CERES :: Browsing by Author "Shehab, Essam"

Browsing by Author "Shehab, Essam"

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Open Access
A3 thinking approach to support knowledge-driven design
(Springer, 2013-03-01) Mohd Saad, Norhairin; Al-Ashaab, Ahmed; Maksimovic, Maksim; Zhu, L.; Shehab, Essam; Ewers, P.; Kassam, A.
Problem solving is a crucial skill in product development. Any lack of effective decision making at an early design stage will affect productivity and increase costs and the lead time for the other stages of the product development life cycle. This could be improved by the use of a simple and informative approach which allows the designers and engineers to make decisions in product design by providing useful knowledge. This paper presents a novel A3 thinking approach to problem solving in product design, and provides a new A3 template which is structured from a combination of customised elements (e.g. the 8 Disciplines approach) and reflection practice. This approach was validated using a case study in the Electromagnetic Compatibility (EMC) design issue for an automotive electrical sub-assembly product. The main advantage of the developed approach is to create and capture the useful knowledge in a simple manner. Moreover, the approach provides a reflection section allowing the designers to turn their experience of design problem solving into proper learning and to represent their understanding of the design solution. These will be systematically structured (e.g. as a design checklist) to be circulated and shared as a reference for future design projects. Thus, the recurrence of similar design problems will be prevented and will aid the designers in adopting the expected EMC test results.
Open Access
A3 thinking approach to support lean product and process development
(Cranfield University, 2013-03) Mohd Saad, Norhairin; Al-Ashaab, Ahmed; Shehab, Essam
This research project aims to develop a novel A3 thinking approach to support knowledge driven design that aids the generation of decision making within a Lean Product and Process Development (LeanPPD) environment. This research comprises the development of a new A3 template as a technique of problem solving in product design, the adoption of a reflection practice structured in a new A3 template for knowledge capture and sharing, and the generation of the process of using the A3 thinking approach for effective implementation. Providing useful knowledge as a design reference to generate decision making at the initial stages of product development in product design helps the designers to prevent recurrence of the same problem, eliminate design mistakes and enhance design decision. In order to achieve a novel A3 thinking approach, a research methodology consisting of four phases was developed. The first phase synthesises the A3 best practice through literature and documentation reviews. The gap analysis and results from the reviews have identified several problem-solving approaches and learning cycles that have to be considered in the research. The second phase is to evaluate the approaches and their impacts and applications in product design. In order to complete this, several research methods are selected and performed (e.g. focus group and semistructured interview) within the collaborative companies. The third phase is to develop the A3 thinking approach by utilising the LAMDA learning cycle, developing a new A3 template or so-called A3LAMDA, adopting the reflection practice and generating the process of using the new A3 thinking approach. Finally, the validation of the new A3 thinking approach through industrial case studies and expert judgements have been performed. This approach has been implemented in the automotive sector and was applied to four industrial case studies and six A3LAMDA reports were collected. As a result of the findings of this research, the utilisation of the A3 thinking approach aided the generation of knowledge driven design in product design by integrating the knowledge management capabilities; knowledge creation, capture and sharing.
Open Access
Advances in Manufacturing Technology XXVII: Proceedings of the 11th International Conference on Manufacturing Research (ICMR2013)
(Cranfield University, 2013-09-19) Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
ICMR2013 was organised by Cranfield University on the 19-20 September 2013. The conference focuses on any aspects of product development, manufacturing technology, manufacturing systems, information systems and digital technologies. It provides an excellent avenue for researchers to present state-of-the-art multidisciplinary manufacturing research and exchange ideas. In addition to the four keynote speeches from Airbus and Rolls-Royce and three invited presentations, there are 108 papers in these proceedings. These papers are split into 24 technical sessions. The International Conference on Manufacturing Research is a major event for academics and industrialists engaged in manufacturing research. Held annually in the UK since the late 1970s, the conference is renowned as a friendly and inclusive environment that brings together a broad community of researchers who share a common goal; developing and managing the technologies and operations that are key to sustaining the success of manufacturing businesses. For over two decades, ICMR has been the main manufacturing research conference organised in the UK, successfully bringing researchers, academics and industrialists together to share their knowledge and experiences. Initiated a National Conference by the Consortium of UK University Manufacturing Engineering Heads (COMEH), it became an International Conference in 2003. COMEH is an independent body established in 1978. Its main aim is to promote manufacturing engineering education, training and research. To achieve this, the Consortium maintains a close liaison with government bodies concerned with the training and continuing development of professional engineers, while responding to the appropriate consultative and discussion documents and other initiatives. COMEH is represented on the Engineering Professor’s council (EPC) and it organises and supports national manufacturing engineering education research conferences and symposia.
Open Access
An aerospace requirements setting model to improve system design
(Elsevier, 2014-10-31) Tomas Centrich, X.; Shehab, Essam; Sydor, Piotr; Mackley, Tim; John, Philip; Harrison, A.
Decisions at an early conceptual stage of the product lifecycle, are made with relatively low confidence, but such decisions greatly influence the overall product and service development. It is, therefore, critical to define the risks involved in order to help designers to make informed decisions. This research project investigates the risk and uncertainties in delivering products to meet top-level business requirements. The aim is to improve the existing process of setting business requirements and the current design approaches to achieve an optimised system design. This project also examines different approaches in assessing the risk of product and service delivery. To achieve that, a dedicated software tool, based on Weibull distribution function reliability model, has been created. An example of Rolls-Royce Civil Large Engine (CLE) gas turbine design process is used in this research as the case study. An analysis of the gap between the current design achievements and the targeted business requirements of a new product is performed at whole engine, module and component level. Further comparison of the new product business requirements, the novelty in the design and the historical reliability data is used to define and assess the risk of new product delivery.
Open Access
Affordability Assessment of Industrial Product-Service System in the Aerospace Defence Industry
(Cranfield University Press, 2009-04-01) Bankole, O. O.; Roy, Rajkumar; Shehab, Essam; Wardle, P.; Rajkumar Roy; Essam Shehab
The Industrial Product-Service System (IPS2) takes a whole life cycle view in order to consider the total cost of the IPS2 offering. This paper focuses on the concept of customer affordability which aims to review current practice in industry and with interaction between customer and solution providers to identify factors affecting affordability. It secures a standard definition and proposes a measurement technique called the Affordability Index (AI) within the aerospace defence industry. A preliminary Affordability Capability Audit Tool is developed to give an indication of the confidence level about the AI. It identifies challenges in industry and outlines opportunities for further research scope.
Open Access
An approach for selecting cost estimation techniques for innovative high value manufacturing products
(Elsevier, 2016-11-02) Schwabe, Oliver; Shehab, Essam; Erkoyuncu, John Ahmet
This paper presents an approach for determining the most appropriate technique for cost estimation of innovative high value manufacturing products depending on the amount of prior data available. Case study data from the United States Scheduled Annual Summary Reports for the Joint Strike Fighter (1997-2010) is used to exemplify how, depending on the attributes of a priori data certain techniques for cost estimation are more suitable than others. The data attribute focused on is the computational complexity involved in identifying whether or not there are patterns suited for propagation. Computational complexity is calculated based upon established mathematical principles for pattern recognition which argue that at least 42 data sets are required for the application of standard regression analysis techniques. The paper proposes that below this threshold a generic dependency model and starting conditions should be used and iteratively adapted to the context. In the special case of having less than four datasets available it is suggested that no contemporary cost estimating techniques other than analogy or expert opinion are currently applicable and alternate techniques must be explored if more quantitative results are desired. By applying the mathematical principles of complexity groups the paper argues that when less than four consecutive datasets are available the principles of topological data analysis should be applied. The preconditions being that the cost variance of at least three cost variance types for one to three time discrete continuous intervals is available so that it can be quantified based upon its geometrical attributes, visualised as an n-dimensional point cloud and then evaluated based upon the symmetrical properties of the evolving shape. Further work is suggested to validate the provided decision-trees in cost estimation practice.
Open Access
An autonomous system for maintenance scheduling data-rich complex infrastructure: Fusing the railways' condition, planning and cost
(Elsevier, 2018-02-22) Durazo-Cardenas, Isidro; Starr, Andrew; Turner, Christopher J.; Tiwari, Ashutosh; Kirkwood, Leigh; Bevilacqua, Maurizio; Tsourdos, Antonios; Shehab, Essam; Baguley, Paul; Xu, Yuchun
National railways are typically large and complex systems. Their network infrastructure usually includes extended track sections, bridges, stations and other supporting assets. In recent years, railways have also become a data-rich environment. Railway infrastructure assets have a very long life, but inherently degrade. Interventions are necessary but they can cause lateness, damage and hazards. Every day, thousands of discrete maintenance jobs are scheduled according to time and urgency. Service disruption has a direct economic impact. Planning for maintenance can be complex, expensive and uncertain. Autonomous scheduling of maintenance jobs is essential. The design strategy of a novel integrated system for automatic job scheduling is presented; from concept formulation to the examination of the data to information transitional level interface, and at the decision making level. The underlying architecture configures high-level fusion of technical and business drivers; scheduling optimized intervention plans that factor-in cost impact and added value. A proof of concept demonstrator was developed to validate the system principle and to test algorithm functionality. It employs a dashboard for visualization of the system response and to present key information. Real track incident and inspection datasets were analyzed to raise degradation alarms that initiate the automatic scheduling of maintenance tasks. Optimum scheduling was realized through data analytics and job sequencing heuristic and genetic algorithms, taking into account specific cost & value inputs from comprehensive task cost modelling. Formal face validation was conducted with railway infrastructure specialists and stakeholders. The demonstrator structure was found fit for purpose with logical component relationships, offering further scope for research and commercial exploitation.
Open Access
Benchmark pre-production practice in manufacturing engineering
(IOS Press, 2017-12-31) Shehab, Essam; Rao, Yogeesh; Al-Ashaab, Ahmed; Beadle, Chris; Sarfraz, Shoaib
Prototyping stage is a very important phase of new product development, where many decisions need to be taken to get high quality, zero defect products at the right time with minimum cost. Therefore, any value added improvements or best practices in the prototyping stage will support competitiveness of manufacturing companies. This research aims to benchmark the best practices in prototype part manufacture to support early stages of product introduction. A set of of best practices in the prototype component manufacture, along with validated four step prototyping strategy model and best practice prototype journey path model were developed. Research findings provide insight about prototyping trends, best practices and optimum ways of doing prototyping in the manufacturing companies around the globe. Manufacturing companies can use the developed models and best practices to make better prototype strategy in their new product introduction system to achieve their business objectives.
Open Access
Benefit realisation modelling for ERP systems using system dynamics
(Cranfield University Press, 2013-09-19) Badewi, Amgad; Shehab, Essam; Peppard, Joe
Achieving success for ERP systems is not only concerned with deploying the technology on time and on budget but also concerned with the level of achieving targeted benefits from the system. This level of achieving targeted benefits can be managed indirectly through managing the organisational attitude toward the new system. Thus, the aim of this paper is to use the System Dynamics (SD) to reveal how managing organisational attitude leads to an increase in the level of system use and, therefore, leads to a decrease in the level of resistance to change to new system for achieving high level of performance. SD is used to investigate the causal loops of organisational attitude, perceptions, behaviours, and policies taken to achieve desired benefits. The ability to manage an organisational attitude toward ERP is an important factor for achieving desired levels of benefits is the main conclusion of this research.
Open Access
Capturing the Industrial Requirements of Set-Based Design for the CONGA Framework
(2013-09-19T00:00:00Z) Al-Ashaab, Ahmed; Golob, Matic; Noriega, Paula; Torriani, Filippo; Alvarez, Pedro; Beltran, Ana; Busachi, Alessandro; Ex-Ignotis, Lambert; Rigatti, Carlotta; Sharma, Sanjiv; Shehab, Essam; Ball, Peter; Tjahjono, Benny
The Configuration Optimisation of Next-Generation Aircraft (CONGA) is a proposed framework in a response to industrial need to enhance the aerospace capability in the UK. In order to successfully address this challenge, a need to develop a true multi-disciplinary Set-Based Design (SBD) capability that could deploy new technologies on novel configurations more quickly and with greater confidence was identified. This paper presents the first step towards the development of the SBD capabilities which is to elicit the industrial requirement of the SBD process for the key aerospace industrial partners involved in this CONGA approach.
Open Access
Challenges and benefits of digital workflow implementation in aerospace manufacturing engineering
(Elsevier, 2017-05-09) Rojo Abollado, Jaime; Shehab, Essam; Bamforth, Philip
Companies who operate in highly regulated industries have further challenges to the usual competition, continuous cost reduction and product development challenges. To address these requirements companies optimise their business processes and change their applications and information systems to support their evolving way of doing business. Workflow management technology eases the achievement of these necessities by providing methodologies, software and tools to support business process modelling, reengineering and workflow automation. Business process mapping is necessary in order to capture business processes as workflow specifications. Then, these systems allow business process reengineering, helping the optimisation of specified processes, and workflow automation, in order to generate a lean digital workflow from the specifications. There are many opportunities to benefit from this technology in aerospace applications, however these bring several implementation challenges in large global companies operating in multiple markets and need to be carefully managed. This research provides an overview of the benefits that digital workflows implementation can potentially bring to aerospace companies, together with a detailed description of significant challenges, regarding both the implementation of digital workflows and risks related to human factors. The study increases industry awareness on the importance of driving a digital transformation through implementing digital workflows, and where to start this implementation in a manufacturing business, highlighting the success factors.
Open Access
Challenges in cost analysis of innovative maintenance of distributed high-value assets
(Elsevier, 2014-10-31) Kirkwood, Leigh; Shehab, Essam; Baguley, Paul; Amorim-Melo, P.; Durazo-Cardenas, Isidro
Condition monitoring is an increasingly important activity, but there is often little thought given to how a condition monitoring approach is going to impact the cost of operating a system. This paper seeks to detail the challenges facing such an analysis and outline the likely steps such an analysis will have to take to more completely understand the problem and provide suitable cost analysis. Adding sensors might be a relatively simple task, but those sensors come with associated cost; not only of the sensor, but of the utilities required to power them, the data gathering and processing and the eventual storage of that data for regulatory or other reasons. By adding condition monitoring sensors as a sub- system to the general system an organisation is required to perform maintenance to the new sensors sub-system. Despite these difficulties it is anticipated that for many high value assets applying condition monitoring will enable significant cost savings through elimination of maintenance activities on assets that do not need such cost and effort expended on them. Further savings should be possible through optimisation of maintenance schedules to have essential work completed at more cost efficient times.
Open Access
Challenges in cost modelling of recycling carbon fiber composites
(IOS, 2020-07-10) Shehab, Essam; Meiirbekov, Arshyn; Sarfraz, Shoaib
The use of carbon fiber composites (CFCs) has become broad in many industries due to its superior properties compared to conventional materials. However, the increased demand coupled with environmental regulations has led to the development of different recycling methods for CFCs such as mechanical, thermal and chemical processes. Each recycling method has its own requirements and outputs along with some economic implications which need to be justified through cost modelling. This paper aims to identify current challenges associated with cost modelling of different processes for CFC recycling. The main challenges identified are grouped into three main categories such as technical issues, supply chain and market challenges
Open Access
Challenges of cloud technology in manufacturing environment
(Cranfield University Press, 2013-09-19) Yadekar, Yaser; Shehab, Essam; Mehnen, Jorn
The rapid growth Information systems and advanced network technologies have significant impact on enterprises around the world. Enterprises are trying to gain competitive advantage in open global markets by using the latest technologies, along with advanced networks, to create collaboration, reduce costs, and maximize productivity. The combination of latest technologies and advanced manufacturing networks technologies lead to growth of new manufacturing model named Cloud Manufacturing which can shift the manufacturing industry from product-oriented manufacturing to services-oriented manufacturing. This paper explores the literature about the current Manufacturing problems, understands the concept of Cloud Computing Technology, introduces Cloud Manufacturing and its role in the enterprise, and investigates the obstacles and challenges of adopting Cloud Manufacturing in enterprises.
Open Access
Challenges of digital twin in high value manufacturing
(SAE International, 2018-10-30) Singh, Sumit; Shehab, Essam; Higgins, Nigel; Fowler, Kevin; Tomiyama, Tetsuo; Fowler, Chris
Digital Twin (DT) is a dynamic digital representation of a real-world asset, process or system. Industry 4.0 has recognised DT as the game changer for manufacturing industries in their digital transformation journey. DT will play a significant role in improving consistency, seamless process development and the possibility of reuse in subsequent stages across the complete lifecycle of the product. As the concept of DT is novel, there are several challenges that exist related to its phase of development and implementation, especially in high value manufacturing sector. The paper presents a thematic analysis of current academic literature and industrial knowledge. Based on this, eleven key challenges of DT were identified and further discussed. This work is intended to provide an understanding of the current state of knowledge around DT and formulate the future research directions.
Open Access
Challenges of lean thinking application in product-service system
(Cranfield University Press, 2013-09-19) Elnadi, Moustafa; Shehab, Essam; Peppard, Joe
Lean thinking is claimed to be as important to services as it has been to manufacturing. However, there is yet a lack of empirical research examining the possibility of applying lean thinking in Product-Service System (PSS). This paper aims to bridge this gap by focusing on the challenges of applying lean thinking in PSS. To achieve this aim, twenty interviews were conducted with participants that have a good experience in lean implementation. Those participants are working in UK manufacturing companies that implement PSS. Also, a comprehensive review of the published literature was executed to achieve a depth understanding of the various challenges already identified by other researchers. The findings highlight a number of challenges that emerge during the application of lean thinking in PSS, among them: understanding of lean, limited communication and leadership, and defining waste.
Open Access
Challenges of model-based definition for high-value manufacturing
(IOS, 2019-09-12) Goher, Kamran; Shehab, Essam; Al-Ashaab, Ahmed
Manufacturing Industry is moving towards adoption of 3D models as the ultimate authoritative source for complete product definition replacing 2D drawings, which is called “Model-Based Definition”. Starting its journey from geometric information on design, manufacturing, and inspection, the targets are to achieve the ultimate goal of lifecycle model based enterprise, requiring MBD to be more comprehensive and challenging structure of information instead of just a geometric model. The industry has not yet fully achieved implementation of MBD to whole product lifecycle. This journey is long and tough, and we are still at an early stage, but it will be a decisive factor in gaining competitive advantage by the early adopters, especially in high-value manufacturing. Complete adoption of MBD has several issues and challenges that need to be addressed. This paper presents a review of current literature, intending to cover present state of knowledge, issues, challenges, and future research directions, in the development and adoption of MBD.
Open Access
Chapter 5: Comprehensive study on tool wear during machining of fiber-reinforced polymeric composites
(Springer, 2020-12-23) Ismail, Sikiru Oluwarotimi; Sarfraz, Shoaib; Niamat, Misbah; Mia, Mozammel; Gupta, Munish Kumar; Pimenov, Danil Yu; Shehab, Essam
The use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost of the machining process annually. It occurs due to sudden geometrical damage, frictional force and temperature rise at the tool-work interaction region. Moreover, tool wear is an inevitable, gradual and complex phenomenon. It often causes machined-induced damage on the workpiece/FRP composite materials. Considering the geometry of drill, tool wear may occur at the flank face, rake face and/or cutting edge. There are several factors affecting the tool wear. These include, but are not limited to, drilling parameters and environments/conditions, drill/tool materials and geometries, FRP composite compositions and machining techniques. Hence this chapter focuses on drilling parameters, tool materials and geometries, drilling environments, types of tool wear, mechanisms of tool wear and methods of measurement of wear, effects of wear on machining of composite materials and preventive measures against rapid drill wear. Conclusively, some future perspectives or outlooks concerning the use of drill tools and their associated wears are elucidated, especially with the advancement in science and technology
Open Access
Comparison of the environmental impact of the CRIMSON process with normal sand casting process
(2013-09-02T00:00:00Z) Zeng, Binxu; Salonitis, Konstantinos; Jolly, Mark R.; Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes.
Open Access
The Conceptual LeanPPD Model
(2012-06-30) Al-Ashaab, Ahmed; Shehab, Essam; Alam, Rahman; Sopelanad, Amaia; Sorli, Mikel; Flores, Myrna; Taisch, Marco; Stokic, Dragan; James-Moore, Mike; Jerzy, Pokojski; Shuichi, Fukada; Jozef, Salwinski
This paper is presenting the conceptual Lean Product and Process Development (LeanPPD) model which is a project funded by the EU-PF7. The project is addressing the needs of European manufacturing companies of a new model that goes beyond lean manufacturing, to ensure the transformation of the enterprise into lean environment. This is a respond to the market demand of value creation, incorporating sustainability and customisation as well as ensuring business growth through the development of high quality products in a cost effective manner at the shortest time. The authors believe that significant change in enterprise performance can be achieved through the adoption of lean thinking throughout the product life cycle. The paper presents the LeanPPD enablers which represent the building block of the model.