Engineering Research Seminar Series 15, 2011: Process Re-Engineering in The Shop Floor of A Fan and Blower Production

Mr Kumares Wara Rao, a senior lecturer from Mechanical Engineering Department, Nilai University College

Date: 2011-05-05
Time: 11:00 to 12:00
Venue: Meeting Room 1, 5-4-22, School of Engineering


The most common approach to business problem solving and making improvement is by starting at the core of the business: the sequence of different elements of the business process. The fan and blower industry is best described as job shop environment that requires different levels and process techniques. The amalgamation of all these process and the quality control system is the final desired outcome of this project. The system was designed using guidelines of the Process Quality Model (PQM). The PQM is suitable for the purpose of designing a system that will identify and document any non-conformance. The design encompasses the four major departments that are involved in the production. The most important department, which is the production, consists of several sections doing their own processes. This department received through attention in order to create the optimum solution.

The first step was to get the necessary comments from the personals in charge of the departments. After this, the present system is analysed to determine the present manufacturing process and its quality control measures. When this is achieved, the right definition of quality is created to be the motto for the creation of the new system. Then appropriate solutions are thought of and reworked many times to ensure for acceptance. To do this, the accurate information is sent to the workers through training and education.

When new measures are in place, right measurement to determine the effectiveness of the system is needed to justify its existence. The shop floor consists of eight different sections that gives different rates of non-conformances. The improvements were conducted in a period of eleven months from September 2001 to August 2002. In this period of time, the sections recorded an increase of non-conformances from 15 times (at September 2001) to 57 times (at August 2002) which is an increase of 280.00%. While the labour hours lost to correct or remedy them decreased from 97.5 hours to 38.5 hours (decrease of 60.51%) in the same period. For the same period, the losses decreased 95.77%. These figures show that the implemented improvement detects more quality issues but decreases the cost losses and time spent to solve them. A significant cost saving in energy in the plant can be translated into a better work environment which leads to a more positive impact to environment.

About the Speaker

Kumares Wara Rao finished his Bachelor of Engineering (B.Eng.) in Mechanical Engineering at Universiti Putra Malaysia (UPM) in the year 1999. He continued his Masters of Science (M.Sc.) at UPM specializing in Manufacturing System Design finishing in the year 2004. Currently he is attached at Nilai University College as Senior Lecturer for the Mechanical Engineering Department.