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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The Pre-Development Process Implementation of Product Innovation: A Malaysian Food and Beverage Manufacturing SMEs Survey

The Pre-Development Process Implementation of Product Innovation: A Malaysian Food and Beverage Manufacturing SMEs Survey

Noor Hidayah Abu, Baba Md Deros, Dzuraidah Abd Wahab, Mohd Nizam Ab Rahman and Mohd Fitri Mansor

Abstract: The pre-development phase is an important driver of new product development (NPD) project success. SMEs have not received adequate attention from researcher for their pre-development process compared large-scale organizations. The main objective of this research is to identify the practice of pre-development activities among Malaysian manufacturing SMEs. This study presents the results of a quantitative analysis on a sample of 156 SMEs in the food and beverage industry. Our study confirms earlier finding about the develop quality product becomes an important goal for SMEs. Listening to customer become important sources for SMEs to generate new ideas. Creative technique is frequent use as formal assessment technique during the idea assessment. Lastly, SMEs to be intensively involved in business analysis on project evaluation process. The results present a clarified view of pre-development activities that may serve as a guide for the successful development and market launch of new product among SMEs.

Keywords: Pre-development process, Malaysian manufacturing SMEs, product innovation.

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A Survey on the Barriers of Benchmarking Implementation in Malaysia Oil Palm Industry

A Survey on the Barriers of Benchmarking Implementation in Malaysia Oil Palm Industry

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

Abstract: Malaysia is the largest producer and exporter of palm oil. Nevertheless, Malaysia may soon lose its position if there are lacks of initiatives to sustain it. Benchmarking can be used to stimulate process improvement by determining best practices across oil palm organizations through understanding critical success factors which enabled higher performance in leading organizations. The main objective of this paper is to identify benchmarking barriers that hinder or disrupt the benchmarking implementation in oil palm industry. To achieve these objectives, 700 sets of questionnaire were distributed among oil palm planters and millers in Malaysia. The survey results had indicated that the three main obstacles faced in implementing benchmarking in oil palm industry are: lack of understanding of benchmarking knowledge, lack of clarity with regard to specific areas to be benchmarked and management culture. In the authors’ opinion this survey findings would be useful and considerable interest to all level of benchmarking practitioners in the oil palm industry.

Keywords: Oil palm industry, benchmarking, survey, barrier.

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Benchmarking Technique in Lean Manufacturing (5s) Practice

Benchmarking Technique in Lean Manufacturing (5s) Practice

Baba Mohd Deros, Tan Jun and Mohd Nizam Abd Rahman

Abstract: In today’s competitive market, low cost production and high quality product could assists manufacturers to win new and maintain their existing customers thus gain bigger market share. Manufacturing cost is one of the key dominant factors towards achieving business success. As such, manufacturing firms are struggling to produce product with lowest manufacturing cost while at the same time maintaining their product quality. Lean manufacturing practice could be applied to lower the manufacturing cost and benchmarking technique to ensure on the implementation effectiveness. A case study was conducted in a small and medium manufacturing firm located in China. One of the lean manufacturing tools, i.e. 5Ssystem was implemented in the production line of the case study company. For future reference, the present situation was studied prior to the 5S system implementation. Later, the result of the study was benchmarked against before, after and the best in class manufacturer. A framework was developed to guide the user during implementing the 5S system. The benchmarking result shows significant improvement in productivity and lower manufacturing cost after implementing the 5S system. The implementation of 5S system had created more comfortable workspace to production workers, standard procedures and method to produce the product. Therefore, it can be concluded, the 5S system was able to help the production workers to implement the lean manufacturing and benchmarking technique more effectively to bring additional advantages in producing lower cost and high quality product, which eventually helps the company to gain better market share.

Keywords: low cost, high quality, lean manufacturing, benchmarking, market share, competitiveness

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A framework for organisational change management in lean manufacturing implementation

A framework for organisational change management in lean manufacturing implementation

Nordin, N., Md Deros, B., Wahab, D.A. and Ab. Rahman, M.N.

Abstract: Lean manufacturing system has been widely applied in manufacturing companies worldwide. However, the low success rate of lean transformations in many countries has given a cause for concern. Much of the literature had pointed out that the main reasonis due to the failure in managing the change process during a lean manufacturing transformation. This paper presents a thorough literature review for lean manufacturing approach in the context of organisational change management. Finally, the authors have proposed an organisational change framework for lean manufacturing implementation that would serve as the basis for further empirical research and validation. The framework will further expand the body of knowledge by linking organisational change management with the transition to implementing a lean manufacturing system. 

Keywords: Critical success factors, framework development, lean manufacturing, organisational change

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A Study of Indoor Air Quality Issues for Non-Industrial Work Place

A Study of Indoor Air Quality Issues for Non-Industrial Work Place

Baba Md Deros, Siti Hamimah Ismail, Nor Kamaliana Khamis, Mohd Yusri Yusof and
Ahmad Rasdan Ismail

Abstract: In non-industrial sector, two major issues that led to fungal growth, outbreak of disease like SARS and H1N1 are lack of research and health regulations. This study has three main objectives: to identify major complaints; to verify these complaints; and to determine their effects towards employees’ productivity. It focused on related legal requirement, identify source of problem, occupational exposure and control measures required to mitigate Indoor Air Quality (IAQ) issues. Quantitative and qualitative IAQ studies were performed in Company A and Company B office areas equipped with centralized air conditioning system. The purpose is to investigate whether they complied with Malaysian Department of Occupational Safety and Health (DOSH) IAQ Code of Practice. A total of 125 subjects performing specific activities within the building took part in the study against a 5000m² of floor area. It was found that 77% of IAQ issues are due to inadequate ventilation supply in the building, high level of carbon dioxide, microorganism, Total Volatile Organic Compound (TVOC) and humidity that exceeded ceiling limit set by DOSH and World Health Organization. In conclusion, major factors that contribute towards IAQ problems are uncontrolled renovation, lack of awareness among occupants, micro organism, ventilation rate, temperature and humidity.

Keywords: Carbon dioxide, Humidity, Indoor air quality, Micro organism, Total volatile organic compound.

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Lean Manufacturing Perceptions and Actual Practice among Malaysian SME’s in Automotive Industry

Lean Manufacturing Perceptions and Actual Practice among Malaysian SME’s in Automotive Industry

A.N.M. Rose, B. Md. Deros and M.N. Ab. Rahman

Abstract: Stiff business challenges and product competition faced by automotive component manufacturers has forced them to look into lean manufacturing (LM). Presently there are more than 100 LM practices. However, small and medium enterprises (SMEs) are not able to implement all LM practices due to financial, expertise and skill constraints. Therefore, in this study the authors investigated the level of perception and actual practice within 24 LM practices, regarding actions believed feasible to be implemented in SMEs. In addition, the authors gathered LM information sources, reasons for implementing LM and its benefits to SMEs. A questionnaire survey was conducted in 35 SMEs involves in manufacturing automotive components. The majority of SMEs have a high perception of the importance of LM practices but in reality are not undertaking them. The SMEs mainly received their LM information from their customers, and they strongly believe that LM practices could improve their long-term business sustainability and competitiveness in the market place.

Keywords: Lean manufacturing, SME, automotive, lean perception, lean practices

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Biomechanical analysis on instep kicking: Comparison of football shoe design

Biomechanical analysis on instep kicking: Comparison of football shoe design

Ahmad Rasdan Ismail, Zahari Taha, Baba Md. Deros and Isa Halim

Abstract: The design of shoe plays a vital role to improve the performance of football players in kicking action. The objective of this study is to quantify the velocity and force generated by different shoe designs during instep kicking. Six amateur football players from different field positions participated as subjects in this study. The experimental work was carried out using high speed cameras integrated with Qualysis Track Manager System. The results of biomechanical analysis revealed that P shoe design generated the highest velocity (14552.28 mm/s) and football shoe of N brand produced highest force of 1774.3775 N. This study concluded that shoe design is one of the key factors to determine the velocity and force in kicking action. For future work, this study suggests ergonomics analysis to improve the performance and satisfaction of the players. 

Keywords: Biomechanical, Instep kicking

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Manufacturing Performance in Green Supply Chain Management

Manufacturing Performance in Green Supply Chain Management

Wan Hasrulnizzam Wan Mahmood, Mohd Nizam Ab Rahman, Baba Md Deros, Kamruzaman Jusoff, Adi Saptari, Zuhriah Ebrahim, Al Amin Mohamed Sultan, Mohd Hadzley Abu Bakar, Sivarao Subramonian and Zanariah Jano

Abstract: The purpose of the study is to examine the influence of manufacturing performance on green supply chain management amongst Malaysian companies. A conceptual model is proposed and is subjected to an empirical verification with the use of a survey of manufacturing companies in Malaysia. The AMOS structural equation modelling was used to measure the respondents’ overall perceptions of the green supply chain management and current manufacturing performance. Results indicate that improving manufacturing performance leads to an integrated green supply chain, which ultimately leads to an enhancement of environmental compliance as well as an optimisation of the operational resources and product recycling activities. However, most practices have a very weak correlation with overall manufacturing system performance. Being the first ever empirical investigation of the link between manufacturing performance and green supply chain management practices amongst organisations in Malaysia, this study helps industrialist to enhance improvement in productivity. Future research should include different industrial sectors or countries, to enable comparative studies. A larger sample would also allow a detailed cross-sector comparison.

Keywords: Green Supply Chain Management (GSCM), Manufacturing Performance, Structural Equation Modelling (SEM)

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Multi-regression modeling for springback effect on automotive body in white stamped parts

Multi-regression modeling for springback effect on automotive body in white stamped parts

Nagur Aziz Kamal Bashah, Norhamidi Muhamad, Baba Md Deros, Ahmad Zakaria, Shaharum Ashari, Achmed Mobin and Mohd Safuan Mohd Abdul Lazat 


Abstract: The use of high strength steel (HSS) materials in automotive body in white (BIW) stamped parts has increased the occurrence of springback after the forming process. Although HSS exhibits superior strength, weight reduction, and crash energy, it strongly influences springback impact on the sustainable development of BIW stamped parts. In this study, an empirical springback prediction model was synthesized based on the contemporary data sets of springback-prone components of automotive BIW stamped parts. Two different BIW stamped parts from an actual industrial stamping production line were selected as pilot parts for this study. A statistical multi-regression (MR) analysis was used to model the springback prediction effect by examining the sensitivity of springback input parameters on existing die geometry. The outputs represent the total springback values of the stamped parts. A total of 240 data from samples of selected stamped parts were tabulated to synthesize the springback prediction model. The results show that the MR models for the two parts were linear with the springback estimated errors between the measured and predicted values between 0.5 and 3 , which is acceptable from an industrial viewpoint. The proposed MR models are capable of predicting the springback effect with minimal error by incorporating all possible variations that are inherent in the shop floor process.

Keywords: Springback, stamped part, multi-regression technique, body in white

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Philosophy of Taguchi Approach and Method in Design of Experiment

Philosophy of Taguchi Approach and Method in Design of Experiment

Jaharah A. Ghani Haris Jamaluddin, Mohd Nizam Ab. Rahman and Baba Md. Deros

Abstract: In recent market and global requirements, the desires to provide higher level of quality in products and services for increasing market shares continues competitively among the manufacturers to ensure customer satisfaction will return with consistent orders. The important of product and process optimization has caused manufacturers focus greater attention to design optimization in order to stay competitive in the world market. The understanding on the fundamental of basic experimentation will be a starting point to improve process yield, product performance and productivity of company-wide operation. Thus, a more reliable and effective experimental approach subsequently will be the right choice to study the possible design factors that satisfy customers and process compatibility. This study presents the philosophy and method applied for Taguchi method design of experiment. The concept such as quality should be designed into the product, quality loss function, determining the optimization condition for the product or process, designing product and process that insensitive to the influence of uncontrollable factors or noise, signal-to-noise ratio and orthogonal arrays among the important terms in application of Taguchi method design of experiment.

Key words: Taguchi Method, quality, signal-to-noise ratio, orthogonal arrays

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Effect of Temperature, Humidity and Illuminance Towards Worker’s Performance in Automotive Industry

Effect of Temperature, Humidity and Illuminance Towards Worker’s Performance in Automotive Industry 

Mohd Yusri Mohd Yusof, Baba Md. Deros* and Ahmad Rasdan Ismail

Abstract: Working environmental conditions in automotive industry are very challenging to the human workers. Meanwhile, products quality is very much dependent on workers’ health, safety and comfort in their working environment. Environmental factors, such as temperature, illuminance and humidity levels have significant effect on workers’ performance at the production line. In this experiment, temperature, humidity, illuminance levels and productivity rate were observed in a control room. An automotive manufacturing firm production line was chosen to be simulated in the control room to observe the temperature, relative humidity, illuminance and worker’s productivity rate. The experimental data collected was analyzed using Response Surface Method (RSM). RSM is an analysis technique, which combined statistical systems and mathematical methods. It can be applied for research and development, reform and optimize a process, which involves several design variables. As a result, the combined effect of temperature, illuminance and humidity toward productivity can be clearly seen. Optimum environmental factor cannot be predicted using first order RSM analysis because it gives low reliability for obtaining the optimum level. Thus, a second order RSM analysis was generated for obtaining the optimum level of environmental factors.

Keywords: Environmental; humidity; illuminance; response surface method; temperature

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4th International Conference on Noise, Vibration and Comfort (NVC 2012)

International Conference on Noise, Vibration and Comfort 2012

Understanding the effect of discomfort level towards motorcycle riders among teenagers : a preliminary study

Author: Nor Kamaliana Khamis, Baba Md Deros and Mohd Zaki Nuawi

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Curriculum Vitae

Name	:	Prof.Dr. Baba Md Deros
Title	:	Prof
Institution	:	Universiti Kebangsaan Malaysia
Nationality	:	Malaysian
Gender	:	Male
Race	:	Malay
Address(Office)	:	Department Of Mechanics And Materials Engineering, Faculty Of Engineering & Built Environment, Universiti Kebangsaan Malaysia,  43600 UKM Bangi, Selangor, Malaysia.
Tel. No(Office)	:	03-89216117
Fax No.	:	03-89118314
Email	:	hjbaba@eng.ukm.my
Designation	:	Professor
Appointment Status	:	Permanent
Administrative Post	:	Coordinator, Master Of Engineering (Manufacturing System) & Master Of Science (Industrial & Technology Management)

ACADEMIC QUALIFICATION

(Qualification),(Discipline),(Institution),(Year).

1. PhD, Mechanical Engineering (Thesis Title: Development of a Benchmarking Framework for Small & Medium Enterprises), Universiti Teknologi Malaysia, 2004.
2. Master, Manufacturing Systems Engineering, University of Warwick, England, United Kingdom, 1991.
3. Bachelor, Mechanical Engineering, University of Glamorgan (Polytechnic of Wales), Wales, United Kingdom, 1986.
4. Diploma, Mechanical Engineering, Universiti Teknologi Malaysia, 1980.

PROFESSIONAL QUALIFICATION 
(Qualification),(Discipline),(Institution),(Year).

1. Graduate Member (G15196), Mechanical Engineering, Institute of Engineers, Malaysia, 1995.
2. Member, Mechanical Engineering, Board of Engineers, Malaysia, 1989.

PREVIOUS APPOINTMENT
(Post),(Organisation),(From)-(Until).

1. College Lecturer, Politeknik Sultan Haji Ahmad Shah, Kuantan, Pahang, Malaysia, 1980-1989.
2. Lecturer, Politeknik Kota Bharu, Kelantan, Malaysia, 1990-1997.
3. Lecturer, Universiti Kebangsaan Malaysia, Selangor, Malaysia, 1997-2005.
4. Senior Lecturer, Universiti Kebangsaan Malaysia, Selangor, Malaysia, 2005-2006.
5. Associate Professor, Universiti Kebangsaan Malaysia, Malaysia, 2006-2011.
6. Professor, Universiti Kebangsaan Malaysia, Selangor, Malaysia, 2012-Present.

AREAS OF EXPERTISE
(Main),(Sub),(Area).

1. Industrial Ergonomics
2. Agriculture Ergonomics
3. Quality Management System
4. Lean Manufacturing
5. Human Resource Management
6. Engineering Economy

RESEARCH

(Project title),(Role in project),(From)-(Until),(Source),(Level).

1. Intelligent Optimization Software for Turning Operations in a Computer-Aided Process Planning (CAPP) System, Co-Researcher, 1999-2001, MOSTI (IRPA), National.
2. Prediction of Tool-Life in Machining of Aerospace Material: Titanium Alloy Ti-6242, Co-Researcher, 2000-2002, MOSTI (IRPA), National.
3. Development of an Integrated Quality Engineering Approach for Malaysian Automotive Industry, Researcher, 2001-2003, MOSTI (IRPA), National.
4. Optimum Ergonomic Design of Workstation in the Production Line Using Genetic Algorithm and Expert System, Co-Researcher, 2002-2004, MOSTI (IRPA), National.
5. Study on the Heat Affected Zone of Welded Components, Project Leader, 1998-1999, UNIVERSITI KEBANGSAAN MALAYSIA, National.
6. Survey on Benchmarking Implementation in Malaysian Automotive Components Manufacturing SMIs, Researcher, 2002-2003, MOSTI (IRPA), National.

EXPERT CONSULTATION/CONSULTANCY
(Title),(Organisation),(Role),(From)-(Until),(Level).

1. Market Survey and Research on Computer Integrated Manufacturing (CIM) Programme in Institute of Higher Education, Solutions Engineering Sdn. Bhd., Consultant, 2000-2001, National.
2. Benchmarking for National Technology Mapping II in Machinery and Equipment Industry, MIGHT & EPU, Prime Minister Department, Consultant, 2000-2003, National.
3. Consultant for Market Survey for Equipment for Engineering Education, Solutions Engineering Sdn. Bhd., Consultant, 2004-2004, National.

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