PELAKSANAAN PENGGUNAAN RUBRIK PROJEK ILMIAH PROGRAM SARJANA MUDA KEJURUTERAAN MEKANIK DAN PEMBUATAN

PELAKSANAAN PENGGUNAAN RUBRIK PROJEK ILMIAH PROGRAM SARJANA MUDA KEJURUTERAAN MEKANIK DAN PEMBUATAN

Jaharah A. Ghani, Baba Md Deros, Jaafar Sahari and Ahmad Kamal Ariffin Mohd. Ihsan

Abstrak: Projek Ilmiah merupakan satu kursus yang sangat sukar untuk dinilai secara adil. Ini disebabkan oleh penyelia yang terdiri daripada pensyarah–pensyarah yang kebiasaannya mempunyai pemahaman dan harapan serta jangkaan yang berbeza-beza sebagai seorang insan. Oleh itu, bagi mengurangkan masalah ini satu kaedah penilaian menggunakan rubrik telah diperkenalkan. Kajian mendapati bagi tujuan penilaian Projek I, semua pensyarah telah memberikan markah kepada pelajar di bawah penyeliaan mereka seperti dalam borang pemarkahan yang disediakan. Sementara bagi tujuan penilaian Projek II, bagi pelajar kursus KP4923, pensyarah telah menilai mengikut rubrik yang disediakan. Walaubagaimanpun, bagi kursus KJ4023, hampir 40% penialaian markah mereka tidak berdasarkan rubrik yang telah disediakan.

Kata Kunci: rubrik, projek ilmiah, penyelia, penilaian, markah.

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PENILAIAN OBJEKTIF DAN HASIL PROGRAM PENDIDIKAN BERASASKAN HASIL (OBE): SOAL SELIDIK MAJIKAN INDUSTRI DAN ALUMNI

PENILAIAN OBJEKTIF DAN HASIL PROGRAM PENDIDIKAN BERASASKAN HASIL (OBE): SOAL SELIDIK MAJIKAN INDUSTRI DAN ALUMNI

Shahrir Abdullah, Norhamidi Muhamad, Riza Atiq Abdullah O.K. Rahmat, Baba Md. Deros, Noorhisham Tan Kofli, Mardina Abdullah, Mazlan Mohd. Tahir dan Andanastuti Muchtar 

Abstrak: Konsep pengajaran Pendidikan Berasaskan Hasil (OBE) mula diamalkan di Fakulti Kejuruteraan UKM bermula tahun 2005. Melalui pendekatan ini, setiap program perlu menggubal objektif pendidikan program dan hasil program setelah mengambil kira input daripada pihak berkepentingan seperti kerajaan, majikan, dan alumni. Justeru, kertas kerja ini membentangkan kaedah yang digunakan untuk mengukur persepsi kepentingan serta pencapaian penyataan-penyataan objektif pendidikan program (PEO) dan hasil program (PO) bagi program-program kejuruteraan yang ditawarkan. Dalam kaedah ini, setiap penyataan dikenal pasti ciri-ciri yang membentuknya dan dinilai mengikut skala Likert 1-5. Kaji selidik ini dihantar kepada industri dan alumni yang ada dalam pangkalan data Latihan Industri dan Alumni Fakulti Kejuruteraan dan soalan yang ditanya berkisar kepada paras signifikan penyataan tersebut atau pencapaian para graduan dan alumni. Keputusan kaji selidik ini dibentangkan berdasarkan input tersebut.

Kata kunci: pendidikan berasaskan hasil (OBE), objektif pendidikan program (PEO), hasil program (PO), soal selidik.

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KAJIAN KES PERLAKSANAAN PROSES KAWALAN STATISTIK (SPC) DI INDUSTRI PEMBUATAN MALAYSIA: PERMASALAHAN DALAM PERISIAN SPC

KAJIAN KES PERLAKSANAAN PROSES KAWALAN STATISTIK (SPC) DI INDUSTRI PEMBUATAN MALAYSIA: PERMASALAHAN DALAM PERISIAN SPC

Rosmaizura Mohd Zain, Mohd Nizam Ab Rahman, Zulkifli Mohd Nopiah, Jaharah A Ghani, Baba Md Deros, Nurhamidi Mohamad and Ahmad Rasdan Ismail

Abstrak: Proses Kawalan Statistik atau Statistical Process Control (SPC) merupakan satu teknik penting dalam kawalan kualiti. Penggunaan kaedah berstatistik ini ternyata dapat mengawal proses pengeluaran serta meningkatkan kualiti produk. Artikel ini menerangkan tentang kajian kes perlaksanaan SPC yang dijalankan di industri pembuatan Malaysia. Kajian ini memfokuskan kepada permasalahan dalam perlaksanaan perisian khusus SPC serta penglibatan pihak syarikat dalam mengendalikan aktiviti ini.  Kajian ini dilaksanakan melalui kaedah temuramah serta soal selidik ke atas perwakilan dari setiap syarikat, dan kaedah pemerhatian persekitaran syarikat. Hasil kajian ini didapati bahawa terdapat kelemahan atau permasalahan dalam perlaksanaan SPC di industri pembuatan. Antara permasalahan yang telah dikenalpasti adalah fungsi perisian SPC yang kurang efektif seperti tidak dapat memaparkan nilai data pada masa sebenar (real time data), dan mempunyai fungsi statistik yang terhad, contohnya tidak menyokong pembinaan carta kawalan sifat.  Selain itu, kelalaian dalam mengambil bacaan dan kesilapan memasukkan nilai data oleh pekerja adalah merupakan permasalahan yang terlibat dalam perlaksanaan SPC. Walaupun SPC yang diaplikasi di industri pembuatan adalah terdiri dari pakej perisian yang berbeza, namun ia dapat menawarkan fungsi terbina statistik yang berguna. SPC merupakan satu teknik yang mudah, tetapi implementasi dalam organisasi begitu kompleks kerana ia melibatkan sokongan dari beberapa faktor utama seperti penglibatan pihak pengurusan yang sepenuhnya, memberi latihan dan pendidikan SPC kepada pekerja dan meningkatkan komunikasi yang berkesan di antara pihak pengurusan dan operator.  

Kata kunci: Kualiti, Proses Kawalan Statistik (SPC), Pengurusan Kualiti secara menyeluruh (TQM), kajian kes.

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FUNDAMENTAL SITTING ANTHROPOMETRIC AND DIFFERENCES AMONG MALAYSIAN MALAYS, CHINESE AND INDIANS

FUNDAMENTAL SITTING ANTHROPOMETRIC AND DIFFERENCES AMONG MALAYSIAN MALAYS, CHINESE AND INDIANS

Md Deros,B., Daruis, D.D.I. and Mohd Nor, M.J.

Abstract: In ergonomic point of view anthropometric data is very important in product design and other applications. Hence, it is important that the data is representative of the target user or consumer of a product being designed. Few individual efforts has taken place in Malaysia in order to establish an anthropometry database that could be use to represent the Malaysian population. This is an addition to those efforts where each main race of Malaysian namely the Malays, Chinese and Indian has been measured. The measurement comprised of 16 dimensions, using traditional measuring tools. In this paper, 226 subjects were analyzed. Focus is given to seat design requirements such as sitting shoulder height for seatback lateral support, buttock to popliteal length for thigh support and sitting hip breadth for cushion width. There are significant differences between some body parts among the three races particularly in stature the proportion of the upper body part and the lower body part, which are highly correlated to body height. 

Keywords: Malaysian anthropometric, seat design, ethnic difference, stature, sitting.

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PEMBANGUNAN PANGKALAN DATA ANTROPOMETRIK UNTUK RAKYAT MALAYSIA

PEMBANGUNAN PANGKALAN DATA ANTROPOMETRIK UNTUK RAKYAT MALAYSIA

Darliana Mohamad, Baba Md Deros dan Ahmad Rasdan Ismail

Abstrak: Data antropometri untuk sesuatu populasi adalah amat penting bagi proses rekabentuk dan pembuatan sesuatu produk atau tempat kerja. Walaupun kepentingan data antropometri dapat dilihat dengan jelas namun sehinga kini masih belum terdapat pangkalan data antropometri  yang dibangunkan bagi mewakili populasi rakyat Malaysia. Kertas kerja ini membentangkan mengenai keputusan kajian data antropometri yang telah dijalankan ke atas rakyat Malaysia. Tujuan kajian pengumpulan data ini dilakukan adalah untuk membangunkan satu pangkalan data statik untuk rakyat Malaysia bagi memudahkan suatu rekabentuk dan pembinaan kemudahan diwujudkan. Seramai 408 individu diukur yang terdiri daripada 193 lelaki dan 215 wanita. Sebanyak 18 data antropometri dikumpul bagi setiap individu. Data dikumpul menggunakan cara pengukuran manual iaitu dengan pita pengukur dan pembaris. Penulis percaya data yang dikumpulkan ini dapat mewakili ukuran badan rakyat Malaysia secara umum.  

Kata kunci: Antropometrik, Ergonomik, Malaysia

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PRACTICAL APPLICATION OF BENCHMARKING TECHNIQUE IN SEMICONDUCTOR COMPANY

PRACTICAL APPLICATION OF BENCHMARKING TECHNIQUE IN SEMICONDUCTOR COMPANY

Tan Jun, Baba Md Deros and Mohd Nizam Ab Rahman

Abstract: This paper presents the practical application of benchmarking technique in Semiconductor Company. It begins with the literature review of benchmarking implementation. A study is carried out to understand the relationship between semiconductor industry’s supply chain and benchmarking practice. This study is focus on the semiconductor companies and professional personnel in semiconductor field. From the study, the result shows that benchmarking term and activities is not very familiar in the industry personnel. However, a lot of comparison had made in data presentation. Thus, a better and easier decision could be made. Through benchmarking technique also, a clearer view will be seen to have a better understanding on internal and external strengths and weaknesses respectively.

Keywords: benchmarking, semiconductor company.

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ANALISIS OWAS DAN RULA KE ATAS OPERATOR PENGENDALIAN MANUAL DI INDUSTRI AUTOMOTIF

ANALISIS OWAS DAN RULA KE ATAS OPERATOR PENGENDALIAN MANUAL DI INDUSTRI AUTOMOTIF

A.R.Ismail, Y.M.Lee, B.M.Deros and M.N.A.Rahman

Abstrak: Work related musculoskeletal disorders (WMSDs) merupakan salah satu masalah kesihatan pekerjaan yang terbesar dalam industri. Pekerja industri mudah terdedah dalam ketidakselesaan dan kesakitan semasa bekerja dalam postur yang bermasalah (awkward posture). Selain daripada membawa masalah kesihatan pada pekerja, ia juga membawa kesan jangkamasa panjang terhadap prestasi pengeluaran. Objektif kajian ini adalah bertujuan untuk mengkaji postur kerja pekerja di industri dan mencadangkan postur optimum pada pekerja tersebut bagi meningkatkan kadar pengeluaran di industri. Projek ini dilakukan dengan menggunakan tiga kaedah iaitu soal selidik ketidakselesaan kerja, analisis postur OWAS dan RULA. Sebanyak 80 borang soal selidik ketidakselesaan kerja diedarkan kepada operator dalam industri automotif untuk mengenalpastikan tahap ketidakselesaan kerja. Analisis postur dilakukan ke atas seorang operator di industri automotif. Postur pergerakan kerja postur akan direkodkan ke dalam perisian WinOWAS dan CATIA V5 R16 dan kedua-dua analisis dijalankan masing-masing. Analisis OWAS dan RULA dapat mengenalpasti postur bermasalah (awkward posture). Melalui keputusan yang diperolehi melalui analisis, perbandingan antara soal selidik ketidakselesaan kerja, kaedah analisis postur OWAS dan RULA dilakukan dan postur yang bermasalah akan diperbaiki bagi mendapatkan postur pergerakan optimum bagi subjek. Terdapat beberapa batasan kajian yang dikenalpasti semasa kajian ini dijalankan iaitu disebabkan pengunaan hanya seorang sampel sahaja dan pengunaan anggaran sudut badan semasa merekod kerja postur ke dalam perisian. Postur optimum untuk subjek melakukan kerja bagi mengelakkan masalah ketidakselesaan dan meningkatkan tahap keselamatan dapat diperolehi melalui kajian ini.

Kata Kunci: OWAS, RULA, Postur Awkward, WinOWAS, CATIA, Ergonomik

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KAJIAN BEBANAN MELAMPAU MENGGUNAKAN KAEDAH LUBA DI KALANGAN PEKERJA PEMASANGAN INDUSTRI AUTOMOTIF DI MALAYSIA

KAJIAN BEBANAN MELAMPAU MENGGUNAKAN KAEDAH LUBA DI KALANGAN PEKERJA PEMASANGAN INDUSTRI AUTOMOTIF DI MALAYSIA

A. R. Ismail, N.M.F.Fahmi, M.R.A.Mansor and B.M.Deros

Abstrak: Kecederaan di tempat kerja yang berkaitan dengan ergonomik boleh menyebabkan majikan dan pekerja menanggung kos yang tinggi samada di persekitaran kilang mahupun di pejabat. Banyak kilang yang dibina di Malaysia tidak mempertimbangkan keadaan persekitaran kerja yang ergonomik. Ini menyebabkan prestasi perkerja terutama dari sektor pengeluaran mengalami bebanan melampau sekaligus menjejaskan prestasi pekerja terbabit. Oleh itu kajian ini dijalankan untuk mengukur tahap bebanan (excessive loading ) ke atas operator kilang terutamanya operator kilang yang melibatkan pemasangan komponen automotif di Malaysia. Dengan menggunakan analisis LUBA (loading on the upper body) bahagian-bahagian badan yang terdedah kepada bebanan melampau akan dikenalpasti. Kemudian cadangan pengubahsuaian ke atas postur bekerja dan stesen kerja terbabit akan dilakukan bagi mengurangkan kesan bebanan melampau ke atas produktiviti keluaran pekerja terbabit. Sebanyak 80 borang soal selidik yang digunakan untuk menentukan tahap ketidakselesaan telah diisi oleh operator. Hanya seorang subjek dan satu stesen kerja sahaja digunakan dalam kajian ini. Penggunaan perisian CATIA V5 R16 adalah untuk menentukan atau menganggarkan sudut postur yang dilakukan oleh subjek. Kemudian analisis LUBA digunakan untuk mengenalpasti postur yang bermasalah dan sekaligus memperbaikinya supaya mendapat postur yang optimun dan selamat. Beberapa batasan kajian telah dapat dikenalpasti iaitu hanya satu subjek sahaja yang digunakan dan sudut postur yang digunakan hanyalah anggaran yang diperolehi melalui penggunaan perisian.

Kata kunci: ergonomik, LUBA, postur.

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LEAN VIEWED AS A CULTURE

LEAN VIEWED AS A CULTURE

Norani Nordin, Baba Md Deros and Dzuraidah Abdul Wahab

Abstract: For the past few years, almost every manufacturing industry has been trying to get “lean”. However, many of these firms were not successful or faced difficulties to sustain the success in lean manufacturing. One of the reasons is misapplication of existing lean manufacturing tools that is often due to inadequate understanding of lean manufacturing concept and philosophy. The aim of this paper is to thoroughly discuss the question of “What is Lean Manufacturing?”. In order to address the elements of misconception surrounding lean manufacturing, this paper shall focus on the history, definition, philosophy and existing tools of lean manufacturing. Based on the literatures reviewed, the authors would like to propose a general theoretical framework that will be used as guidelines to the research conducted.

Keywords: lean manufacturing, culture, industry.

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Internal Benchmarking Practice in Malaysia Company

Internal Benchmarking Practice in Malaysia Company

Deros, B.M., Tan, J. and Ab Rahman, M.N.

Abstract: This paper presents the practical application of internal benchmarking technique in a semiconductor company. A qualitative study was carried out to understand about the internal benchmarking technique and its implementation process. In today’s competitive market, companies are forced to design and manufacture high quality and marketable products that are required by the customers. As such, one of the techniques used to achieve these goals is to benchmark the current product that is currently available in the market and to make it better. This internal benchmarking process includes cost effectiveness, quality improvement and process optimization. The result of the study shows internal benchmarking implementation enables the company to understand their strengths and weaknesses. It will eventually drive the company to initiate the continuous improvement activities to improve them. In addition, internal benchmarking implementation also contributes many advantages towards lean manufacturing practices and helps to achieve the company’s business goals. 

Keyword: Internal benchmarking, continuous improvement, cost effectiveness, quality.

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A LITERATURE REVIEW ON BENCHMARKING

A LITERATURE REVIEW ON BENCHMARKING

Baba Md. Deros, Masoomeh Zeinalnezhad, Mohd. Nizam Ab.Rahman and Towhid Pourrostam

Abstract: In today's highly competitive and rapidly changing global economy had forced organizations to consider and implement a wider variety of innovative management philosophies and techniques. One such technique is benchmarking which has been attracting considerable attention for its effectiveness. A large number of publications by various authors reflect the interest in this technique. In the pass, many reviews of literature on benchmarking have been done by many authors. However, considering the contributions in the recent times, the authors had attempted to conduct a more comprehensive review with respect to bench marking technique. In this paper, the authors had reviewed the benchmarking literature in a way that would help researchers, academicians and practitioners to take a closer look at the growth, development and applicability of this technique. There are about 450 articles on the benchmarking topic were published in the last 10 years, as revealed in this literature review. Considering the number of publications it can be said that the benchmarking technique has seen a steady growth and appears to be heading towards maturity level.

Keywords:  Benchmarking, classification, competitive, technique, effectiveness.

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MUSCULOSKELETAL DISORDERS AND JOB SATISFACTION AMONG OPERATORS IN AUTOMOTIVE ASSEMBLY JOBS

MUSCULOSKELETAL DISORDERS AND JOB SATISFACTION AMONG OPERATORS IN AUTOMOTIVE ASSEMBLY JOBS

Mohd Hanifiah Mohd. Haniff , Ahmad Rasdan Ismail and Baba Md. Deros

Abstract: Assembly processes occupy an important position in the automotive industry. Research has explored the association of psychosocial and work organization factors such as job satisfaction and work stress with both lower and upper extremity musculoskeletal disorders. Thus, this study aims to examine the discomfort level base on ergonomics factors and to determine discomfort distribution body relating with the task made. In addition, this study carried out to analyze a core factor that contribute to the worker productivity in determining the features interaction among comfort level, environmental factors (noise, temperatures and evidence light) and workstation dimension. Two hundred and ten samples of operators were derived from five automotive manufacturing companies to identify the dominant factors. This study will be carried out using questionnaire in those factories and data gathered will be analyzed using SPSS software. In the data analysis, research showed that the left shoulder is part of the body most involved in a lot of activity like lifting, pulling, twisting, carrying and holding. Apart from that, majority of respondents reported that their works are exposed to a high level of noise and it was a dominant factor associated with productivity. Improvement must be made and companies must have a particularly important role in establishing a balance between job satisfaction and working methods, and the protection of employees' health, safety and other interests.

Keywords: Musculoskeletal disorders, job satisfaction, automotive industry, assembly work, environmental factors.

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INTRODUCTION OF NEW PRODUCT COMPETITIVE CAPABILITIES, TOOLS AND TECHNIQUES

INTRODUCTION OF NEW PRODUCT COMPETITIVE CAPABILITIES, TOOLS AND TECHNIQUES

Nor Hidayah Abu, Baba Md. Deros and Norani Nordin

Abstract: Competitive Capabilities is very crucial in new product development to sustain market competitiveness. It also influences a firm’s performance. In order to avoid failure in new product development, top management needs to assign product with greater competitive advantage at the very early stage of product design and development activities. Product competitive advantage provides strength of a firm’s ability to meet customer needs, good quality performance and design, at the right time, suitable price, and flexible to uncertainty change. In addition right tools and techniques should be implemented in the firm to ensure the product are better, cheaper and takes shorter time from idea conception to market place. The tools and techniques used in developing the new product must utilise the latest (up-to-date) technology.

Keywords: Quality tool, product development.

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Postural Angle Measurement: Manual vs. Picture Recognition Software

Postural Angle Measurement: Manual vs. Picture Recognition Software

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail, Dian Darina Indah Daruis and Slamet Riyadi

Abstract: At present, there are vast selections of ergonomics measurement tools that have been developed for tasks, equipments and environments analysis. The measurement method for ergonomic assessment is done either by traditional or modern methods. This paper presents a comparative study of two different methods for measuring postural angles of driver’s posture. The first method is manual measurement and the second method is using picture recognition software. The main objective of this study is to validate a new measurement method using the picture recognition software. A simple experiment was conducted in order to gather the required data. During the experiment each subject is required to sit on the driver’s seat in their preferred comfortable driving postures. Angles measurement is then taken after five minutes the subject has been in the sitting position to allow him/her adapt with the seat environment and fabrics. Later, postural angle of the subject’s is measured using angle measurement kits and at the same time picture of subjects on the set is also taken. Results from both methods shows that the new measurement method using the picture recognition software was reliable and could avoid the hassle by reducing time and effort in

the measurement process.

Keywords:  Ergonomic, postural angle, comfort, car seat, Mann-Whitney U test.

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THE BASIC OF BENCHMARKING

THE BASIC OF BENCHMARKING

Baba Md. Deros, Norashikin Rahman and Mohd. Nizam Abdul Rahman

Abstract: The main objective of this paper is to understand the basic of benchmarking technique. It discusses the relationship between quality, TQM and benchmarking, different views of definitions and benchmarking types, evolution of modern benchmarking as well as the advantages of the implementation. Previous studies showed that benchmarking adoption could help the companies to get higher profit and improve their performance. Since benchmarking is a great improvement tool, companies which involved comprehensively in benchmarking implementation would achieve significance benefits than others.

Keywords: Benchmarking, total quality management (TQM), quality

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Application of Malaysian Anthropometric Data in Home Furniture Design

Application of Malaysian Anthropometric Data in Home Furniture Design

Baba Md Deros, Darliana Mohamad, Ahmad Rasdan Ismail and Muhammad Nazeer Muhammad Nazree

Abstract: The objective of this paper is to present the design of home furniture that incorporates the Malaysian anthropometric data. In this study, anthropometric data of 1007 Malaysian respondents’ physical body parts were measured manually using an anthropometer and recorded. It is assumed that the 1007 respondents represent the overall Malaysian population. The collected data were later analysed to determine the: mean, standard deviation, 5th and 95th percentile values of the respondents. Having done that the authors then starts designing the home furniture by using the AutoCAD software. In conclusion, the home furniture designed using Malaysian anthropometrics data would fit, appropriate, comfortable to at least 90% of the Malaysian population with respect to ergonomics, helps to reduce the risks of injuries and pains among Malaysian home furniture users.   

Keywords: home furniture, anthropometric data, Malaysian, ergonomics, respondents.

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DESIGN OF AN ANTHROPOMETRIC MEASUREMENT CHAIR PROTOTYPE

DESIGN OF AN  ANTHROPOMETRIC MEASUREMENT CHAIR PROTOTYPE

Baba Md. Deros, Chia Swee Yoon, Darliana Mohamad and Ahmad Rasdan Ismail

Abstract: Anthropometry plays an important role in ergonomics and product design. Currently, there are various standardized measurement equipments to measure the human body dimensions available in the market. However, these measurement equipments have to be used separately for measuring different dimensions of the human body. In this study, the authors had designed a prototype of anthropometric measurement chair, which could be used to measure 20 anthropometric data both in sitting and standing positions. This prototype that is easy to use can measure the body dimensions of female and male adults. In addition, an analysis on the design of anthropometric measurement model chair prototype was also done. To design this anthropometric measurement chair, the development steps began with the preliminary study and literature review.  During the conceptual design phase, the authors had generated many concepts with respect to the design of anthropometric chair.  After making critical comparisons and analysis, the authors finally selected the most practical design for the anthropometric chair.  Having done that, the authors then determined the final design and dimension of key features for the prototype. Later, it was followed by the detailed design and design analysis with respect to the prototype.  

Keywords: Anthropometry, ergonomics, anthropometric chair.

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DETERMINATION OF OIL PALM PROCESSING ACTIVITIES FOR BENCHMARKING

DETERMINATION OF OIL PALM PROCESSING ACTIVITIES FOR BENCHMARKING

Fatimah Mahmud, Baba Md Deros and Dzuraidah Abdul Wahab

Abstract: Currently, Malaysia is the largest producer and exporter of oil palm. Nevertheless, Malaysia may soon lose its position if there are lacks of initiatives to sustain it. Therefore, this paper aims to introduce the use of benchmarking steps in oil palm processing activities with specific review on various factors influencing the oil palm yield production. With this effort, it will drives the improvement in the oil palm yields; both Fresh Fruit Bunches (FFB) and the Crude Palm Oil (CPO) extraction.

Keywords: Benchmarking, oil palm processing industry, influential factor

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A REVIEW ON LEAN MANUFACTURING PRACTICES IN SMALL AND MEDIUM ENTERPRISES

A REVIEW ON LEAN MANUFACTURING PRACTICES IN SMALL AND MEDIUM ENTERPRISES

Ahmad Nasser Mohd. Rose, Baba Md. Deros and Mohd. Nizam Abdul Rahman

Abstract: The literature studies showed lean manufacturing started at Toyota car manufacturing plant, Japan, which is known as Toyota Production System (TPS). The main pillars in TPS are Just in time and automation which main objective is to identify and eliminate waste in an organization.  Lean manufacturing can be applied successfully in all industries providing a full understanding on lean ingredients i.e. concept, principles and practices. There are numerous practices being highlighted by academicians and practitioners which are compulsory to be implemented in order to gain full benefits of lean.  As small and medium enterprises (SMEs) are resources constraints, facing difficulties to adopt all lean principles. To compete in global competitive marketplace, the SMEs have to strive for world class performance through implementation of lean manufacturing. The main objective of this paper is to carry out a critical review on the lean manufacturing practices. Previous studies showed total lean manufacturing practices could help manufacturing organization to gain full benefits i.e. reduction in inventory, lead time, set up time, and etc., provided they’re adopting all practices. As the resources constraint to SMEs, the selected practices should be feasible to the company problem and low investment.

Keywords: Lean manufacturing, TPS, Small and Medium Enterprises (SME)

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PREVALENCE OF MUSCULOSKELETAL DISORDERS DUE TO MANUAL MATERIAL HANDLING AMONG WORKERS IN AN AUTOMOTIVE MANUFACTURING PLANT IN MALAYSIA

PREVALENCE OF MUSCULOSKELETAL DISORDERS DUE TO MANUAL MATERIAL HANDLING AMONG WORKERS IN AN AUTOMOTIVE MANUFACTURING PLANT IN MALAYSIA

Baba Md. Deros, Dian Darina Indah Daruis and Sawal, N.A.

Abstract: A cross sectional study was carried out among workers at an automotive manufacturing plant in Malaysia. The study has two major objectives: first, to determine the prevalence of musculoskeletal disorders (MSD) among workers who perform the manual material handling (MMH) task; and second, to determine the ergonomics risk of MMH at selected workstations. For the first objective, respondents were selected through random sampling. Then, a body parts symptoms survey (BPSS) data sheets were given to the respondents to obtain the prevalence of MSD among these workers. For the second objective, respondents were selected based on the in-house clinic (IHC) visitations data. Results from 500 respondents showed that the highest prevalence of MSD was low back pain (LBP). It was found from interviews of 17 workers who had 3 or more visitation times to the IHC that the main reason of the ergonomic risk comes from the task that they perform.

Keywords: Malaysian automotive, musculoskeletal disorders, prevalence, manual material handling, back pain.

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A study on Noise Exposure and Its Effects on Employees’ Health, Safety and Productivity in Plastic Based Industry

A study on Noise Exposure and Its Effects on Employees’ Health, Safety and Productivity in Plastic Based Industry

B. M. Deros, M.H.M. Haniff, D. Mohamad, T. J. Yee and A. R. Ismail

Abstract: The objective of this paper is to present a study on noise exposure and its effects on employees’ health, safety and influence to their productivity performance. In this study noise levels were measured at several work locations to determine whether there noise problems or not. Employees may suffer permanent hearing loss due over exposure to high noise level. Therefore, noise level measurement is an important activity at workplace to preserve employees hearing capability and implementing noise control procedure. Sound level meter and noise dosimeter were used for measuring noise level and noise dose at the designated work locations. The study was carried out at three different plants in plastics based industry. The results of the study shows all the work location in the three plants are within the allowable levels according to the First Schedule of Factories and Machinery (Noise Exposure) Regulations 1989, which falls under the Factories and Machinery Act. 5. In essence, the authors could conclude that workers working in plastic based industry in Malaysia are not over exposed to high noise levels beyond the permissible limits as required by law.

Keywords: Noise, exposure, effects, health, safety.

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THE INFLUENCE OF SOUND PRESSURE LEVEL TOWARDS WORKERS’ PRODUCTION RATE

THE INFLUENCE OF SOUND PRESSURE LEVEL TOWARDS WORKERS’ PRODUCTION RATE

A. R. Ismail, M. H. M.Haniff, B. M.Deros, M. N. A. Rahman, M. Z. Nuawi and M. R. A. Rani

Abstract: The aim of the study was to determine the effects of noise on the operators’ productivity and performance at Malaysian automotive industry. One automotive assembly factory had been chosen as a subject for the study. The subjects were workers at the assembly section of the factory. The environment examined was the sound pressure level (dBA) of the surrounding workstation area. One set of representative data, which is the sound pressure level (dBA) and production rate were collected during the study. The production rate data were collected through observations and survey questionnaires while the sound pressure level (dBA) was measured using Quest Hand Held Pro Sound Level Meter. The correlation and linear regression analysis were conducted in order to obtain the relationship between the effects of sound pressure level (dBA) to the worker productivity and performance. The results from the correlation analysis revealed there is a weak negative relationship between the sound pressure level (dBA) and the productivity of the workers. The linear regression analysis further reveals that there is a linear equation model with negative slope to describe the relationship of sound pressure level (dBA) and workers productivity for the assembly section involved.

Keywords: Sound Pressure Level, Productivity, Automotive Industry.

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OPTIMIZING NOISE LEVEL TO ENHANCE INDUSTRIAL WORKERS PERFORMANCE USING ARTIFICIAL NEURAL NETWORK

OPTIMIZING NOISE LEVEL TO ENHANCE INDUSTRIAL WORKERS PERFORMANCE USING ARTIFICIAL NEURAL NETWORK

A. R. Ismail, M. Y. M Yusof, B. M. Deros, M. M. Noor and K. Kaardigama

Abstract: Noise is one of the environmental factors that contribute significant effect on the worker performance in automotive industries. This paper presents an optimization of noise level towards the worker productivity rate at one of the Malaysian industry. An assembly automotive manufacturing industry was chosen to conduct the study by observing and measuring the noise level and worker’s productivity rate. The data then were analyzed by using Artificial Neural Network (ANN) analysis and it is commonly used to analyze and obtain the best linear relationship from the collected data. It is apparent that from the linear relationship obtained, the optimum value of production (value≈1) is attained when the noise level is 81.62 dBA. The optimum value production rate (value≈1) for one manual production line in that particular company is successfully achieved. Using ANN analysis, the optimum environmental factor managed to be predicted.

Keywords: Artificial Neural Network (ANN), Optimum, Productivity, Noise, Environmental.

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CORRELATION BETWEEN HUMAN ANTHROPOMETRIC DATA AND COMFORTABLE DRIVING POSTURAL ANGLES

CORRELATION BETWEEN HUMAN ANTHROPOMETRIC DATA AND COMFORTABLE DRIVING POSTURAL ANGLES

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail and Dian Darina Indah Daruis

Abstract: Drivers fatigue is always associated with road accidents and fatalities. In general, fatigue is a result of long driving duration and static posture. Therefore, in designing a car driver’s seat, it is important to ensure a comfortable driving posture. In addition, presently car buyers have the preference to buy cars that incorporates safe and comfortable features. The main objective of this paper is to discuss the relationship between anthropometric data and comfortable driving postural angles. Forty five participants were involved in this study, which comprise of 19 females and 26 males. Both anthropometric data and postural angles measurement was measured and recorded by using photographic technique and analysed by using a software. During the experiment, each participant was required to sit on the driver’s seat in his or her preferred comfortable driving postures. Images of the participant’s driving posture was taken after five minutes he or she has been in the driving position to allow him/her adapt with the seat environment and fabrics. In order to get high level of data accuracy and reliability, body joints will be marked with sticker markers. Prior to that, 10 anthropometric data of each participant was measured and recorded. The anthropometric and the comfortable driving postural angles were analysed statistically with Pearson correlation using the SPSS software. The correlation relationship result showed that low positive correlation between the stature and elbow angle (correlation coefficient 0.398, p<0.01). Meanwhile, there are three relationships that show low negative correlation for the shoulder to elbow length; between the trunk-thigh angle (correlation coefficient -0.311, p<0.05) and the knee angle (correlation coefficient -0.298, p<0.05); and also between the elbow to grip length and the trunk-thigh angle (correlation coefficient -0.327, p<0.05). The experimental result shows that there is a correlation between the human body anthropometric data and the comfortable driving posture angles.

Keywords: Pearson correlation, anthropometric, driving postural angles, seat comfort.

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DEVELOPMENT OF A MALAYSIAN ANTHROPOMETRIC DATABASE

DEVELOPMENT OF A MALAYSIAN ANTHROPOMETRIC DATABASE

Darliana Mohamad, Baba Md Deros, Ahmad Rasdan Ismail and Dian Darina Indah Daruis

Abstract: Human being plays an important role in the functioning of socioeconomic system such as in developing equipment, machinery, workstation, and objects. The most important criteria which have been suggested in ergonomic were the system must fit anthropometrically, comfortable and safe to use. Therefore the designer must ensure those important criteria such as the anthropometric data were applied before the system could be use by the user. Several literatures were presented in this paper to show the importance of incorporating anthropometric concern in designing processes. Eventhough the importance of anthropometric database is recognised, a published anthropometric database for Malaysian population is still not available. This paper presents a summarized data of a Malaysian population anthropometric study. The objective of the study was to develop an anthropometric database for Malaysian population. The study was conducted using anthropometric data of 1,007 Malaysian consisting of 516 males and 491 females. The equipments used in this study were measuring tools comprised of Human Body Measuring Kit and Anthropometer for body dimension measurements. A total of 40 anthropometric dimensions were measured in this study. The data collection was for both standing and sitting postures. The database comprised of the important values such as the mean and the standard deviation, the 5th and 95th percentile. The study had successfully produced a detailed and comprehensive anthropometric database for Malaysian population which can be used in the future by all designer and engineers in designing process.

Keywords: ergonomics, anthropometry, human-machine, design.

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A CONCEPTUAL FRAMEWORK FOR FRONT-END PROCESS IMPLEMENTATION FOR SMEs

A CONCEPTUAL FRAMEWORK FOR FRONT-END PROCESS IMPLEMENTATION FOR SMEs

Noor Hidayah Abu, Baba Md Deros and Dzuraidah Abd Wahab

Abstract: The purpose of this paper is to present a conceptual framework for front-end process implementation in small medium-sized enterprises (SMEs) taking into consideration their characteristics. The proposed framework described in this paper encompasses two main elements: the “foundation elements” and “general methodology”. In order to ensure success, SMEs need to fundamentally understand the implementation of NPD process within SMEs context, rather than fitting large organizational practice. Current frameworks for front-end implementation process have been developed however some of the frameworks unaware with the characteristics of SMEs which are constraint by knowledge, skills and resources (e.g.: financial, technological, human and time). The first part of this paper elaborates front-end process definition and background. The next part focuses on differences in characteristics between large organizations and SMEs with respect to front-end implementation. Later it followed by comparing and revising some existing frameworks found in the literature. The proposed conceptual framework is believed to be applicable and suitable for SMEs. SMEs are chosen because they played a major role in the development of Malaysian economy. In other words by improving SMEs business process the resultant effect on the overall Malaysian economy will be very significant.

Keywords: font-end, small to medium-sized enterprises, implementation, new product development.

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DATA COLLECTION FOR CAR DRIVER’S COMFORTABLE POSTURAL ANGLES USING PICTURE RECOGNITION SOFTWARE

DATA COLLECTION FOR CAR DRIVER’S COMFORTABLE POSTURAL ANGLES USING PICTURE RECOGNITION SOFTWARE

D. Mohamad, B. M. Deros, D. A. Wahab, A. R. Ismail and D. D. I. Daruis

Abstract: Driver’s posture is one of the most important factors to be considered in car seat design because consumers nowadays prefers to choose a car that is perceived as comfortable and safe. There are many ergonomics measurement tools that have been developed for tasks, equipments and environmental analysis including driver’s posture study. The measurement method for ergonomic assessment can be done either by using traditional or modern methods. In this study, the driver’s posture study was done through image analysis using picture recognition software. The main objective of this study was to compare the comfortable driving angles for three different types of cars. The cars chosen in this study namely Compact Hatchback, Mid Size Saloon, and Saloon B were from compact and entry midsize segment. The total numbers of participants involved in this study were 45. During the experiment, each participant was required to sit on the driver’s seat in their preferred comfortable driving postures. Angles measurements were taken after five minutes the participant has been in the sitting position to allow him/her adapt with the seat environment. The picture of each participant on the set was then captured and later analyzed using picture recognition software. ANOVA One-Way statistical analysis was conducted on the experimental results data. Results show that there are no significant differences between the car types for elbow, neck, shoulder and trunk-thigh angles (at α<0.05 level of significance). However, for knee and foot angles, there are significant differences showed (at α<0.05 level of significance). From post comparison Tukey’s test, the difference for knee and foot angle is between Compact Hatchback and Saloon B.

Keywords: ergonomics, one-way ANOVA, postural angles, comfort.

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VIBRATION TRANSMISSIBILITY OF VARIOUS SEAT OCCUPANTS’ BODY PARTS – A FIELD TEST

VIBRATION TRANSMISSIBILITY OF VARIOUS SEAT OCCUPANTS’ BODY PARTS – A FIELD TEST

D. D. I. Daruis, M. J. M. Nor, B. M. Deros, and M. Hosseini Fouladi

Abstract: Vibration transmissibility from seat to various parts of the body of a number of seat occupants was investigated. The study was carried out in the field using a Malaysian made compact car. Vibration from two types of road and three different vehicle speeds for each road were studied. The effects of three head and back conditions namely head and back supports, back and no head supports and no head and no back supports, were also investigated. Eleven subjects participated in the study. Measurement was done while subject was seated at the front passenger seat. The various body parts measured were right thigh, under the buttock, lumbar, upper back and head (in x-, y- and z-axes). Results show agreement with previous literatures where the median primary resonances were between 4-9 Hz. It was also shown that there were only slight differences with the head and back condition variation except for x- and y-axes for head transmissibility. For both lateral and fore-aft directions, there are large increases of amplitudes when the head and back was not supported as compared to supported back and head conditions. Although it was a field test, coherence values were found to be high (median value of 0.8 to 0.9) for vertical transmissibility however only moderate for fore-aft and horizontal transmissibility (median value 0.7).

Keywords:  seat transmissibility, seat vibration, seat, transmissibility, vibration.

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Modeling of Environmental Factors Towards Workers’ Productivity For Automotive Assembly Line

Modeling of Environmental Factors Towards Workers’ Productivity For Automotive Assembly Line

Ahmad Rasdan Ismail, Mohd Hanifiah Mohd Haniff, Baba Md. Deros, Nor Kamilah Makhta and Zafir Khan Mohd Makhbul

Abstract: The objective of this study is to determine the effects of humidity and of air temperature on the operators’ productivity and performance in the Malaysian automotive industry. One automotive components assembly factory was chosen as the sources of subjects of the study. The subjects were the workers in the assembly section of the factory. The examined parameters were the relative humidity (%) and wet-bulb globe temperature (WBGT) of the surrounding workstation area. Two sets of representative data consisting of the relative humidity (%), WBGT and production rate were collected during the study. The production rate data were collected through observations and survey questionnaires, while the relative humidity (%) and WBGT was measured using thermal comfort multi-station (TCM) equipment. Linear regression analysis was performed to obtain the relationship between the effects of relative humidity (%) and of temperature (WBGT) on worker productivity and performance. The linear regression analysis further revealed a linear model with a positive slope between relative humidity (%) and worker productivity for the assembly section involved. The obtained relationship was Y = 2.79X – 46.1. For WBGT, the linear regression analysis revealed a linear model with a negative slope between temperature (WBGT) and worker performance for the assembly section involved. The obtained relationship was Y = -13.3X + 425.

Keywords: Productivity, Performance, WBGT, Relative Humidity, Relationship.

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Optimizing Humidity Level to Enhance Worker Performance in Automotive Industry

Optimizing Humidity Level to Enhance Worker Performance in Automotive Industry

Ahmad Rasdan Ismail, Mohd Yusri Mohd Yusof, Baba Md Deros,Mat Rebi Abdul Rani and Muhamad Mat Noor

Abstract: The production of automotive parts is an important part of Malaysia’s economy. The main work involved in producing automotive part is the manual assembly process which dependent on manpower capability.  Thus the quality of the product heavily depends on the worker’s comfort under the working conditions. Humidity is an environmental factor that has a significant effect on the worker’s performance. Humidity level and productivity rate were observed in automotive factory. The data were analyzed using an Artificial Neural Network Analysis (ANN). The ANN analysis technique is a common analysis method used to determine the best linear relationship from the collected data. It is apparent from the linear relationship the optimum value of production (value• 1) is attained when the Humidity is 54.86 %RH. At that level, the optimum value production rate (value• 1) for on e manual production line in a particular company is successfully achieved. Through the ANN system, the optimum environmental factor can be predicted.

Keywords: Automotive, Environmental, Productivity, Humidity.

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Organisational Change Management Framework for Lean Manufacturing Implementation

Organisational Change Management Framework for Lean Manufacturing Implementation

Norani Nordin, Baba Md Deros, Dzuraidah Abdul Wahab and Mohd Nizam Ab. Rahman

Abstract: Lean manufacturing system has been widely applied in manufacturing companies worldwide. However, the low rate of success towards the lean transformation in many countries has given a cause of concern. Many literatures had pointed out that the main reason is due to the failure in managing the change process during lean manufacturing transformation. This paper attempts to develop a framework for lean manufacturing implementation. The framework is of particular significance not only because it is about lean manufacturing, but it is set in a context of process change in lean manufacturing transition. This study employed an explanatory mixed method approach, which began with survey distribution, and then the general picture was further refined by conducting in-depth interviews on Malaysia automotive companies. The quantitative and qualitative results shows that the key factors to smooth lean manufacturing transition are: change readiness, leadership and management, change agent system, team development and empowerment, communication, and review system. This stream of lean implementation efforts are the basis of the development of organisational change framework in lean manufacturing implementation. This framework may add to the body of knowledge for both academics and practitioners. At the theoretical level, the framework has important strengths because it explicitly framing the relationship between change management and lean manufacturing implementation. Failure to recognize the required organisational changes to adapt lean manufacturing system will hinder the long-term benefits to the organisation. The framework also may provide practitioners with a better understanding on the lean transition process to minimize resistance and conflicts and thus improve its chance of success.

Keywords: lean manufacturing, organisational change, mixed method research, framework development.

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EPC 2011 REGIONAL ENGINEERING POSTGRADUATE CONFERENCE

A STUDY OF PRE-DEVELOPMENT IMPLEMENTATION IN MALAYSIAN MANUFACTURING SMEs 

N.H.Abu, B.Md.Deros, D.Abd.Wahab, M.N.Ab.Rahman and N.Nordin  

Abstract: Pre-development is an important driver for a successful implementation of a new product development (NPD) project. While large-scale organizations have adopted an efficient pre-development implementation, small and medium enterprises (SMEs) have not received adequate attention from the research community for their pre-development implementation. Therefore, this paper identifies the practice of pre-development implementation among Malaysian food and beverages manufacturing SMEs. It was based on the results of a survey of 156 SMEs in the food and beverage industry. Quantitative data analysis was conducted using Statistical Package for Social Science (SPSS) software version. Descriptive analysis was carried out for this study in order to: explore the goals SMEs have set for their pre-development implementation; identify main sources of the idea generation; explore useful assessment tools and techniques to support pre-development activities; and project evaluations which are analysis used by SMEs to terminate or select the most potential proposed projects. The results of the study are in-line with earlier findings that the implementation of a pre-development is important for the development of quality products; listening to the customer becomes an important source for SMEs to generate new ideas; creative technique is frequently used as a formal assessment technique during idea assessment; and SMEs are intensively involved in business analysis on the project evaluation process. The results presented a clarified view of pre-development implementation that may serve as a guide for the successful development and market launch of new products among food and beverages manufacturing SMEs.

Keywords: Pre-development process, Malaysian food and beverages manufacturing SMEs, product innovation

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A Case Study on Peer Review and Lecturer Evaluations in an Academic Setting

A Case Study on Peer Review and Lecturer Evaluations in an Academic Setting

Nor Kamaliana Khamis, Abu Bakar Sulong and Baba Md Deros

Abstract: Students can enhance their soft skills and learning experience through the use of group projects. However, evaluating group project performance has become very challenging. This paper presents the concept of group management in measuring individual performance in group projects in an academic setting. Individual performances in similar courses were also compared based on two consecutive semesters (Semesters 1 and 2). The respondents for this study were first year students who attended similar courses for both semesters. Performance measurement was based on peer review and lecturer evaluations. The criteria for these evaluations were similar for both semesters. The current study aims to determine the weaknesses and strengths of an individual in a group, and relate them with group performance based on the individual presentation marks. The study also analyzes the relationship between these two performance tools. Findings indicate that peer review and lecturer evaluations can be used to determine the performance of students in a group project, and that these two evaluation tools are not significantly correlated.

Keywords: group project, peer review, lecturer evaluation, individual performance, correlation.

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Journal of Occupational Safety and Health

Journal of Occupational Safety and Health

June 2012, Vol. 9, No. 1
ISSN 1675-5456

PP13199/12/2012(032005)

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Organisational Change Management Framework for Lean Manufacturing Implementation

Organisational Change Management Framework for Lean Manufacturing Implementation 

Baba Md Deros, Norani Nordin, Dzuraidah Abdul Wahab and Mohd Nizam Ab.Rahman

Abstract: Lean manufacturing systems have been widely applied inused by manufacturing companies worldwide. However, low rate of success towards lean transformation in many countries in making the transition to lean manufacturing had created a cause of concern. Many literatures publications had pointed out the main reasons for under performance is primarily due to the failure in managing the change process during transitioning to lean manufacturing from an existing system. This paper attempt to develop a framework that could assist organisation implements lean manufacturing system. This framework is of particular significance not only because it is about lean manufacturing, but also because it is set in a context of process change when transitioning to lean manufacturing. This study had employed an explanatory mixed method approach, which begins with survey distribution. Conducting in-depth interviews at Malaysian automotive companies further refines the general picture attained from the survey. The quantitative and qualitative results show the key factors to managing a smooth transition to lean manufacturing are: change readiness, leadership and management, the change change-agent system, team development and empowerment, communication, and the review system system. This stream series of lean implementation efforts steps serves as the basis for the development of organisational change framework for implementing a lean manufacturing system. This framework may add to the body of knowledge for both academics and practitioners. At the theoretical level, this framework has important strengths, because it explicitly framing the relationship between change management and lean manufacturing and the management of its implementation. Failure to recognize the required organisational changes to adapt an organization to a lean manufacturing system will hinder its the system’s long-term benefits to the organization. This framework may also provide practitioners with a better understanding of the lean transition process to lean

manufacturing, which will to minimize resistance and conflicts; and thus improve its the system’s chances of success.

Keywords: lean manufacturing, organizational change, mixed method research, framework development, automotive industry.

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SCM Implementation in Malaysian Food and Automotive Industries: an Empirical Study

SCM Implementation in Malaysian Food and Automotive Industries: an Empirical Study

Malihe Manzouri, Mohd Nizam Ab Rahman, Harlina Wasilan, Baba Md. Deros and Haslina Arshad

Abstract: The purpose of this paper is to empirically compare the implementation of supply chain management (SCM) in the automotive and food industries in Malaysia. A questionnaire was used to identify the perceived problems and attitudes towards SCM. The questionnaire was distributed to 600 food and automotive organisations in Malaysia. A total of 62 usable replies were received from the automotive industry, and 140 from the food organizations. Structured interviews were used to find out how problematic issues in these organisations could be overcome. The key problems were identified as: a lack of information (automotive industry) and high costs (food industry). Benchmarking from experienced companies and conducting training courses were identified as important methods to reduce these problems. The paper provides insightful information on how Malaysian automotive and food organizations can improve SCM within their own organisations and supply chains. This includes the identification of important problems among these companies as well as measures to counter them. There is little documentation regarding the status of SCM implementation in the food and automotive organizations in Malaysia. Therefore, recognizing the most important problems in these industries, and focusing on the best techniques for overcoming these problems, was identified as a gap in the existing literature.

Keywords: SCM implementation, problematic issues, Food and Automotive companies

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Top Management’s Role in Benchmarking Implementation in the Palm Oil Processing Industry

Top Management’s Role in Benchmarking Implementation in the Palm Oil Processing Industry

Fatimah Mahmud, Baba Md Deros, Dzuraidah Abdul Wahab and Mohd Nizam Ab Rahman

Abstract: To remain competitive, cost effective and sustainable market share in the world market place for edible oil, millers in the palm oil processing industry needs to focus on the process for extracting high quality and high palm oil yield from fresh fruit bunch economically. Benchmarking technique can be used to identify and investigate palm oil processing industry best practices adopted by palm oil millers. Past studies showed that the success of benchmarking initiative is very much dependent on top management’s commitment and leadership. The main objective of this paper is to discuss managers’ perception on the importance and actual practice in palm oil processing industry with respect to eight attributes of top management’s commitment and leadership. In this study, survey questionnaire was developed and employed to collect the data. The survey questionnaire was sent by postal mail to 350 palm oil mill managers in Malaysia. The survey response rate was 51.1%. Analysis of the survey results shows significant differences between respondents’ perception on the importance and actual practice of the eight attributes of top management’s commitment and leadership. In other words, they have high perception of importance for the eight attributes; however, in reality the attributes are not really put into practice. In conclusion, to ensure benchmarking implementation success, top management need to practice these attributes systematically.

Keywords: Top management, perception, practice, palm oil processing industry, benchmarking.

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Fatigue factors among regional pilots in Malaysia

Fatigue factors among regional pilots in Malaysia

Baba Md Deros, Dian Darina Indah Daruis and Nuhmandeen Bahurudeen

Abstract: Fatigue among pilots and aircrew has been acknowledged as a human factor safety issue since commercial aviation started. The first objective of this study is to investigate the promoting and interfering factors that are involved in pilots’ sleep patterns. Meanwhile, the second objective of this study is to understand pilots’ duty hours and delay factors that eventually lead to fatigue. The findings from the study demonstrate that most pilots have no difficulty in getting to sleep and most had never taken any sleeping aid. The study found five sleep-interfering factors, all of which can be categorised as either environmental or physiological factors. Environmental interfering factors include heat, noise and lighting. Physiological factors include biological needs and personal worries. Personal worries top the list of the five interfering factors that were identified in this study. The study also found that flight delays can easily fatigue pilots and aircrews. Fatigue is a serious problem because 93% of pilots have admitted that they had nodded off while in control of their flights. It can be concluded that pilots have no problem with sleeping; however, their duty hours and, especially, flight delays cause them to experience fatigue.

Keywords: Fatigue, survey, aircraft fatigue, pilots, aircrew

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A Study on Benchmarking Technique Understanding and Knowledge in Malaysia Palm Oil Milling Industry

A Study on Benchmarking Technique Understanding and Knowledge in Malaysia Palm Oil Milling Industry

Norashikin Rahman, Baba Md.Deros and Mohd. Nizam Ab Rahman

Abstract: Benchmarking is a tool that can lead to broad improvements to an organization. It has been implemented in various industries such as manufacturing and services. The objective of this study is to identify the level of understanding and knowledge on benchmarking in palm oil milling industry. A survey instrument, tested for reliability and validity by experts and practitioner was developed to collect data from respondents involved the palm oil milling industry. Later, the survey questionnaire which comprise of two sections was distributed through postal mail and email to 230 respondents in different palm oil milling industry. Seventy four survey questionnaires were completed and returned, giving a response rate of 32.2%. Analysis of survey results shows that 18.9% of respondents are in good category, 71.6% are still in moderate category and 9.5% in low category. Thus, it can be concluded that 81.1% of survey respondents in palm oil milling industry is still lacking of knowledge and understanding in benchmarking concept. Further guidance, support and awareness are really needed to encourage more organisations in palm oil industry to use benchmarking in order to survive and remain competitive.  

Keywords: Benchmarking, palm oil, study, understanding, knowledge

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A Study on the Difference Between Radical Innovation and Incremental Improvement in Pre-Development Practices of NPD Projects

A Study on the Difference Between Radical Innovation and Incremental Improvement in Pre-Development Practices of NPD Projects

Noor Hidayah Abu, Baba Md Deros, Dzuraidah Abd Wahab, Mohd Nizam Ab Rahman and Norani Nordina

Abstract: This paper presents an exploratory study of pre-development practices in Malaysian food and beverage manufacturing SMEs. A questionnaire survey is used to explore the difference in pre-development implementation practices between radical and incremental new product development (NPD) projects. The survey was performed at 164 food and beverage manufacturing SMEs. The respondents were chosen from those who are directly involved with pre-development practices, such as the owner/CEO of the SMEs. The analysis was conducted using Statistical Package for Social Science (SPSS) software version 17. Descriptive statistics and independent-samples t-test were carried out to generate and validate the results observed. The significant difference values for independent-samples t-test is less than .05 (p≤0.05). Survey results revealed the differences in pre-development implementation practices between radical and incremental NPD projects for several activities in pre-development phases. Incremental NPD projects considered listening to customer needs (p=0.00) is an important activity during idea generation phase, however radical NPD projects emphasis that analysis of competitors‟ products (p=0.02) and continuous product improvement (p=0.00) are crucial. Mean while during development of new product concept phase, and project evaluation phase radical NPD projects were more innovative compared to incremental NPD projects in several activities such as creating prototypes/product samples, linking company‟s operational capabilities with proposed product, and conducting a formal risk analysis. The significant values of the activities were between 0.00 and 0.04 which is lower than significant level 0.05.

Keywords: Pre-development implementation, radical innovation, incremental improvement, SMEs

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