Industrial and Manufacturing Engineering

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Industrial Management & Data Systems POM: a highly visual production and operations management environment
(Emerald, 1997) Onwubolu, G. C.; Mhlanga, S.
Reports the development and successful implementation of a computer‐integrated production and operations management system (POM), encompassing schedule activities such as aggregate production plan, master production schedule and material requirements plan, and capacity activities such as financial plan, resource requirements plan, rough‐cut capacity plan and capacity requirements plan, at the planning level. POM’s icon‐menu driven system which associates icons with decision model spreadsheets makes it very user‐friendly, and facilitates the integration of decisions encountered by industrial/ manufacturing engineers and operations managers.
Scheduling linearly deteriorating jobs on parallel machines: a simulated annealing approach
(2001) Hindi, K.S.; Mhlanga, S.
Scheduling deteriorating jobs on parallel machines is an NP-hard problem, for which heuristics would be the ®rst solution option. Two variants of linearly deteriorating jobs are considered. The ®rst is that with simple linear deterioration, i.e. where there is a deterioration rate only, which is meaningful only if the jobs are assumed to be available at a positive time t0 . In the second variant, there is a basic processing time and a deterioration rate and all jobs are available at time t ˆ 0. In both cases, we seek to minimize the makespan. Starting from simple heuristics, both steepest descent search and simulated annealing are designed and implemented to arrive at optimal or near-optimal solutions. Computational results for randomly generated problem instances with diåerent job/machine combinations are pre sented.
Performance analysis of immigration operation by discrete event modelling and simulation
(2009) Gandure, J.; Mhlanga, S.
Discrete event modelling and simulation were used to analyse the performance of immigration operation in Botswana. The relationships between length of queues of immigrants, queuing time, service time and engagement of duty officer were investigated. Data collected by direct observation and clock-timing of processing immigrant request at an inland office on a normal working day was used to determine whether to increase or reduce the number of serving officers to balance the operations. The findings indicated that the system of operation was balanced or fairly matched by 75 % utilization of the officer, average immigrant queuing time of 4.2 min, and required no changes. The pilot study could be replicated at other boarder posts and airports prior to the expected influx of tourists during the 2010 World Cup Football Competition in South Africa.
Air pollution control techniques for the cement manufacturing industry: A case study for Zimbabbwe
(2012) Zimwara, D.; Mugwagwa, L.; Chikowore, T.R.
Technological advancement has resulted in cement making companies being able to produce higher volumes compared to the past. However the higher production levels have also been largely labelled as the leading cause of pollution. The main sources of air pollution in the industry include excavation activities, dumps, tips, conveyer belts, crushing mills and kiln emissions. Harnessing appropriate technology for use in the cement industry could go a long way towards minimising on-site wastes and pollution. This review examines various options in practice for reducing pollution at cement manufacturing companies, which help ensure legislative compliance. By adoption of appropriate technology and computer modelling, industry will not only reduce production waste but also comply with legislation to do with environmental protection. The paper examines certain methods of pollution control used for air and looks at how computer modelling can be adopted for the classification, quantification and control of particulate matter; and how efficient energy use can contribute to better air quality. An analysis of gas stack emissions was done for a cement manufacturing company in Zimbabwe where compliance was investigated. Emissions samples were randomly selected at various points within the company and concentration of various emission constituents were analysed.
Implementation Of A Computerized Balanced Scorecard (BSC) System In A Manufacturing Organisation In Zimbabwe
(2013) Gwangwava, N.; Mhlanga, S.; Goriwondo, W.
This modern era’s high technological improvements present manufacturers and other organizations with a plethora of Management Information Systems (MISs) which makes them face challenges when choosing a corporate information system. High initial investment in setting up the information systems make it very difficult for companies to adopt new systems as they come into market before realizing a reasonable return from the previous system. In line with these concerns, a methodology for building a Balanced Scorecard module as a strategic management platform that can be integrated smoothly into already existing information system such as MRP/ERP is presented. The paper uses a case study of a manufacturing company based in Zimbabwe. Various manufacturing based metrics are reviewed with the main intent of showing how these can be tracked in a computerized platform. Sample data extracted from the production system is used to test the built system. The paper shows a methodology for software design, setting up and adopting a BSC system. The proposed approach is used to design a computerized BSC system for the case study company, which incorporates a BSC dashboard for the four main perspectives derived from various operational metrics.
Cost of Quality as a Driver for Continuous Improvement - Case Study – Company X
(2013) Zimwara, D.; Mugwagwa, L.; Maringa, D.; Mnkandla, A.; Mugwagwa, L.; Ngwarati, T.T.
In the manufacturing, metal casting industry is one of the oldest basic principal and most important industries. The casting process is hindered by the occurrence of various defects. High casting reject levels and customer returns have a considerable adverse effect on productivity, delivery performance, customer satisfaction and employee morale. In addition excessive rejection reduces yield, wastes valuable raw materials and involves management time in problem solving. All foundry processes generate a certain level of rejection that is closely related to the type of casting, the processes used and the equipment available. This paper seeks to establish the extent to which cost of quality can impact on continuous improvement of the products and the relationship with the customers of the organization. To determine the cost of quality (COQ) at casting company X, the researchers used existing company records, publications and historical evidence of the company. The researchers utilized techniques such as, bar charts and tables in presenting and interpreting data. The above techniques have the ability to provide methods for collecting, presenting, and analysis and meaningfully interpret data. The research findings estimated the COQ to be 6.6% of sales revenue.
Design of a Dual Operating Mode Sheet Folding Machine.
(2013) Gwangwava, N.; Mugwagwa, L.; Ngoma, S.
A sheet folding machine that can be operated through hydraulics by two hydraulic cylinders or manually (with the cylinders disengaged) was designed. The design need emanated from the strained national electrical grid system that has recently seen industrialists and households in Zimbabwe experiencing major power cuts. The machine enables manufacturers to shedule heavier jobs during periods when power supply is up and lighter jobs during power cut periods hence run their workshops throughout the daily production shifts. The two hydraulic cylinders can be disengaged from the machine’s folding beam so that manual operation can be done through a manual clamping lever system. The folding force at full capacity is 294.6 KN (29.46 Ton), total bending length of 1.8 m and working height of 1 m. The folding force decreases significantly in manual operating mode to 500 N, considering that on average an operate can manually exert that force. A student version of Simulation X 3.5 was used to simulate the hydraulic operation of the machine
Soft Computing Methods for Predicting Environmental Quality: A Case Study of the Zimbabwe Sugar Processing Industry
(2013) Zimwara, D.; Mugwagwa, L.; Nherera, K.
Sugarcane growing and processing is associated with environmental degradation and pollution. The impact that sugar processing industries have on the environment affects the ecosystem. Methods of soft computing that is fuzzy logic, neural networks, and genetic algorithms can be adopted for environmental protection, particularly in the developing countries. Soft computing techniques, particularly neural networks and fuzzy logic, have been used to predict and sometimes control air quality. This paper looks at how fuzzy logic can be adopted for predicting air quality. The common environmental impacts associated with sugarcane production are water and air pollution. This paper focuses on air pollution. The major waste streams are identified and the extent of air pollution is predicted by classifying the air quality as poor, ordinary, very good, and excellent. This paper presents a fuzzy rule base that can be used to classify the pollutants and predict the air quality based on the amount of the specific pollutant in the air. The Mamdani fuzzy inference system is used to build the rule base, with the membership functions being non-intersecting and triangular. The adoption of fuzzy logic techniques will help sugar processing industries to be aware of the impact their operations have on the environment.
Academic staff development strategies in engineering fields of study: case study of Zimbabwe
(2013-06) Mhlanga, Samson; Matope, Stephen; Mugwagwa, Lameck; Phuthi, Nduduzo; Moyo, Vincent S.
Higher education is the basic instrument of economic growth and technological advancement in any society. The economic meltdown in Zimbabwe which climaxed 2008 with an inflation level of 231million % exacerbated the brain drain. After the economic meltdown, Zimbabwe is in the process of rebuilding the quality of staff and the staffing levels in its higher education institutions. The challenge has been the decision on the mode of study: whether to go via taught masters or masters by research; where to allow the faculty members to study: in the region, or beyond; on a fulltime or on a part-time basis or on a split-site basis. These challenges have been due to the need to have a quick but quality programme of staff development, while maximising on the resources available for staff development. A survey was undertaken of the engineering related departments in Zimbabwe universities focusing on the existing staffing levels, their qualifications, current numbers undergoing study and their levels. The challenges faced by each institution from the administrative side and from the staff side are summarised. Recommendations on staff development strategies are given in conclusion.
Academic staff development strategies in engineering fields of study: case study of Zimbabwe
(2013-06) Mhlanga, S.; Matope, S.; Mugwagwa, L.; Phuthi, N.; Moyo, V. S.
Higher education is the basic instrument of economic growth and technological advancement in any society. The economic meltdown in Zimbabwe which climaxed 2008 with an inflation level of 231million % exacerbated the brain drain. After the economic meltdown, Zimbabwe is in the process of rebuilding the quality of staff and the staffing levels in its higher education institutions. The challenge has been the decision on the mode of study: whether to go via taught masters or master's by research; where to allow the faculty members to study: in the region, or beyond; on a fulltime or on a part-time basis or on a split-site basis. These challenges have been due to the need to have a quick but quality programme of staff development, while maximising on the resources available for staff development. A survey was undertaken of the engineering related departments in Zimbabwe universities focusing on the existing staffing levels, their qualifications, current numbers undergoing study and their levels. The challenges faced by each institution from the administrative side and from the staff side are summarised. Recommendations on staff development strategies are given in conclusion.
INVESTIGATION OF THE EFFECTS OF LUBRICANT FAT CONTENT ON DRAWN COPPER WIRES
(2013-07) Chiduwa,A.C.; Nyanga, L.; Mhlanga, S.; van der Merwe, A.F.; Kanyemba, G.
The Lean Manufacturing goal of reducing waste and increasing productivity has made it a necessity to produce good quality products in manufacturing industries at a low cost. In the cable manufacturing companies this can be achieved by optimising the wire drawing process. One way to meet the desired quality of the drawn wires is to improve lubricant efficiency through installation of an automatic, continuous lubricant fat content control system on the drawing machine. The paper shows a method of finding the optimum lubricant concentration for producing good quality copper wires using Taguchi experiments. Taguchi experiments are employed to analyse the effects of different lubricant fat content levels on the tensile strength and lubricant temperature. The results from the experiments indicated that the tensile strength of the wire is affected by low lubricant fat content. The lower the lubricant fat content: the lower the tensile strength drawing lubricant resulting in numerous wire breakages that affect the quality of the final product, namely the cable
Towards the implementation of e-manufacturing: design of an automatic tea drying control system.
(2014) Mabvuu, N.; Nyanga, L.; van der Merwe, A. F.; Matope, S.; Mhlanga, S.
Many of the production costs for producing tea are attributable to the process of drying the tea. E-manufacturing can assist companies to reduce these production costs by making crucial information available to decision-makers so that they can make informed decisions. This paper presents an application of e-manufacturing to the design of an automatic tea drying control system. This control system will ensure that the multiple drying parameters such as temperature, dryer-exit tea moisture content, and fuel consumption are maintained at optimal states during the course of the drying of tea. The additional aim of this system is to balance the cost of production and the quality of the final product. Using the Guggenheim-Anderson-De Boer (GAB) model, the optimum drying temperature was found to be 100-110°C, while maintaining a dryer-exit tea moisture content of 3 to 3.12 per cent, at a drying rate of 3 per cent per minute. A Barix control application to control the system’s activities, using the web user interface (WUI), was also developed.
Development of a condition based maintenance system for a sugar producing company
(2014-07-14) Chindondondo, B.; Nyanga, L.; Merwe, A. V.; Mupinga, T.; Mhlanga, S.
With globalisation taking centre stage in almost every market; traditionally monopolistic manufacturing companies in Zimbabwe are struggling to compete with international companies whose operations are optimised. This paper focuses on maintenance practises of a Zimbabwean sugar manufacturer with an aim to improve the company’s asset care plans. The company’s current maintenance philosophy and its shortcomings on certain equipment in the plant were identified together with the associated annual maintenance costs. A Pareto analysis on the equipment’s breakdown history was used to determine the conditions that can be monitored using Condition Based Maintenance (CBM); and experiments to establish the feasibility of monitoring these conditions were done. The paper then recommends and proposes a CBM system replete with its three main elements of data acquisition, data processing and maintenance decision making to reduce breakdowns on the subject equipment by at most 76%.
Reliability Engineering: A Demonstration of How Reliability Engineering Techniques and Methods Improve Processes, Products and Services
(2015) Chikuruwo, M. N. H.; Takawira R Chikowore, T. R.
Understanding what, when and where to use the wide variety of reliability engineering tools available helps in achieving the highest reliability in products, processes and services. This paper outlines the value of using Weibull Analysis, Reliability Block Diagrams Reliability Centered Maintenance and Root Cause Analysis and as techniques for processes, products, equipment and services improvement. Reliability Engineering tools help to determine the relationship between the process and the equipment. A demonstration of where and how the reliability engineering techniques can be applied is shown in the research. Every product and process design and their development are unique such that meticulous planning is required to map the reliability tasks to the identified constraints. A product with complex multidisciplinary integrated functions requires efficient reliability tools. These tools are required to be used to assess built-in safety and reliability features of the product under an applicable environment. The techniques discussed in this research will help in determining the present and future reliability of the products or processes.
Design of a Control System for a Vending Machine
(Elsevier, 2020) Murena, E.; Sibanda, V.; Sibanda, S.; Mpofu, K.
Vending machines are available in many public places for vending of items like snacks, beverages, newspapers, tickets and smoking cigarettes Recently developed vending machine requires a control system to offer a variety of products to the general public. In this light, this paper, therefore, is aimed at developing a control system for the developed vending machine by developing various inputs required to make the machine function efficiently. The system controls and monitors the vending machine functions, namely: alarm system, product dispensing, refrigeration and payment system. The microcomputer capitalises on the evolution of high-performance processors and stable operating systems to implement control requirements. The project shall use intelligent vending machine input/output board to link other machine peripherals. The control system shall enable the machine to handle coin, mobile and point of sale terminal payment options. Implementation of the control system enhances flexibility in payment, remote machine monitoring and inventory control, and improved user experience through the integration of digital touch screen user interfaces and high-speed transaction processing
Zimwara, D., Maphosa, E., Goriwondo, W.Modelling the environmental impacts of noise and dust from quarry stone mining in Harare–a case study of Pomona Quarry
(NUST, 2021) Zimwara, D.; Maphosa, E.; Nyadongo, S.T.; Goriwondo, W.M.
Granite quarry mining has contributed significantly to infrastructure development of many nations and Zimbabwe is no exception. However it has also contributed to environmental pollution and other socio ecological ills. This study investigated the environmental impacts of quarry stone mining and processing at Pomona Quarry mine in Harare. Ambient noise and dust concentrations were measured at different distances and directions from the source. The correlation between the distance and noise level as well as dust concentration were carried out to determine a safety zone from the quarry mine. Multiple regression analysis of the data was conducted and a model developed for the prediction of noise and dust levels.
Effectiveness and impact determination for Enterprise Resources Planning Systems: A case for manufacturing entities in Zimbabwe
(NUST, 2021) Nduna, M.; Goriwondo, W.M.; Tayisepi, N.; Goriwondo, W.M.
The research looked at utilization and impact of Enterprise Resource Planning (ERP) systems for manufacturing organizations in Zimbabwe. Existing literature on adoption of Enterprise Resource Planning systems, its utilization and benefits realized was reviewed. A survey of eighteen Zimbabwean manufacturing organizations was conducted to establish the utilization of Enterprise Resource Planning systems. The survey centered on operational, strategic, managerial, and Organizational functions and their interaction with the Enterprise Resource Planning systems. The strategic, managerial, and Organizational functions, results reflected positive feedback on the system usage. Operational functions had mixed responses with an overall of 58% being positive and 42% negative. Various impact dimensions were determined and mechanisms of effectiveness in the application of ERP systems established. The research went on to develop a tool using C-Sharp that organizations can use to determine their level of Enterprise Resource Planning system utilization and gave recommendations on how organizations can improve on their Enterprise Resource Planning system utilization for competitive advantage.
Analysis of the properties of a glass/sisal/polyester composite
(Springer Nature, 2021-01-11) Baloyi, R.B.; Ncube, S.; Moyo, M.; Nkiwane, L.; Dzingai, P.
Composites are gradually becoming an integral material for structural and manufacturing processes. Sisal fibre has the potential to be one of the leading reinforcement natural fibres, not only in Zimbabwe, but the world over for use in glass composites. This is mainly due to it being inexpensive, exhibiting a low density, high specifc strength, a high stiffness to weight ratio, non-toxicity, its abundance in Zimbabwe and its renewability. With an aim of coming up with a composite for partition board applications in the construction industry, five samples of sisal-glass composite were prepared with varying sisal fibre content and diferent layering techniques. Sisal fbres were pre-treated with 20% NaOH to enhance their crosslinking with the resin and reduce the chemical impurities such as lignin and waxes. Mechanical (fexural test, hardness, and tensile strength) and physical tests (density and water absorption) were conducted to analyse the properties of the composite. The results showed that treated sisal fibres had a higher breaking tenacity of 33.11 g/tex which is higher than untreated fibres with a breaking tenacity of 25.72 g/tex. The best properties were obtained in the sample with 4 layers of glass and 9 layers of sisal fibres using 200 ml of resin. The composite had a tensile strength of 57.60 MPa, fexural strength of 36 N/mm2, moisture absorption of 10% and a burning rate of 9.82 mm/ min. These results were then compared with those of the current partition boards in the market. It was noted that the composite was suitable for use in partition boards. Again, regarding cost, these composites are cheaper to produce at a rate of $11.33/m2 compared to the timber costing at $16/m2.
Effects of Palladium Chloride Concentration on the Nanoscale Surface Morphology of Electroless Deposited Palladium Thin Film
(The Electrochemical Society, 2021-05-27) Mpofu, B.S.; Mangosho. T.; Rugwejera, T.; Munjeri, K.; Dera, T. O.; Gutu, T.
Understanding the effects of thin film electroless deposition parameters at nanoscale is crucial for complete understanding and control of the thin film deposition process. In this study, we investigated and optimized the effect of PdCl2 precursor concentration on the nanoscale surface morphology of electroless deposited Pd thin film. The FESEM characterization of plain substrates showed that the dominant features of plain alumina substrates were terraces, steps and bumpy microstructures and the final surface morphologies of the deposited Pd thin film was strongly dependant on the surface morphologies of the substrate. FESEM characterization results of seeding technique displayed a thin film of Pd nanoparticles on the surface of the alumina substrate. The number of times that the seeding process was carried out was optimized at five seeding times using hydrazine as a reducing agent. FESEM characterization revealed that the nanoscale surface morphology of the Pd thin film was strongly dependent on PdCl2 precursor concentration. Three types of secondary nanoscale surface morphologies formed were nanorods, nanoflakes and flowerlike Pd nanostructures at various concentrations. The nanoflake surface density was strongly dependent on PdCl2 precursor concentration. Results of this research provided a foundation and method to tailor the nanoscale surface morphology to the specific requirement of surface dependent processes or reactions.
Agility as a strategy in Zimbabwean manufacturing industries
(NUST, 2023) Muhla, T.; Mapindu, I.; Munyau, M.; Mhlanga, D.M.S.; Goriwondo, W.
Customer needs as well as requirements are always in a continuous state of flux and more often than not, Manufacturing Companies find themselves in a quandary as they try to meet these. The inherent ability of Manufacturing Companies to meet the ever-changing customer requirements is key in ensuring that they are able to gain a competitive advantage over their counterparts as well as succeed in this highly volatile market. The advent of the COVID-19 pandemic as well as its noticeably widespread effects also brought about disruptive effects within an already turbulent environment as the Zimbabwean Manufacturing Sector was not spared the scourge of the pandemic. The organizations thus have to gain resilience so as to be able to thrive as well as grow competitively within their sector. The purpose of this paper was to assess how applicable the Agile Strategy is within the Zimbabwean Manufacturing sector as well as to come up with effective methods by which the strategy could be adopted by more organizations within the sector. The key drivers to the implementation of the strategy within these sectors as well as challenges associated with the implementation were also reviewed in depth.

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