Rosmaini Ahmad
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Preferred name
Rosmaini Ahmad
Official Name
Rosmaini, Ahmad
Alternative Name
Ahmad, Rosmaini
Ahmad, Rasyidah
Ahmad, R.
Main Affiliation
Scopus Author ID
14021065800
Researcher ID
EJM-9902-2022

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Applying lean six sigma approach: A study in recipe recovery and backup process environment

2021-07-21 , Kiang B.K. , Jusoh M.S. , Sri Sarah Maznah Mohd Salleh , Rosmaini Ahmad , Din M.S.H.

Lean and Six Sigma are recent developments in continuous improvement methodology that have been popularized by several companies. The success and complementary nature of these methodologies has led to their combination into a single methodology, commonly called Lean Six Sigma. It is a key driver in enhancing the continuous improvement opportunity in various industries. Thus, this study aims to explore the Lean Six Sigma approach implementation in small, medium and large scale firms in detail, and apply the DMAIC concept in the recipe recovery and backup project. DMAIC stands for Define, Measure, Analyze, Improve and Control. Besides, the knowledge of the study will not limit to Lean Six Sigma analysis and literature analysis in the past. Thus, the findings will assist the subsequence case studies and idea to further improve on other industry process. Besides, it will seize great improvement opportunity in improving the efficiency of the existing process in any fields. Therefore, an analysis was constructed in assisting scholars and practitioners to better understand the concept and the influence of this approach. It helps to eliminate the existing impact of high configuration time and establish an excellent operational process in manufacturing. By applying the Lean Six Sigma methodology, it is targeted to achieve MTTR < 30 minutes after the implementation of centralized recipe backup solution. It is recommendation to use Lean Six Sigma methodology in various industries for continuous improvement such as in cost and quality.

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On time delivery improvement - Implementing six sigma DMAIC method

2021-07-21 , Salvaragh I.R. , Muhammad Shahar Jusoh , Sri Sarah Maznah Mohd Salleh , Rosmaini Ahmad , Din M.S.H.

The likelihood of meeting on time delivery expectation for electronic manufacturer is demonstrated as the productivity's result. It depicts that adequate item is accessible for delivery, permitting the variability in yield, and the likelihood that the item will be sent in the submitted time frame, taking into consideration process duration change. Numerous service firms use delivery time assurances to go after clients in the commercial focus. This study reports the application of a 6σ project on the improvements of Company X products on time delivery. The methodology adopted in this study is the Define Measure Analyse Improve Control (DMAIC) technique of 6σ. This method is adopted as Six Sigma gives a viable instrument to concentrate on customer prerequisites, through improvements of process quality. Six Sigma projects are performed with the goal of improving on time delivery, in- process quality and product quality. This study describes the application of the Six Sigma methodology, focusing the five phases - Define, Measure, Analyze, Improve and Control, by taking the example of a project, and demonstrates the benefits attained.

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Performance evaluation on locomotion system, body size and hull design on amphibious-based design of unmanned ground vehicle using Taguchi method

2023 , Mohd Iqhwan Izhar , Muhammad Shahar Jusoh , Rosmaini Ahmad , Mohd Shihabudin Ismail , Wan Nor Munirah Ariffin

Unmanned Ground Vehicle (UGV) is a robotic structured-based vehicle that operated on the ground but did not contain any human on board. It controlled either autonomously or remote controlled by a human operator from a distance. The operator observes the situation by using a camera that contains live feed that had been attached to the UGV. More advanced version of UGV is called "Autonomous UGV", where it controlled fully by sensors system. Thus, make this version of UGV highly reliable in replacing human for doing jobs in hazardous area or a place that is impossible for human to reach. This paper study the performance evaluation of UGV in term of their locomotion system, body size and hull design by using Taguchi method. The current UGV design under study is less flexible as it only operates on land. The objective of this study is to identify the optimal design parameters of the UGV towards amphibious functionality development. This study bridge the gap between engineering and management perspectives in reducing the time needed to perform testing on new design and reducing cost of experiment by using the Taguchi Method. The result shows that the ideal parameters design combination based on the signal-to-noise ratio calculated using the larger the better formula is the wheeled locomotion system with 350 X 250 X 200 dimension of body size and round-bottom shape of hull design.

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Implementation of kanban-based fifo system to minimize lead time at automated optical inspection operation - A case study in semiconductor industry

2021-01-01 , Krom P. , Rosmaini Ahmad , Shaliza Azreen Mustafa , Tan Chan Sin

This paper presents an improvement project in a semiconductor industry to minimize product lead time in automated optical inspection (AOI) operation. The Lean Thinking (LT) approach is applied to drive this improvement project, which it performed based on three main stages; observation, improvement and validation. Initial observation study found a significant cause of this problem (lead time). There have improper record and control mechanisms of receiving the product lots from production department, picking the products lots for inspection and restoring the products lots after inspection. Therefore, this not only cause the high and inconsistent lead time of products lot to be inspect (due to random rack location searching during picking and restoring processes) also the right sequence of product lots from one type to another that went through the AOI operation cannot systematically managed and controlled. In improvement stage, a production control system, namely Kanban-based First-In-First-Out (FIFO) system is proposed to solve the stated problem. Generally, Kanban technique applied in this research project is to systematically guide the inspection operator for performing AOI operation based on FIFO rule. There are two keys rules behind Kanban technique application; First is to record the sequence of the product lots that been received from production department and obtained the rack location for their temporary store. Second is to provide input information for the inspection operator to perform the activities picking and restoring in the right sequence of product lot direct to the rack location that has been stored before. Another technical mechanism included in Kanban-based FIFO system is the application of supermarket buffer system to minimize the wafer lot searching activity. In validation stage, the proposed solution has been tested within the period of one month. Results show that the searching times for picking and restoring the product lots has reduced to 77.0% and overall product lead time due inspection process has reduced 54.2%. The mechanism of Kanban-based FIFO system is then proposed to the top management of the case study company to be embedded with Internet of Thing (IoT) technology to support Industrial 4.0 evolution.

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Root cause analysis using extended cause-effect chain analysis plus method for cleanroom relative humidity problem in the semiconductor industry

2023-06 , Sri Rahayu Salehan , Rosmaini Ahmad

This study presents a systematic root cause analysis (RCA) to investigate the relative humidity (RH) problem. The RCA method, known as extended cause-effect chain analysis plus (CECA+) is proposed. The method provides a systematic and attractive manner to manage multi-inter relationships of causes and effects of a problem. Based on the solutions idea generation and verification processes, a final solution idea was obtained. The cleanroom RH trend showed significant improvement that it met the specification of fewer fluctuations at <50%. In addition, the cleanroom temperature trend remained unchanged at the normal allowable cleanroom operation temperature target of < 23.5°C. These results indicate the proposed solution idea is effective for the problem being investigated. The proposed method has the potential to be applied independently to solve other complex manufacturing problems due to its generic structure design. Finally, it can be applied concurrently with other continuous improvement methodologies such as Lean Six Sigma.

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Application of fuzzy failure mode, effect and criticality analysis (fuzzy FMECA) with extended rule of criticality ranking assessment: a case study in ghee and soap industry

2023 , Adel Ali Azawqari , Rosmaini Ahmad , Badiea Aswaidy M , Shaliza Azreen Mustafa

This paper presents the application of fuzzy FMECA for item criticality ranking assessment. A case study from Yemen's ghee and soap industry was used, which focuses on a critical production system of seaming process. The proposed fuzzy FMECA framework is divided into three main phases. The first phase is the FMECA procedure that is commonly applied with criticality analysis is performed based on risk priority number (RPN) calculation of severity (S), occurrence (O) and detection (D) parameters measures. The second phase is the estimation of RPN based on the fuzzy approach, which is carried out based on Gaussian membership function application. The third phase is the final criticality ranking assessment process to prioritize the production components under study. In this phase, an extended rule is introduced to avoid/minimize overlapping values in criticality ranking determination. A case study on a critical production system that consists of overall 32 components was used for framework validation. The MATLAB fuzzy logic toolbox was used to assist the fuzzification process towards RPN numbers estimation. The overall results of FMECA with comparison values of typical RPN and fuzzy RPN are presented. The discussion on the implications and benefits of the extended rule application towards final criticality ranking determination is then given.

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Phase Analysis of Different Liquid Ratio on Metakaolin/Dolomite Geopolymer

2022-01-01 , Sauffi A.S. , Wan Mastura Wan Ibrahim , Mohd. Mustafa Al Bakri Abdullah , Masdiyana Ibrahim , Rosmaini Ahmad , Fakhryna Ahmad Zaidi

Geopolymer is widely studied nowadays in various scope of studies. Some of the ongoing studies are the study of the various materials towards the geopolymer strength produced. Meanwhile, some of the studies focus on the mixing of the geopolymer itself. This paper discussed the phase analysis of metakaolin/dolomite geopolymer for different solid to the liquid ratio which was, 0.4, 0.6, 0.8, and 1.0, and the properties that affected the geopolymer based on the phases. The constant parameters in this study were the percentage of metakaolin and dolomite used. The metakaolin used was 80% meanwhile dolomite usage was 20%. Besides that, the molarity of NaOH used is 10M and the alkaline activator ratio used is 2.0. All the samples were tested at 28 days of curing. The results show that the 0.8 solid to the liquid ratio used gave better properties compare to other solid to liquid ratio. The phases analyzed were quartz, sillimanite, mullite, and faujasite. The 0.8 S/L ratio shows the better properties compared to others by the test of phase analysis, compressive strength morphology analysis, and functional group analysis.

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A Case Study of Coffee Sachets Production Defect Analysis Using Pareto Analysis, P-Control Chart and Ishikawa Diagram

2021-01-01 , Idris N.I. , Sin T.C. , Safwati Ibrahim , FadzliRamli M. , Rosmaini Ahmad

Nowadays, food and beverages companies in Malaysia are struggle to survive with their rival, hence improving quality and increase productivity are vital. This paper propose the method of analysis a coffee sachet production defectives by using statistical process control (SPC) tools and also to identify each types of defects with their root cause. This paper are using methodology of physical observation through examination of automated production flow line, then Ishikawa cause-and-effect diagram are created. The company valid information are obtained from the professional such as production managers, quality control executives and line supervisors, also staffs and operators that direct or indirectly involves the production line activities through interview and distributed feedback form. After that, a Pareto diagram analysis is done hence creating a control chart (p-chart) to illustrate the result analysis. The result shows there are high number of product defectives according to each type and waste production occur. The problem found was underweight, leaking, overweight, empty, unsealed and height out of the standard. The major causes of defectives coffee sachet and root causes of each defect types are specified which are human, machine, work methods, and materials. While the main root cause of underweight and leaking defect are caused by unskilled worker and improper adjustment at the machine each time before running the production.

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Defect Factor Analysis Using Statistical Process Control Analysis: A Case Study in Spices Defected Packaging Production

2021-01-01 , Idris N.I. , Tan Chan Sin , Safwati Ibrahim , Mohammad Fadzli Ramli , Rosmaini Ahmad

The problems faced by food and beverages in Malaysia are still the emergence of defect products in every production and it escaped from quality control checked thus it reaches the consumer. This study aims to analyze the variability of defects in the production line in XX Food Industries Sdn. Bhd., using p-chart control and fishbone diagram. This company produce a food spices products whether it is well within the control or not and looking for the factors that causing to the defect products. Data collection and information obtained from interviews and documentation for the number of products and production defects for three months in XX Food Industries. The methods used to analyze products quality control by using p-chart, one of the statistical process control and fishbone diagram to determine the cause of defects products. The defects that usually occur in the production line are types of packaging defects such as leaking sachets, eyemark on the sachet sealing, and less product fill in the sachet that cause lightweight sachet. Results showed that products quality control in XX Food Industries Sdn. Bhd. is still controlled by the largest type of defects that are leaking with defects percentage 46.3 and with 36.28% percentage of defects caused by eyemark. Then, followed by defect caused by lightweight is 17.5%. Factors causing defects products are human, machine, work methods, and materials. In this case unskilled worker and the material of the plastic wrapping for the spices packet are primary cause of defects products. This study is useful in providing useful information in identifying causes for rejection or defect analysis. This research also helpful in proposing optimal solution to be implemented for productivity and quality improvement.

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Product defect prediction model in food manufacturing production line using multiple regression analysis (MLR)

2021-07-21 , Illa I.N. , Tan Chan Sin , Fadzli R. , Safwati Ibrahim , Rosmaini Ahmad , Mohd Fathullah Ghazli@Ghazali

This paper aims to develop an improved general mathematical model by focusing on human factors variables that related to the product defect in the manufacturing production line. This is because many studies found that almost 40% of total defects resulted from the operator error and the defects are usually not obvious and neglected. The objective to have defect prediction mathematical model to satisfy as early quality indicator of the manufacturing flow production line and assist the quality control team in manufacturing industries. Thus, the human factor variables will be investigate thoroughly and final model can be used to predict product defect on the line to improve product quality. Product defects quantity are identified and analyzed to determine the potential predictors for developing the mathematical model. A case study is offered that illustrates in a spice packaging semi-automated production line the effect that complexity variables have on assembly quality. By using Minitab, Multiple Regression analysis is conducted to model the relationship between the input variables towards response variables. From the analysis, the predicted data showed reasonable correlation with the observed data improved with adjusted R-Sq from 2.6% to 7.9%. Hence, the regression equation obtain is selected to be the prediction mathematical model for defects based on human factor input variables.

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