Journal of Modern Manufacturing Systems and Technology
JMMST is a peer reviewed journal published by Faculty of Manufacturing and Mechatronic Engineering Technology, University Malaysia Pahang Al-Sultan Abdullah. The journal is published twice a year, in March and September. The journal publishes research and review articles. Only original articles that are not under consideration by other publishers are welcomed. Special issues are also welcome but interested special issue editors must submit a proposal to the Managing Editor for consideration. The journal is indexed by Malaysia Citation Index (MyCite) and Google Scholar.
Lean Six Sigma and Sustainability in the Energy Sector: A State of the Art Review
The energy industry is particularly put under pressure to enhance the efficiency of its operations and at the same time maintain high targets in sustainability and decarbonization. Lean Six Sigma (LSS) as a systematic approach to combine waste minimization with variation control has become a promising operating scheme to overcome these issues. The narrative review is a synthesis of the current research on the use of LSS in the energy sector and specifically on its environmental, economic, and social sustainability consequences. The review follows the development of LSS since its beginning with traditional energy operations through the growth of its application in renewable energy systems and utilities, and smart grids. It is always evident that LSS has the potential to bring quantifiable results, such as energy conservation, emission cuts, cost effectiveness, increased asset durability, and worker safety through operational strategies, by integrating sustainability goals into the workplace. One of the current trends that have been pointed out in the literature is the integration of LSS with computer technologies, including Industry 4.0 tools, real-time monitoring, artificial intelligence, and digital twins, which enhance the work on data-driven decision making and scale improvement. Irrespective of these benefits, structural, organisational, and regulatory impediments continue to curtail its implementation even in complicated resource-hindered environments. This review makes LSS a critical interaction point between sustainability and efficiency by defining patterns of application, its effect on sustainability, and implementation issues. It also provides.
Copyright (c) 2026 The Author(s) https://creativecommons.org/licenses/by-nc/4.0/
Advancements in Solar-Driven Seawater Electrolysis for Green Hydrogen Production: Innovations, Challenges, and Future Prospects
Solar-driven seawater electrolysis has become one of the attractive options for sustainable hydrogen production by utilizing plentiful seawater with the energy of natural solar. However, using seawater itself poses complicated electrochemical issues such as chloride-induced corrosion, competition for chlorine evolution reactions, catalyst instability, and low energy efficiency in actual marine environment. This review highlights significant advances in solar-based seawater electrolysis technologies such as photovoltaic-driven electrolysis and photoelectrochemical technologies, photocatalytic processing methods, vapor-phase water splitting systems and several others. Specific focus is placed on the reaction mechanisms targeted at seawater types, relevant performance indices, and material design strategies with a view to increasing reaction selectivity and operational persistence. The merits and shortcomings of various system designs are compared to emphasizing the achievements and challenges. Finally, future studies for the stability of catalyst, integration of systems, and realistic testing scenarios are discussed to facilitate development of scalable and environmentally friendly hydrogen production from seawater.
Influence of Different Materials on Inductance and Resistance Values of Nanocrystalline Alloy at High Temperature
The purpose of this study is to evaluate the effect of mild steel as dummy on the inductance value of core. A high permeability nanocrystalline alloy strip was used as the main material and the magnetic heat treatment process was carried out using magnetic field annealing furnace. The inductance value is measured for each core after the heat treatment. Prior to heat treatment process, a test on the magnetic field strength inside the furnace was done to check the strength of magnetic field where the data indicate a non-linear strength along the furnace, which is the strength will be greater at the middle and lowest at the bottom of the furnace where the cores is placed. Quantitative analyses showed the inductance value of bottom core decreased greater than 10% as compared to the neighboring core with the absence of the mild steel. One should keep in mind that the value for the tested cores is not specified, only the deviation of the inductance value of bottom core will be considered. This phenomenon occurred due to the attraction strength of bottom dummy towards the magnetic field. Further experiment was done to evaluate the effect of different height of mild steel and it is worth to note that various height of mild steel does not gives any significant effect on the inductance value of core.
Copyright (c) 2025 The Author(s) https://creativecommons.org/licenses/by-nc/4.0/
Mental Workload Assessment in Visual-Mechanical Inspection Tasks: Insights from the Electronics Manufacturing Industry
The increasing complexity of tasks in modern manufacturing environments has elevated cognitive demands on workers, particularly in operations requiring precise visual-motor coordination. This study investigates mental workload in visual-mechanical inspection (VMI) tasks within the electronics manufacturing industry by integrating subjective and objective workload assessments. Twenty trained female operators participated in a structured experimental protocol involving VMI tasks categorized into three levels of complexity: low, medium, and high. Mental workload was evaluated using the NASA Task Load Index (NASA-TLX) and physiological indicators were assessed via eye-tracking metrics, including pupil dilation, blink rate, and fixation rate. The statistical analysis revealed significant differences in mental workload scores and eye-tracking responses across task complexities. Specifically, higher task complexity was associated with increased pupil size, elevated blink rates, and reduced fixation rates, indicating heightened cognitive demand. Moreover, Spearman’s correlation analysis demonstrated a significant positive relationship between subjective workload ratings and eye-tracking metrics, particularly under high complexity conditions. The results emphasize the importance of integrating both subjective and objective measures to achieve a comprehensive understanding of cognitive load in VMI tasks. These insights offer practical implications for managing the workforce, designing ergonomic tasks, and monitoring cognitive load in precision-focused manufacturing environments.
Safety Culture Maturity Level in Malaysian Electronic Manufacturing Industry
The Main objective of this study is to assess the safety culture level in one selected electronic manufacturing plant located in the Southeast region of Malaysia. Quantitative and qualitative approaches were utilized to measure the climate factors, behavioral indicators, and the current OSH management system. The safety culture maturity model by Fleming was used to map the findings. A total of 393 respondents completed the safety climate survey. Document reviews were conducted to retrieve incident records from 2017 to 2023, and a semi-structured interview was conducted with safety representatives to assess the current state of health and safety system practices, including cooperation, competence, training, management style, change management, and shared values. Results revealed that the safety climate survey showed the highest mean scores for personal appreciation (priorities and need for safety), a supportive environment, and management commitment. Most of the respondents perceived that their company had a good safety climate. Behavior-related incidents among workers were calculated using a formula with the retrieved incident data. The results reported a score of eight. A semi-structured interview was conducted to assess the health and safety systems, resulting in a score of two. The safety culture maturity was decided by combining all three findings (safety climate score, behavior-related incident, and OSH system practices). Results indicate that the level was at four, which is the cooperation level, representing engagement of all staff in developing cooperation and commitment to improving safety, which is visible. The findings were further validated through interviews with three safety experts. All panels reviewed the conclusions of each profile and agreed with the findings that the current safety level at this company is at a cooperative culture. In conclusion, this study successfully assessed the safety culture level in the electronics manufacturing industry.
Study of the Durability of Office Chair Components through User-Centered Design and Finite Element Analysis
Office chairs are essential elements of modern workplaces, yet they frequently experience structural failures, particularly in caster assemblies, leading to discomfort, frequent repairs, and increased costs. While much research has focused on ergonomics and user comfort, relatively little attention has been given to the durability and structural optimization of chair components. This study aimed to improve the performance of office chairs by integrating user-centered feedback with engineering analysis. A survey of staff in an academic workplace environment was conducted to identify common failures and important design features. The results revealed that casters were the most failure-prone component, prompting a redesign of the caster assembly using three alternative wheel materials that are Rubber, Nylon, and Plexiglas along with reinforced steel holders and aluminum pins. The redesigned models were developed using computer-aided design (CAD) software and analyzed under a 250 N load condition through finite element analysis (FEA), which simulated stress distribution, deformation, and safety factors. The findings showed that rubber and nylon wheels significantly reduced deformation and provided superior durability compared to Plexiglas, which exhibited brittleness under load. Reinforced steel holders and aluminum pins further improved stress distribution and stability of the caster assembly. Overall, the study demonstrates that combining ergonomic insights with engineering simulations can yield practical design improvements that extend chair lifespan, reduce repair frequency, and enhance workplace ergonomics. Future work should include prototype testing under dynamic conditions and explores sustainable materials to further improve performance and environmental impact.
Advances In 3D-Printed Ultraviolet Light Responsive Hydrogels In Drug Release - A Mini Review
This review digs into how ultraviolet (UV) light-responsive hydrogels, paired with cutting-edge 3D and 4D printing, enable personalized drug delivery. These hydrogels can absorb UV light and shift the structure, so that the hydrogels can release the drug straight to the target site. Photochromic compounds like azobenzene, spiropyran, and spirooxazine give the function of absorbing UV light to activate the release mechanism of the drugs to the target area. These molecules flip back and forth in response to UV light, letting the hydrogel swell, change its pores, and control the movement of drugs through it. Basically, the hydrogel becomes a programmable carrier. By using 3D and 4D printing, these hydrogels can be built with various precision, containing tiny channels, built-in drug reservoirs, and complex, layered shapes. The review lines up UV-responsive hydrogels against traditional drug delivery systems and shows how these hydrogels are better at releasing drugs on demand, limiting exposure to the rest of the body, and cutting down on side effects. To understand on how these hydrogels work, the review also discussing a few tests of the hydrogels: FTIR, UV-Vis spectroscopy, SEM, and rheology. These tests show whether the hydrogels hold up physically, stay chemically stable, and actually respond to UV light according to the wavelength and area of the hydrogel exposed to the UV light. As for the disadvantages affected the hydrogels performance towards manufacturing process—cost, environmental impact, how to scale up production, and whether these materials stay safe in the body for a long term. The review looks at how researchers are tackling these problems, from suggestion of the materials themselves, to mixing in hybrid polymers, to adding nanoparticles for extra responsiveness. The paper points to new frontiers: hydrogels that respond to visible or near-infrared light, platforms that respond to more than one trigger, and smart 4D-printed patches that adapt to patients in real time. Overall, UV-responsive, 3D-printed hydrogels are shaping up to be a big leap forward for safer, smarter, and more sustainable healthcare.
Enhancing Sustainability in Sunflower Supply Chain: A Life Cycle Assessment Approach
The sunflower industry in Indonesia holds significant potential, but its production process generates substantial environmental impacts, particularly greenhouse gas emissions from transportation and production stages. This study evaluates the industry’s environmental footprint using life cycle assessment and determines its eco-efficiency within a sustainable supply chain. Applying a gate-to-gate boundary, emissions, energy consumption, and waste generation were analysed, revealing that sunflower oil production emits 1249151.71 kg CO₂-eq per month, with transportation contributing the most (429009.98 kg CO₂-eq). Despite these environmental challenges, the industry remains economically viable, with an eco-efficiency index of 11.23% and an eco-efficiency ratio of 1.141%, indicating strong economic sustainability relative to environmental impact. Limitations include the reliance on secondary data and the exclusion of post-production phases, suggesting further research should explore alternative energy sources, waste management innovations, and transport optimization to enhance sustainability. These findings provide a basis for strategic improvements, supporting a more environmentally responsible industry.
A case study on the prevalence of musculoskeletal disorders and hand pain among cooks in the local catering industry
In recent times, millions of people worldwide have been affected by musculoskeletal disorders (MSDs). MSDs are a major occupational health problem among workers in the food industry due to prolonged standing, repetitive movements, and unfavourable postures. The aim of this study was to determine the prevalence of musculoskeletal disorders and hand pain in cooks working in restaurants in Pahang, Malaysia. A total of 150 cooks from 35 restaurants took part in an approximately one year longitudinal study (2023–2024). The data was collected using a structured questionnaire on musculoskeletal complaints covering 20 body parts Cornell Musculoskeletal Discomfort Questionnaire (CMDQ). The Cornell Hand Discomfort Questionnaire (CHDQ) was also used to assess the frequency, intensity, and disturbance of pain in the hand. Results revealed that musculoskeletal disorders were most common in the lower extremities, particularly in the left foot (8%), right foot (7.9%), and lower back (6.9%), indicating the effects of prolonged standing and static postures. Upper body discomfort was also reported in the upper back (6.4%), right wrist (6.1%), and right shoulder (5.3%), which can be attributed to repetitive use of the dominant hand during cooking. The hand pain was most severe in the palm and at the base of the thumb of both hands, with the right hand being affected slightly more frequently, which is consistent with the dominance of the right hand among the participants. The results show that cooks have a high risk of MSD symptoms and hand pain caused by repetitive and forceful hand movements, prolonged standing, and inadequate ergonomic support. Measures such as the ergonomic design of workstations, the use of anti-fatigue mats, the rearrangement of tools, the rotation, of tasks and posture training are recommended to reduce risks and improve workplace health in the catering industry.
Optimizing Surface Finish in Face Milling of Aluminium Alloy Al 6061: An Experimental Analysis of Cutting Speed and Depth of Cut
Surface quality in machining is predominantly influenced by cutting parameters, specifically cutting speed and depth of cut. This study investigates the effect of these parameters on the surface roughness of Aluminium Alloy 6061 during face milling utilizing an HSS cutter. A conventional Schaublin 13.2 milling machine was employed for the experiments. The cutting speed (Vc) was varied at 80, 150, and 200 m/min, combined with a depth of cut (a) of 0.75, 1.00, and 1.25 mm. Nine specimens were machined based on a full factorial experimental design. Surface roughness (Ra) was measured and classified according to international standards (ISO). The results demonstrate that higher cutting speeds generally yield superior surface finish. The optimal surface roughness was achieved at a cutting speed of 200 m/min and a depth of cut of 1.00 mm, resulting in an Ra value of 0.65 µm (N5 classification). Conversely, the highest roughness was observed at the lowest cutting speed (80 m/min) and highest depth of cut (1.25 mm), with an Ra value of 2.36 µm (N7). This study concludes that selecting appropriate cutting parameters is critical for achieving the desired surface quality in the machining of Al 6061, with cutting speed being the more influential factor
An IoT-based Downtime Data Tracking and Alert System to Support OEE Monitoring in Production Lines
This project presents the development of a Downtime Data Tracking and Alert System (DDTAS) to enhance the efficiency of technical support teams and machine operators in monitoring and recording production line downtimes, thereby supporting improved monitoring of Overall Equipment Effectiveness (OEE). The project was conducted in collaboration with an industry partner through a Work-Based Learning (WBL) programme. Previously, machine downtimes were recorded manually using note cards, and breakdowns were signaled using emergency lights. This manual approach led to inaccuracies due to inconsistent time logging and reliance on human input. Additionally, repair times were logged separately through online forms, complicating data integration for performance analysis. To address these limitations, DDTAS was developed using the ESP32 microcontroller, RDM6300 RFID reader, PHPMyAdmin, and custom software. The system automates the capture and storage of downtime data, transmitting it to a centralized database and displaying it through an HTML-based web interface. The interface includes a graphical user interface (GUI) that indicates machine status—such as down, under repair, or operational—along with a Gantt chart visualizing downtime duration, repair time, and idle periods. This real-time dashboard, deployed in the technical team’s workspace, enables faster response and more accurate downtime tracking. By replacing manual recording with automated data acquisition and visualization, DDTAS improves the reliability of downtime data, which is critical for calculating OEE metrics. The system ultimately contributes to enhanced operational visibility, more informed decision-making, and continuous improvement in production efficiency.
Photoresponsive Hydrogel System for Ultraviolet (UV) Controlled Drug Delivery: A Mini Review
This review offers an in-depth examination of the latest developments in UV light-responsive hydrogels, emphasizing their role as advanced platforms for drug delivery, especially considering wound care and topical treatments. The discussion explores how photochromic compounds such as azobenzene, spiropyran, and spirooxazine are incorporated into hydrogel structures. These integrations assist precise and controllable drug release when exposed to UV light. The mechanisms behind this process are analyzed through phenomena like photoisomerization-induced swelling, alterations in porosity, and reversible molecular conformations. The comparison between UV-responsive hydrogels and traditional counterparts emphasizes their superior ability to offer spatial and temporal control, targeted therapy, and minimized side effects. The review critically evaluates various characterization techniques—including swelling tests, FTIR, UV-Vis spectroscopy, SEM, mechanical evaluations, and rheological assessments—to understand how these materials behave before and after UV exposure. Besides, the discussion addresses environmental sustainability, economic viability, and manufacturing scalability, acknowledging current challenges and proposing potential solutions for future innovation. Concluding with prospective research directions, the paper emphasizes advancements in dual-stimulus responsive hydrogels, alternatives responsive to visible or near-infrared light, and the development of intelligent wearable patches. Overall, UV-responsive hydrogels demonstrate major promise as the next generation of drug delivery systems, particularly in wound management, though concerns regarding safety, biodegradability, and commercial translation still need to be addressed.
Design and Fabrication of Foldable Sheet Metal Furniture
The project is on the design and fabrication of foldable furniture constructed from 2 mm mild steel sheet metal via laser cutting technology. The aim was to produce light, sturdy, and compact furniture items that do not need assembly by screws, welding, or adhesives. The process began with idea sketching, followed by 3D modeling through computer-aided design software to design two chairs and two tables with interlocking slot mechanisms. After laser cutting, components were finished by grinding and sanding to remove burrs, achieve smooth finishes, and maintain surface fractures from corrosion. The components were assembled to check dimensional accuracy and fit, then spray painted for better appearance and protection from corrosion. 2 fordable chair and 2 table designs were subjected to physical and simulated load testing to ensure structural integrity and consumer safety. Tests showed that the furniture could be built efficiently, was stable under normal loads, and met all requirements in design. This project shows how sophisticated manufacturing methods and computer-aided design can efficiently produce functional, eco-friendly, and cost-effective fabricated products.
Assessing Key Enablers of University-Industry Collaboration for Technological Innovation in Industry 4.0
This study outlines key variables for conceptual framework in university-industry collaboration (UIC) grounded in Industry 4.0 principles, aiming to harness technological innovation for mutual benefit. Employing a questionnaire survey involving 34 respondents from academia and industry, the research delved into perceptions and potentials of UIC, with a focal point on Industry 4.0 as the optimal platform for collaboration due to its emphasis on innovation and technology. The results revealed that six key variables Perception, Potential, Initiate, Innovation, Screening, and Channels showed a strong and positive correlation with Industry 4.0. Notably, Perception emerged as the most influential factor, highlighting the importance of a positive outlook toward collaboration. The findings also emphasized that initiatives led by industry actors are more likely to result in productive and targeted partnerships, particularly when innovation and advanced technology are the primary goals. Essential components for effective UIC included partner screening and channels. Ultimately, success relied on cultivation openness, fostering proactive industry engagement and networking, thereby enabling stakeholders to leverage the transformative potential of Industry 4.0 for driving innovation and societal progress through university-industry partnership.
A Technical Exploration of Sheet Metal Forming
Sheet metal forming is vital in automotive and aerospace manufacturing for producing strong, lightweight, and complex components. Processes like deep drawing, bending, and hydroforming rely heavily on factors such as material properties, tooling accuracy, and surface conditions. High-strength steels, heterostructure composites, and dual-phase materials offer improved strength and formability, while precise die and tool design help minimize defects.The adoption of Industry 4.0 technologies is revolutionizing forming operations. Smart sensors, strain gauges, and piezoelectrics enable real-time monitoring of force, wear, and material flow. AI models integrated with finite element simulations enhance shape prediction and defect control. Digital twin technology supports predictive maintenance and process optimization, reducing downtime and waste.Advanced techniques like hot stamping, laser-assisted forming, and hybrid processes improve energy efficiency and dimensional accuracy. Hemming and embossing are also used for joining and detailing with high precision. As industries push for lightweighting and sustainability, forming technologies support reduced emissions, better fuel efficiency, and material savings.Challenges such as springback, cracking, and tooling wear are being addressed with smart automation, better materials, and AI-based optimization. These innovations are shaping the future of forming—enabling smarter, cleaner, and more efficient manufacturing systems for high-performance applications.
Recent Advances in Nanostructured Electrocatalysts for Seawater Electrolysis: Towards Sustainable Hydrogen Production
Seawater electrolysis has emerged as a promising and sustainable method for large-scale hydrogen production, utilizing abundant seawater as an alternative to freshwater electrolysis. However, challenges such as catalyst degradation, chloride-induced corrosion, and competition between the oxygen evolution reaction (OER) and chlorine evolution reaction (CER) hinder its widespread adoption. Recent advancements in nanostructured electrocatalysts, including metal-organic frameworks (MOFs), single-atom catalysts (SACs), and transition metal-based alloys, have significantly improved catalytic efficiency, reduced overpotentials, and enhanced stability in harsh marine environments. This review provides a comprehensive analysis of the latest breakthroughs in nanostructured electrocatalysts for seawater electrolysis, with a focus on key material innovations such as nickel-based alloys, molybdenum carbide/phosphide hybrids, and multi-component catalysts optimized for hydrogen evolution reaction (HER) kinetics. Additionally, the role of computational modeling and machine learning in accelerating catalyst design is explored. The economic feasibility and environmental impact of these advanced materials are critically assessed, considering lifecycle analysis, resource sustainability, and industrial scalability. Furthermore, the integration of seawater electrolysis with renewable energy sources, such as offshore wind and solar power, along with hydrogen storage and CO₂ capture strategies, is examined to highlight its potential for a carbon-free energy future. Despite significant progress, challenges remain in enhancing long-term catalyst durability, reducing costs, and achieving large-scale implementation. This review contributes to the ongoing development of sustainable hydrogen production technologies, reinforcing the pivotal role of seawater electrolysis in the global transition toward clean energy.
Enhanced Value Stream Mapping For Streamlining Supply Chains In The Furniture Manufacturing Industry
This study aims to analyze and optimize the supply chain processes of a furniture fabrication company by leveraging Value Stream Mapping (VSM) and simulation software. The current production system is meticulously modeled to identify inefficiencies and bottlenecks, enabling targeted improvements. Using Tecnomatix, both Current State and Future State Mappings are developed to enhance operational efficiency, minimize waste, and streamline workflows. The study commences with comprehensive data collection, followed by a detailed analysis of the Current State Mapping, revealing key inefficiencies such as excessive movement, prolonged waiting periods, and a lack of standardized work procedures. Based on these findings, a Future State Mapping is designed to optimize production flow. Among the alternatives evaluated, Scenario 2 emerges as the most effective, incorporating Kaizen principles in the measurement and cutting process across three workstations. This scenario achieves the highest output of seven units per shift, outperforming other scenarios while maintaining five operators and reducing the number of workstations from 13 to 10. Additionally, Scenario 2 exhibits the lowest lead time, ensuring a seamless production flow with minimized idle time. Scenario 1 effectively reduced waiting time by merging workstations, while Scenario 2, incorporating Kaizen, led to a 40% increase in output while maintaining the same workforce Although waiting and total processing times show slight increases, they remain within acceptable working limits. By implementing these strategic improvements, this study successfully reduces waste, enhances productivity, and promotes sustainable manufacturing practices, ultimately benefiting the industry and the broader economy.
Enhancing Industrial Safety: Analysing Key Failures and Recommendations for Improved Protocols and Ergonomic Practices
This case study analyses critical safety and ergonomic failures in several industrial accidents, emphasizing the need for improved safety protocols and workplace design. The meat-mincing machine accident highlighted the lack of proper lockout/tagout (LOTO) procedures, insufficient worker training, and poorly positioned emergency stop buttons, which delayed emergency responses and worsened the incident. Similarly, the warehouse hoist incident was caused by improper material handling, inadequate safety certifications, and poor ergonomic design, leading to musculoskeletal injuries. The MRT construction site accidents resulted from inadequate safety awareness, lack of equipment maintenance, and failure to adhere to safety regulations. The Pasir Gudang chemical spill demonstrated major deficiencies in waste management and emergency response, exacerbating environmental and public health risks. The study underscores the importance of a comprehensive safety culture, with recommendations including stricter enforcement of safety protocols, regular ergonomic assessments, and the adoption of real-time monitoring systems. Future research should focus on predictive maintenance technologies, the impact of industrial accidents on workers and the environment and overcoming barriers to implementing comprehensive safety measures. By fostering better safety practices, industries can reduce risks, protect workers, and prevent environmental disasters.
Performance analysis of 110 MW steam power plant with solar aided reheating system using GateCycle software
Along with the world's rapid population growth, the demand for electrical energy is also increasing. Hence, it is necessary to take innovative and environmentally friendly steps toward existing power plants to overcome the issue. One is using a solar-aided reheating system implemented in a steam power plant to increase its performance. In this study, an analysis of the reheating system with a solar collector was carried out on a particular steam power plant for the same loadings. The conditions of the Direct Normal Irradiance (DNI) at the location where the steam power plant was established were also considered in this study. A mathematical analysis was carried out to calculate the increase in thermal oil temperature heated by the solar collector with several different conditions throughout the year. The results were in the form of thermal oil outlet temperatures, which were then used as input for the simulation of a steam power plant that was assumed to be integrated with the solar-aided reheating system using GateCycle software. It was found that the performance of the steam power plant worked better when using a solar-aided reheating system compared to those without the solar system. At 100%, 75%, and 50% loading, power increased by 4.51% to 5.86%, 6.18% to 8.18%, and 8.91% to 11.42%, respectively. The highest performance increase occurred in March, and the lowest occurred in January due to the level of DNI in both months.
Enhancing Chemical Safety in Manufacturing: Lessons from Major Chemical Spill Incidents and the Role of Ergonomics
Chemical spills in manufacturing industries pose serious dangers to the safety of the environment, the health of employees, and the effectiveness of operations. This study examines the root causes and effects of significant chemical spill incidents. The analysis focuses on the lessons learned from these incidents, ergonomic and safety issues, and missed preventive measures. The thorough evaluation emphasizes how weak safety measures and poor ergonomic practices contribute to the rise of such incidents. The proposed alternative solutions focus on integrating chemical safety measures with ergonomic principles to reduce hazards and improve worker safety. The findings help to create safer industrial settings by providing industries with insights to prevent future chemical accidents and enhance worker well-being and operational sustainability.
A Mini Review Developing an Integrated Delivery System Model Using a Lean Approach
Delivery system services are a crucial component of the logistical infrastructure supporting Malaysian citizens, particularly in public service delivery. With the rise of digital technology, traditional information dissemination methods have been replaced by advanced digital systems that enhance interactivity, efficiency, and cost-effectiveness. This shift underscores the importance of developing Integrated Delivery System Models (IDSM) to ensure citizens receive timely, accurate information for informed decision-making. This mini review examines the application of lean principles to improve the efficiency and effectiveness of IDSM in Malaysia’s public service sector. Lean methodologies, which focus on reducing inefficiencies and optimizing processes, are explored as a framework to enhance transparency, accessibility, and system performance. Existing delivery system models and theories are reviewed to highlight the need for holistic systems thinking in addressing inefficiencies and overcoming the challenges of conventional delivery methods. Furthermore, the role of public policy in supporting lean integration is critically analyzed, with an emphasis on relational database systems to enable data-driven decision-making. These systems play a vital role in enhancing accuracy and operational efficiency, particularly in applications like general elections.This review presents a step-by-step framework for developing a lean-based IDSM, offering practical insights for policymakers and public administrators. By aligning social innovation, open governance, and technological advancements, this study aims to contribute to the design of a sustainable, citizen-centric public service delivery model that meets Malaysia’s evolving needs.
Design of Technical and Scientific Support Organization (TSO) for Supervision of Nuclear Power Plant Construction
Electricity is a fundamental necessity that requires a continuous and reliable supply. Nuclear energy, a renewable energy source, holds significant potential for electricity production in Indonesia. According to Government Regulation No. 79/2014 on the National Energy Policy, plans for the construction of Nuclear Power Plants (NPPs) in Indonesia are set to commence after 2025. A Technical and Scientific Support Organization (TSO) plays a critical role in supervising NPP construction, as outlined by the International Atomic Energy Agency (IAEA, 2018). A TSO is an organizational unit, department, or institute that primarily focuses on nuclear and radiation safety, providing technical and scientific support to regulatory functions. This study identifies key criteria for TSOs to effectively supervise NPPs, utilizing the Analytical Hierarchy Process (AHP). The criteria are categorized into three perspectives: Safety, Commissioning and Operation, and Human Resource and Management, with respective weights of 0.604, 0.210, and 0.186. The findings highlight safety as the most critical perspective, essential for ensuring the safe commissioning and operation of NPPs and associated facilities. This research provides a technical framework to guide the development of TSOs in compliance with applicable regulations, contributing to the safe and sustainable development of nuclear energy in Indonesia.
Implementation of Tofu Pouring Tool to Reduce Physical Workload and Ergonomic Risks
Industrial workers have an important role in influencing productivity and work efficiency. The problem of decreasing worker productivity due to workload and body posture occurs at UD Harapan Jaya Indah, in the production of fried tofu, where there are 3 work stations, namely pouring, cutting, and frying. In this study, body posture analysis was carried out using the Rapid Entire Body Assessment (REBA) method. Workload was measured by analyzing the Cardiovascular Load, and simultaneously conducted interviews to fill out the Nordic Body Map questionnaire, to find out workers' perceptions of the perceived workload. The results of this study are the design of the Tofu Dough Pouring Tool, which is the station that has the greatest workload. Of the 3 design concepts, concept 2 was selected as the best concept. Finally, the prototyping and implementation was carried out. Previously, workers' complaints on their backs were rated 7 (very painful) reduced to 1 (painful) after implementation. The REBA score before implementation had a moderate risk level (score 5-7), and after implementation was at a small risk level (score 3). The percentage of Cardiovascular Load in the pouring before implementation decreased from 31.55% to 28.7%.
Copyright (c) 2024 The Author(s) https://creativecommons.org/licenses/by-nc/4.0/
3D Printed Mold Insert Infill Analysis for Injection Molding Application
Injection molding (IM) normally made from steel, such as STAVAX because of its ability to withstand molding forces such as clamping, injection, and holding force. Beside of this ability, the fabrication of steel insert requires machining as such CNC machining and electro discharge machining (EDM). In contrast, a 3D printed mold insert can overcome of these constraints as it can be printed in less time and cost compared to conventional method of insert fabrication. In this research, a mold insert is fabricated using a 3D printer with a key chain shape cavity. The 3D printed insert are printed using fused deposition modelling (FDM) 3D printer with a three different infill, namely 50%, 75%, and 100% infill percentage. This could determine the performance of the 3D printed insert with the infill percentage. After several test conducted at injection molding, it is found that the infill percentage could improve the insert life span. The 100% infill contributed to longer life of the insert compared to 50% and 75% infill percentage. As the molten polymer is injected into the mold, the polymer tends to fill the void of the insert with the infill percentage of 50% and 75%. As the insert with 100% infill is used, the void is eliminated, thus the cavity can be filled with the molten polymer efficiently. From this research, the capabilities of 3D printed mold insert with different infill percentage is determined.
VALUE STREAM MAPPING IMPLEMENTATION IN A SMALL AND MEDIUM AGRO-BASED INDUSTRY
This study explores the implementation of Lean Manufacturing Systems at a small and medium-sized enterprise (SME) in the agro-industrial sector to identify and eliminate potential waste. The study analyzes current operational inefficiencies and proposes effective Lean solutions. Data on the company's production processes were collected and analyzed to pinpoint sources of waste. Using Tecnomatix Plant Simulation software, models of the current and improved future states were developed. These models provided a detailed visualization of the process flow, identifying key areas where Lean interventions could yield significant improvements. The effectiveness of these Lean initiatives was further analyzed using Value Stream Mapping (VSM), which facilitated a comparative analysis of process performance before and after implementing Lean improvements. The results demonstrated substantial enhancements in operational efficiency, which is 20.7%, doubled the profits, and improved customer satisfaction. This study not only underscores the feasibility of applying Lean principles in SME but also provides a robust framework for other similar enterprises to follow. The findings and recommendations presented in this study offer SME a strategic approach to achieving sustainable operational improvements and competitive advantage in their respective markets.
Working with cognitive load task: mental fatigue, sleepiness, and performance
Cognitive load experienced over a certain period can cause mental fatigue. Since many studies link mental fatigue with sleepiness, we aimed to investigate whether mental fatigue and sleepiness always co-occur. The aim was to explore the relationship between mental fatigue, sleepiness, and performance. Experiments using mathematics tests were conducted using the method of rm-ANOVA. We use subjective scales such as the Samn-Perelli and KSS to assess the level of fatigue and sleepiness. During the period, reaction times from the PVT and math test scores were also measured, indicating performance. The results showed a statistically significant increase in fatigue and sleepiness scores. Fatigue scores increased sharply while sleepiness scores were still relatively at a safe level. Reaction times increase, especially towards the last stage of the experiment. Over the trial, we find no significant decline in test scores. These findings suggest that although mental fatigue may co-occur with increased sleepiness, it is not always dominant, nor does it necessarily lead to reduced performance. This study increases understanding of the relationship between fatigue, sleepiness, and performance, and cautions against equating indicators of mental fatigue with sleepiness in research.
Analyzing The Effect of Cutting Parameters on Surface Roughness and Tool Life during End Milling of Titanium Alloy using Silicon Dioxide Nanoparticle Minimum Quantity Lubrication
The surface quality of the machined surface, such as the surface roughness, plays an important role in determining the final part of the product. Thus, the selection of the cutting parameters and cutting fluids during machining is crucial to determining the progression of the tool life as well as the surface quality of the machined surface. The objective of this paper is to analyse the effect of cutting parameters on the surface roughness and tool life during end milling of titanium alloy (Ti-6Al-4V) using silicon dioxide (SiO2) nanoparticle minimum quantity lubricant (MQL). In this paper, three cutting parameters were chosen: cutting speed of 20 and 40 m/min, feed rate of 0.2 and 0.3 mm/tooth, and depth of cut of 0.2 and 0.3 mm with two levels. The influence of cutting parameter combinations was evaluated using the Full Factorial method. From the results, it was observed that the depth of cut has the most significant effect on improving the surface roughness quality and extending the tool life compared with cutting speed and feed rate.
A Whale Optimization Algorithm Approach for Flow Shop Scheduling to Minimize Makespan
Flow shop scheduling is crucial in manufacturing and production environments because it directly impacts output and overall production efficiency. It involves processing a set of jobs on multiple machines in a specific order. The objective is to determine the optimal job sequence that minimizes the makespan, which is the total time required to complete all jobs. This study proposes a computerized approach utilizing the Whale Optimization Algorithm (WOA) to solve the flow shop scheduling problem and minimize the makespan. The WOA is a recently developed meta-heuristic algorithm inspired by the bubble-net hunting strategy of humpback whales. The performance of the WOA is evaluated using five benchmark problems with varying numbers of jobs and machines, and the results are compared with those obtained from other algorithms reported in the literature, such as genetic algorithms and heuristic models. The findings demonstrate that the WOA can effectively solve the flow shop scheduling problem and provide improved makespan values, with an average efficiency of 7.33% compared to the other algorithms.
A review on Mahalanobis-Taguchi system and time-driven activity-based costing for production environment
Mahalanobis-Taguchi system (MTS) is a decision-making system that identifies patterns. The fundamental idea of MTS is to select a set of variables and then apply Mahalanobis distance to optimize each of the factors that contribute to the issue. Meanwhile, time-driven activity-based costing (TDABC) is an approach that defined as a costing model that provides the cost of activities based on the amount of time consumed per activity. The current study seeks to address several gaps and presents research motivation with a particular focus on the potential benefits that comes from employing these two approaches individually in a variety of disciplines. The content of this paper generally consists of studies of literature from 2013 to 2023 from the fields of agriculture, industrial, communication, education, health care, hospitality, and finance sectors. To begin, 74 and 140 research publications employing MTS and TDABC, respectively, have been discovered. From the findings, the industrial sector has the greatest proportion of using MTS technique with 60.81% for 45 from overall 74 articles. MTS is widely used in production environment, as it is a powerful method of optimization that revealed the criticality of parameters, thus can reduce the rejected product in a process. Whereas the health care industry has the largest percentage of articles using the TDABC approach in cost accounting systems, with 62.14% for 87 from total 140 articles. TDABC is popularly applied in health care primarily to estimate the cost of clinical procedures and visits in order to inform operational improvement.
Methadone Flexi Dispensing (MFlex) Intelligence System utilizing the Mahalanobis-Taguchi System
Patients who are participating in the methadone flexi dispensing (MFlex) program are obliged to provide their blood samples for various testing, such as lipid profiles. A doctor evaluates three parameters, including cholesterol, HDL cholesterol, and LDL cholesterol to determine whether or not the patient has a lipid issue. Since, the current structure lacks an ideal atmosphere for classification and optimization caused by inaccuracies in measurement methodologies and a lack of explanation for significant aspects that have an effect on the accuracy of diagnostics. The objective is to implement the Mahalanobis-Taguchi system (MTS) in the MFlex program. Utilizing a total of 34 parameters, there are two different types of MTS techniques used for classification and optimization: the RT method and T method. The average Mahalanobis distance (MD) for healthy conditions is 1.0000 whereas for unhealthy is 79.5876. As a result, there is 19 parameters indicate a positive degree of contribution. 15 unknown samples were diagnosed with a variety of positive and negative degree of contribution to achieving a lower MD. Type 5 of 6 alterations was chosen as the best suggested possibility. In conclusion, MTS is able to be applied in medical environment.
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