Muhammad Iqbal Muhammad Hussain
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Preferred name
Muhammad Iqbal Muhammad Hussain
Official Name
Muhammad Iqbal, Muhammad Hussain
Alternative Name
Hussain, Muhammad Iqbal
Hussain, M. Iqbal
Hussain, Muhammad I.
Hussain, Muhammad Iqbal Muhammad
Hussain, M. I.
Main Affiliation
Scopus Author ID
57219333387
Researcher ID
AAH-8315-2019

Research Output
Now showing 1 - 5 of 5
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A Monte Carlo simulation for a variable-value stream mapping (V-VSM) and risk assessment - failure mode and effect analysis (RA-FMEA); a case study

2023 , Mohd Shihabudin Ismail , Mohamad Shaiful Ashrul Ishak , Muhammad Iqbal Muhammad Hussain

Value Stream Mapping (VSM) is one of the most used lean manufacturing methods for determining cycle time (CT) and lead time (LT) in the process flow from customer order to shipment. Value-added (VAA) and non-value added (NVAA) events in the flow must be defined and noted in the VSM. However, there are only a few studies that take risk management into account when calculating lead times. Variable VSM (V-VSM) will be used in this report, with (minimum, most-likely(mean), maximum) values for each CT/LT and Risk Assessment-Failure Mode and Effect Analysis (RA-FMEA) for all risks reported. For a more accurate result, the model will be simulated using Monte Carlo simulation with@Risk software. Prior to the simulation, each process must be described by the best-fit probability distribution. The (minimum, most-likely(mean), maximum) time values of total CT/LT and Risk that the management should consider when preparing the raw material order, VAA/NVAA activities in the production line, Work in Progress (WIP), process layout and shipment schedule are the results of this analysis. For management, the current and future VSMs could be finalized, displaying all relevant variables. This model will be tested in a small and medium food manufacturing facility that produces mixed powder drinks. However, the emphasis of this paper will be on the Monte Carlo simulation using@Risk software based on V-VSM and RA-FMEA model created.

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Development of low-cost, high-efficiency powder transfer system for food industry

2023 , Mohd Shihabudin Ismail , Mohamad Shaiful Ashrul Ishak , Muhammad Iqbal Muhammad Hussain , C. W. Chai

Powder Transfer System (PTS) has been widely used in various industries to transport powder from one workstation to another. It speeds up the loading process while decreasing operator fatigue and manual handling. Majority of food industry in Small and Medium Enterprise (SME), Perlis, is still using the manual handling methods to transfer the powder from mixer to filling funnel station which requires higher needs of manpower. Hence, PTS is introduced to overcome the problems in the industry with the aim of development of low cost (affordable by SME industries) yet high efficiency system. Development of this system started from selecting the most suitable transfer system for food grade powder with the consideration of the working principle and safety for food and environment. Pneumatic Vacuum Conveying System (PVCS) is selected as the most suitable system in this project through the system selection process. This project also includes the system design which involves the designation of system function and design based on requirements by using the functional decomposition and engineering CAD drawing software—SolidWorks, material selections for the system components which suitable for food grade conditions, and cost estimation. Lastly, validation of the system design structure stability, transfer rate analysis, and development of the prototype are carried out at company M, one of the SME companies in Perlis, Malaysia.

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Simulation of a propose new model that integrate variable value stream mapping with a risk assessment tool

2023 , Mohd Shihabudin Ismail , Mohamad Shaiful Ashrul Ishak , Muhammad Iqbal Muhammad Hussain , Amir Yazid Bin Ali

There are limited studies being done that include risk assessment when calculating lead time in manufacturing process. This study proposes a model that integrates Variable VSM (V-VSM) with Risk Assessment- Failure Mode and Effect Analysis (RA-FMEA). Each process needs to define the best fit probability distribution. Value Stream Mapping (VSM) was used in determining total throughput time, cycle time (CT) and lead time (LT). Information on Value added activities (VAA) and Non-value-added activities (NVAA) within the process need to be identified and mentioned prior to VSM analysis. Monte Carlo simulation with @Risk software was then used for the model. The simulated result produces values for (minimum, most-likely(mean), maximum) time values of total CT/LT and risk value for management to deploy in planning raw material order, VAA/ NVAA, Work in Progress (WIP), process layout and shipment schedule. Validation of this proposed model was done using a real case study involving a small /medium scale manufacturer producing several mixes of powdered drink. This paper will focus on the modelling of V-VSM and RA-FMEA for Monte Carlo simulation using @ Risk software.

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Development of a framework for the reduction of manufacturing defects in a composite material process

2008 , Muhammad Iqbal Muhammad Hussain

Reduction of defects is a critical issue in manufacturing operations. It goes without saying that defect reduction leads to manufacturing cost reduction, and this translates to increased profitability for the organization. Company A is a manufacturer of high technology composite materials. Of late, it has been experiencing high levels of defects from its manual hand lay-up and autoclave processes that generate products coded ‘L’and ‘T’in this thesis. Thus, a study that integrates the use of ‘statistical design of experiments’(SDE), ‘failure mode and effect analysis’(FMEA), several side experiments, control charts, and certain process controls is carried out. The study combines time-tested industrial problem-solving and process-improvement methods in a way that is both regimented as well as flexible, in line with the numerous uncertainties that inevitably present themselves in any live manufacturing environment. This culminates to the development of a generic framework, of which its execution enables the determination of the best process set-up that gives the minimum number of defects in the final product. Taking into account the circumstances under which the processes operate, fractional factorial design (2^ (4-1) resolution IV design) is used in production line ‘L’, and , a two-level factorial blocked design with 24 runs and eight center points is used in production line ‘T’. These designs give much insight into this line’s defect-causing variables, and enables the examination of important process parameters such as geometry of core, temperature, pressure, and cooling rates, to name a few. Consequently, after the entire research process is carried out, it is seen that the number of defects is greatly reduced (from 30 panels/month to 3 panels/month for wrinkles, 18 panels/ month to 4 panels/month for delamination in production line ‘L’, and from 25 © This item is protected by original copyright xxviii panels/month to 5 panels/month for delamination in production line ‘T’), leading to tremendous cost savings on the shop floor.

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Development of variable-line balancing chart by risk assessment using Monte Carlo simulation

2023 , Mohd Shihabudin Ismail , Mohamad Shaiful Ashrul Ishak , Nor Zaiazmin Yahaya , Muhammad Iqbal Muhammad Hussain , Mohd Adzrie Radzali

Line Balancing Chart is one of the most used lean tools for determining cycle time (CT) and lead time (LT) in the production line processes flow, from raw material input until finished product output. However, for traditional Line Balancing Chart, only the average (mean) CT and LT are considered which causing inconsistent performance of the actual production line throughput rate (productivity). In this study, Variable-Line Balancing Chart (V-LBC) is introduced by considering the dynamic CT and LT in a form of (Minimum, Most Likely (mean), Maximum) for each process involved in the production line. The risk assessment for Value-added (VAA) and non-value added (NVAA) events in the flow are also considered for this V-LBC. A Monte Carlo simulation by using @Risk software is utilized to simulate each process CT distribution capability. As a result, each process in the V-LBC could be represented in horizontal and vertical time variables that involve a variable CT (VAA and NVAA) and risk assessment using Risk Assessment-Failure Mode and Effect Analysis (RA-FMEA) approach. The actual root cause led to the process variation also could be identified more accurately from the V-LBC. Hence the correct action could be taken in order to reduce the variation which indirectly increase the production line productivity.

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