Showing posts with label Project. Show all posts
Showing posts with label Project. Show all posts

Thursday, January 5, 2012

Taguchi and Quality in Manufacturing Industry

Quality is one of the most important aspects demanded from a product. Quality represents image and reliability of a manufacturing company, thus proves the importance for it to be stressed by the company. In manufacturing and quality engineering in general, the field quality itself could not sway from the name Genichi Taguchi. Taguchi contributed a lot in terms of quality in product and process design. Two of the important methods in quality engineering are robust design and loss function.

In robust design, Taguchi stresses that product and process should create a design that can avoid failure or product performance below specified standard. Meanwhile, Taguchi loss function stresses more on tolerance of design. This is because a product that performance outside the tolerance is considered loss in value and products must always perform within the desired tolerance.

These two ideologies are very important for production of a new product. Acceptance of a new product by consumers depends very much on the initial impression in terms of quality. Physiologically, it is very hard for a consumer to use a new product compared to using a product which the consumer has used before. If a consumer chooses to use a new product rather than an existing product, feedbacks will go very bad if the quality of the product is not good. In fact, quality level of a new product must be very high especially in the initial stage where it is still gaining acceptance from the society.

Friday, August 19, 2011

Fish Pond Project: Part 2 (End)

Waterproofing is not that easy...and not that hard too..quite simple oso...wat's my point?? I oso duno... The thingy is like water really..it's water based... but once they're dried up, it'll form some sort of 'plastic' layer..to apply them, use our ordinary paint brush...


After they're dried up..baru can apply cement over them... I used base coat cement, you can buy a sack from most hardware store for RM36... The cool thing about this cement is that the manufacturer already mix it with sand... So it's already in a good ratio between cement and sand... It's perfect for smooth wall finish and of coz kerja tampal-menampal...


The water ratio is quite hard to control.. coz if the mix is has too much water..then you can't use it so plaster the side walls...but for the base it's good..easier to spread.. For the walls..it's better to make the mix a little dry...


After main plaster... we pray for rain to come to fill in the pond..of coz..don't ask for rain immediately... ask for it to fall the day after or so... Rendam for 1 month..of coz release the water every few days..the idea is to cuci the pond by removing chemical contents released by the cement..adding water plants can help to neutralize the water too...so 1 month should do it...


So..macam itulah ini project... Will post pics of fishes in the pond later later la.. ahaks..

Sunday, July 24, 2011

Fish Pond Project: Part 1

Dad's fish pond was leaking...so dad asked me to handle it... That means moving all fishes into the aquariums and drain all the water in the pond. After draining, spraying the pond surface with the water gun...all these 3 things took 1 full day to do... not that easy eh... Day one, done...


Day two...looking for defects (macam LI pulak)... before applying waterproffing on the surface, it is importan to plaster the defected surfaces (cracks...thinning surface etc..)..


Then baru apply waterproofing... This will take out another full day.. Next step, next post la..to be continued...ahaks...

Friday, March 25, 2011

Process Control Monitoring, Controlling and Management

With the vast pace of change over the years, process control has been an important part of any industry. With scarce sources around, the industry demands a more efficient process control in order to produce quality products with minimum cost. That is why we see evolution of better and better process control system from open loop back in the old days to cascade control, a now commonly used system control option.

In the real world, industries do not just have one process control, but plant wide control level. With so many process control system, it is important for us to have process monitoring and control. The main point is to monitor processes in a plant as well as control them, thus ensuring quality production efficiently. Basically there are 2 process monitoring and control method; traditional method and Statistical Process Control.


Other than controlling the process system by implementing monitoring and controlling, it is equally important to manage monitoring and controlling. This is done by planning, organizing, leading and controlling the management itself. In short, we have to manage the organization properly from top management to floor staffs to ensure proper. This will ensure proper flow of order from executive level to technical staffs and this contribute indirectly to quality production of product based on Cobb-Douglas Equation Function.

R484@RABA

Remember that I've been telling you guys that I'm busy with my projects.... well, one of them was finally over last Thursday when we 'succesfully' demo on stage during Engineering Week.


This project is a simple project where we build robot by using LEGO Mindstorms Education set. Yeah, I know..LEGO... macam budak budak... that's why ada rasa malu sikit during demo coz it's just a simple robot made from LEGO set. Quite a lot of people watching ba...demo openly ba itu...


The project itself lasted 3 weeks, with the hardest part is to calibrate the light intensity sensor. For our robot, light intensity sensor is used to detect track borders as well as identifying red balls.


Basically our robot, R484, is built based on a real life example, a space rover. It runs and move randomly within an area in search of set point objects. Once the robot gathers the object, it will return to base. Thus, our robot searches for red balls instead of blue balls, and it will return to base after that.



Our main problem was the light intensity sensor. It is very hard to calibrate since the sensor only identify an object as white or black. So, it's either darker or lighter....But in the end, ok la....hopefully get enough marks la...byah!

Tuesday, November 2, 2010

Project: River-Taxi Project_Part 7_Model Making

The materials being used for the model construction are polystyrene and cardboard. The selection of these materials is based on the availability of the material, the reliability, affordable in terms of cost and the ease of handling. Polystyrene and cardboard are among the most commonly used materials for a model development and can be bought from any stationery shop. Although these materials have less strength compared to metal, wood or fiberglass, they are dependable and have some advantages for certain criteria. For example, the polystyrene does not absorb water (some wood does) and it also can easily float due to the lightweight (low density). These criteria are the beneficial advantage in the construction of the boat hull or the lower deck for the river taxi model.


Another reason for selecting polystyrene and cardboard as the material for model is the handling equipment. Handling equipment is a very important aspect to be considered in the construction process of the model. It is use to reshape, cutting or joining the material (polystyrene and cardboard) into the desired form. Among the handling equipment being used in the construction of the model is a penknife (cutter), scissors, hot glue, adhesive tape and double-sided adhesive tape. All these handling equipment are easily operated and available.


During the construction process of the model, there are a few methods of joint being used. Each joining methods used are choose based on the required type of joint, the effects on the worked surface (any reaction with material) and the flexibility. The joining method used is such as adhesive bonding, whereby a hot glue or adhesive tape is applied on the contacting surface to be joined. However, there is some type of adhesive bonding such as super glue could not be used as it will erode the material used (polystyrene) due to the chemical content.

Project: River-Taxi Project_Part 6_Material for the hull

Selecting the right material for the hull of boat or any other water transportation is crucial. The information about the material should be revised a few times before it could be selected. Selecting the wrong material may causes flaw in the design and disaster.

In selecting the right material for the hull, three common materials in boat manufacturing are selected to decide which material the most suitable for the design. The materials are wood, aluminium and fibreglass. All sort of aspect should be studied in order the come out with the most suitable material. The characteristic of the wood, aluminium and fibre glass are listed as below:

Wood
Wood usually been seen as the material for the boat. Wood has good floatation, increasing the buoyancy of the river taxi. Besides that wood is strong material and it is flexible, making it easy to be altered in shape. However wood have its own weakness, which is rotting. From the interview made, a boat that uses wood it could sustain up to 10 to 15 years only before the wood rots.

Aluminum
Aluminium is lightweight and this is crucial for the river taxi design. Additionally, aluminium has good strength and it does not rot. However there are still weaknesses in aluminium, which is corrosion. Corrosion is chemical phenomenon that occurs on metal. Not only it would make the appearance of river taxi bad, it also causes leaking to the hull.

Fibre glass
The use of fibreglass in boat manufacturing becomes very popular nowadays. This mainly due to its strength property, which is relatively strong. Besides, fibreglass is also durable compared to wood or aluminium. On the other hand, fibreglass is economical and affordable and this is the factor why fibreglass is widely used nowadays. Fibreglass is a type of polymer; therefore it would not corrode or rot.

As for conclusion, the suitable material to be chosen for the hull is fiberglass. Fibreglass has greater advantages for safety, buoyancy and maintenance.

Project: River-Taxi Project_Part 5_ Problems Regarding River Taxi

Batang Lupar is famous for its tidal bore phenomena that attract a lot of tourist from all over the world. However, in developing river taxi design for this region, the tidal bore itself would be a major problem. The tidal bore can cause problem towards the conventional private boat or express boat if the skipper is not well versed on Batang Lupar. In addition to that, there are not many-experienced skipper around.

The velocity of the river flow that is not uniform means it is hard to determine the suitable engine’s horsepower. Additionally there are debris scattered along the river, especially upstream. Due to this, boat users have to navigate slowly to avoid hitting debris that could cause danger to the boat users.

The formation of sandbanks at several areas especially near to Pulau Seduku limits the boat traffic beyond the area. Boats can only pass through the area during high tide and high-tide only last for 2 hours. After that, the level will be too low and considered unsafe for boaters to pass through.

Other problem associated with the river taxi development is the scattered settlement of the Sri Aman residents. It is important for us to measure the distance required for the river in order to determine the size of fuel tank and the size of the boat itself.

Finally, the cost of building the new river taxi must be considered. From economic point of view it is important to communicate with the client at the early stages so that changes could be made earlier to avoid extra cost and increase the saving towards the cost. Since there are a lot of problems to be tackled by the new design, the cost to solve them will be quite significant. Additionally, the number of demand of the customer is important in order to estimate the utilization of the new river taxi.

Project: River-Taxi Project_Part 4_ Sri Aman Town

Sri Aman is a small town, located around 194 km from Kuching. Formerly known as Sri Aman, it is the 2nd division in Sarawak. Currently, there are 90600 residents scattered all over the division, especially along the river because the river was once the main part of transportation (water transportation) and most areas are reachable by river. Source of income for Sri Aman is agricultural production: rice (along Batang Lupar), palm oil production, pepper, rubber and tourism. Tourism in Sri Aman is centered mainly on Batang Lupar.

Batang Lupar is stretch from Kelingkang Range to South China Sea and the length is around 275km. It is along this river the famous Bujang Senang (a huge crocodile) was found and later shot dead. In fact, Batang Lupar is famous for crocodiles and most crocodiles can be seen sunbathing along the riverbank. Despite the danger posed, crocodiles in Sri Aman are one of tourism attraction and there will be a sanctuary park specially made for the crocodiles in Pulau Seduku.

Other than crocodiles, other tourism attraction along Batang Lupar are Pesta Benak (regatta, benak surfing), tidal bore sighting, Gunong Lesong (for a scenic viewof Batang Lupar), eco-fish (at Batang Ai), Taman Benak and historical sites like Fort Alice and Fort Leonora.

A new attraction proposed to increase number of tourists is the River-Taxi. With the River-Taxi, tourists will be able to ride safely along the river to observe crocodiles, floras and other beautiful scenes. In addition to that, tourists will be able to experience riding the benak and able to reach rural areas to visit Iban longhouses. Other than for tourism purposes, the River Taxi might be able to once again be a source of public transportation for locals.

Saturday, October 9, 2010

Project: River-Taxi Project_Part 3_Personal visit to Sri Aman

It's an advantage for me when I first knew about this River-Taxi project. Yala, Sri Aman is my mum's hometown so I can reach quite a number of people for information. It's even better since my mum's longhouse is along one of the tributaries (Undop, Lemanak, Skrang and Batang Ai) of Batang Lupar. So during the Raya holidays, I went off to Undop to interview a few locals.


Sungai Undop is further upriver of Batang Undop. The river is quite shallow but quite wide. The flow is quite fast (rapid) and there are a lot of dead tree trunks here and there. In addition to that, the river is nothing like Batang Lupar. Undop have clear water (in the picture it's not so clear because every time it rains, muddy water from logging will pollute the river) and it's with rocks rather than mud.


Thus, it is quite hard for one to use power boats but some do use small boats to fish and travel by short distance to their orchard. However, the scenery of flora and fauna along the river is breathtaking. It's no surprise that tourist do come over to the longhouse to stay for a night (home-stay).


Boats for locals to town is not necessary because it's a lot easier to go by road but if we view it in terms for tourism, then it's worth a shot. However, it's not that easy to do due to the depth of the river...How now???? Byah!!!

Thursday, October 7, 2010

Project: River-Taxi Project_Part 3_Travel Log to Sri Aman

On the 19th August, we (Brian, Jong and I from Group 10, Stroyan and Raddy from Group 9) went to Sri Aman as part of our project requirements. We aimed to be able to conduct survey sessions at designated schools and random interview session with some of the locals. Designated schools are SMK St. Luke, SMK Simanggang and SMK Sri Aman. However, we did not conduct survey session at SMK Simanggang due to technical reasons. Brian and I conducted the survey sessions while Jong joined the guys from Group 9 to interview locals at the waterfront. In the end, we went home on the 20th August, satisfied with our trip to Sri Aman. Below is the journey log of our trip:

19th August

6.25 pm – Picked up Brian, Raddy and Stroyan from BRC and then Jong from Cempaka.


6.30 pm – Went off from UNIMAS after double-checking everything.

8.15 pm – Reached Serian. We stopped for dinner because if we continue on to Sri Aman, it’l be 11pm plus. There might be any eatery open at that time, it’s not like Kuching. If you look closely, we reached Serian after an hour plus drive from UNIMAS. Standard driving time to Serian from Kuching is 45 minutes. Thanks to someone, we spent 30 minutes looking for Berita Harian…..hahahaha…boh marah….enjoy… For dinner in Serian, Jong ordered kangkung belachan, deer meat, stewed pork leg, vege-soup and of course..rice.

9.20 pm – Went off from Serian. Raddy nearly got left behind hadn’t it for Jong to inform me that Raddy was not in the car. Sorry Raddy..sik sengaja bah….. Ney la aku tauk ko gik di jamban… Anyway, our jouney from Serian to Sri Aman was not so smooth. The road was dark and it was a rainy night. I had to drive slower, about 80km/hr…..


11.30 pm – Finally we reached Sri Aman (Jong and Raddy muntah..hahaha..tedah). We stayed at Hotel Taiwan, quite cheap la…. Each of us basically spent RM15 for accommodation. For a spring bed, aircond, tv, hot shower and fresh towel…ok wat…. I was soaking wet since I went to offload the stuffs from my car. Dah la sikda mbak spare short pants…huhuhu….

11.50 pm - After we all went for a warm shower (not together-gether okay..), off we went around town looking for supper. We went to a coffee shop but we’re not warmly welcomed. Maybe because we didn’t order beer like other tables. Only Brian and I had something to eat. The rest just ordered drinks… well, we eventually ordered beer, but tapau to our room la. The plan was to drink beer while discussing on who’s doing what and where….mok bincang cara US la tek…. But due to fatigue, we all tido terus lepas minum…ahahahah…


1.00 am - zzzzzz...dah 20th pun...

20th August

7.00 am – Rise and shine everybody….. Stroyan was the last one to get up… But it’s not so important for him (and for Jong and Raddy) to wake up early because they only need to interview a couple of locals and that’s it. For Brian and I, we needed to go to 3 schools.


8.00 am – Off we went to SMK St. Luke. Although I’ve been to Sri Aman a gazillion times, I don’t really know the roads. We just agak agak…hahahha..nasib I printed out a map (TQ google earth..)

8.10 am – Reached SMK St. Luke…Phew..that wasn’t so bad eh… nasib Sri Aman town is a small town…. We went to their office and we warmly welcomed by the staffs. The school principle was out for a meeting, so the Penolong Kanan entertained us. A very nice fellow and he even went on to conduct the survey session for us… Brian and I just jadi tukang pegang form jak…hahahaha…

8.45 am – Semua done…we thanked the Penolong Kanan and we’re off to the next school, SMK Sri Aman…

8.50 am – Thanks to Penolong Kanan SMK St Luke, we didn’t waste a lot of time looking for SMK Sri Aman. Again we were warmly welcomed by the staff (they expected us ba..we faxed and called all schools a few days before coming over). It’s meeting day for all school principles, so the Penolong Kanan again la…. He’s kinda sik hal sik hal type of person..meaning we can do whatever la….and he didn’t really stay with us for long….after showing which classes available for survey session, he went off… sik hal….ok juak….

9.40 am – We wanted to finish SMK Sri Aman before class break but sik sempat… Most teachers preferred us to conduct the surveys by end of class session ba.. That’s why lambat done… Next up, SMK Simanggang….

10.15 am – I basically don’t know where is SMK Simanggang…. I only knew it’s near Jalan Kelab…So I just drove around aimlessly..ikut nasib jak…. Mot of the time we turned right at junctions..and tada!!!! Jumpa sudah….. At SMK Simanggang, things were different… We were escorted to the school office by the guards (rasa betul2 outsider eh..).. Sampai di office, we had to wait for 15 minuted because someone was with the school principle (I tot it’s hari meeting principle eh..ponteng ka??) After waiting and waiting..baru dapat jumpa… The thing is, he didn’t know we’re coming (tapi his staffs tauk pulak..sapa yg sik kerja tok???)..and bla bla bla….. technicalities forbid us to conduct our survey..so we went off to waterfront area with a lil of perasaan kecewa…


11.00 am – Meet up the rest at waterfront…sedang berposing-posing….. yala..1 hour pun dah cukup for interview ba….. Off we went to our hotel, check out time 12 noon…


Noon – check out…. Before pulang..makan dulu mee dawai Sri Aman… sedap wooo……

1.00 pm – Time to pulang…….


1.50 pm – Reached Lachau..stopped over for some refreshments and buang air air di jamban….

2.00 pm – Bergerak lagi…to Serian…. Hujan also la…

3.15 pm – Pit stop at Serian…mok kemeh ba….bocor kelak… kejap jak..then terus jalan to UNIMAS

4.05 pm – Sampai UNIMAS…..sempat gik Raddy and I turun kelas….

Well….that’s all la perjalanan. Overall, fun also….. Penat juak la.. Byah!!!

Tuesday, September 14, 2010

Project: River-Taxi Project_Part 2

Right now I'm in the process of dissecting the outcome of our survey in Sri Aman... The most significant information is shown below. From the picture, we can see out of 198 respondents, 59 of them stay near river while the other 139 stays in villages further in land or in town area.


Interestingly, we observe that out of those staying near river, only 23 respondents uses water transportation while 36 others do not use them. Reasons stated are concerns on the safety aspect of water transportation, the low or non-existent of public water transportation and the availability of roads from their houses to town. From respondents not living near river, we’re surprised that there are water transportation users among them, 32 of them. Of course the other 107 of them do not use water transportation because they don’t need to.

I expected more users from those staying near river and no user at all for those staying further inland... oh well..Byah!!

Thursday, September 9, 2010

Project: River-Taxi Project_Part 1

One of my course for this semester is Engineering Design, where we are required to learn the necessary steps to design something, ranging from a pen to a huge machine. For this course, the biggest marks will come from our project and this semester, the theme is River-Taxi.

River-Taxi project theme came around when CM of Sarawak commented that water transportation should be used in most of Sarawak because we have a lot of rivers and most of them are inter-connected. Thus, there you go. The setting of this project (base) is Batang Lupar in Sri Aman.

Sri Aman is the 2nd Division in Sarawak, roughly 2 hours 30 minutes from Kuching. The town center is located near the river itself and river transportation used to be the main transportation from Sri Aman to other villages until the introduction of proper roads. Since then, water transportation slowly died and the only ones left are fishing boats and personal boats belonging to those living further up and down river (a few villages not linked with roads).


Our task is to come up with a scaled model of a boat (River-Taxi) which can carry at least 10 people. But that is not all since we have to consider the speed of the river and also the occurrence of tidal bore. Plus, we must also consider the needs and wants of the Sri Aman public so that they will be attracted to use water transportation again. In addition to that, the topographical factor of Batang Lupar and it's subsidiary rivers must also be taken into consideration.

It is a daunting task for my group comprising Quazo, Biduq, MD Shukry, Jong and myself. This is the intro of our project, I'll post the rest of our progress as soon as later....Byah!!!!!!!!!