual. Fatigue monitoring systems currently available are highly sophisticated and cumbersome to implement. There is a need for a smart real-time fatigue monitoring system. This study aims to propose an EMG-based fatigue monitoring system by targeting the bicep muscle of workers through real-time fatigue monitoring. EMG signal classifier is developed for data acquisition, manipulation, and analysis to assess muscle fatigue. In the end, a case study of gym-goers was investigated by implementing the developed system to differentiate between fatigued and non-fatigued muscles. The participants involved with poor ergonomics experienced muscle fatigue earlier than others. The proposed system can be utilized to design work-rest schedules, prevent musculoskeletal disorders, and increase the performance of employees.
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© The authors retain all copyrights
This article is open access and distributed under the Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Authors disclose no conflict of interest or having no competing interest.