Faculty Of Engineering Graduation Project 2023 - 2024

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    Design and Manufacturing 3D Printing Machine
    (MSA University Copy Right 2023, 2024) Hamdy, Abdellah
    Designers used 3D printers to quickly create product models and prototypes, also final products and parts can be produced. It easily allows for changes without requiring extra tools or equipment in comparison to other methods There are several types of 3D printing machines. In this project, Fused Deposition Modelling (FDM) where chosen for its cost effective and serves multi-purpose. This project will explain about how to manufacture and improve this type of FDM by fully control using an application through WIFI and monitoring the process by a camera. Also, a sensor was added to adjust the heat bed automatically. The "Solid Work" software is used in the design of 3D printing machine
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    Reducing Cycle Time in Nivea Deodorant Production Line
    (October university for modern sciences and arts, 2024) Ayman Saleh, Karim; Adly Hamed, Nermeen
    Scitra Contract Production factory has been specializing in personal and home care in UAE since 1976. Since 2016, the Egyptian branch has been located in the industrial zone in 6th October City. Furthermore, the plant has swiftly gained a reputation as one of the finest quality producers, which assists other companies in raising their productivity. Scitra specializes in personal care and home care products from firms such as Nivea, Rexona, Tide, Dove and Vanish. After investigating the whole production process of Nivea Deodorant product, it was found out that the washing process of the mixers used to take four and a half hours to be washed, rinsed and sterilized. Furthermore, the pre-weighing process takes around two hours to prepare and weigh all the needed materials to be mixed. Additionally, the changeover time is a considerable delay resulting in a full stoppage for the whole production line for five hours long to change from a size to another. Finally, there is a frequent stoppage occurred in Nivea Deodorant production line because of lack of knowledge of the workers in operating the Cap Screwing machine. The project aims to reduce the time waste of the aforementioned problems which will reduce the cycle time of Nivea Deodorant production process, and the results obtained demonstrated a 15% reduction in cycle time. This is achieved by using industrial engineering techniques such as Operation Analysis, DMAIC, 5S, Value Stream Mapping (VSM), Correlation and Regression Analysis, and Single Minute Exchange of Dies (SMED).
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    Waste Reduction in a Cooker’s Glass Processing Factory
    (October university for modern sciences and arts, 2024) Magdy Mohammed Hassan, Mohammed
    Union air Cooker’s Glass Processing Factory is specialized in manufacturing of different glass products such as cookers, ovens, televisions, heaters, fridges, and deep freezers glass faces. It is a part of Union air Group, which has been operational since 1995, and is recognized for its innovative and high-quality products such as air conditioners, washing machines, refrigerators, and cookers. The glass factory is located in Industrial zone, 6th of October, Giza, Egypt, the factory was established in 2017. The factory produces annually 768,000 square meters of glass products. The aim of this project is to identify the wasted glass material in all glass processing stations and analyze this data to propose suitable solution in order to minimize waste and improve productivity in the factory. The initial status of the factory is that it is highly inefficient and suffering huge losses that have not been reliably quantified prior to this project. This project focuses on implementing lean production techniques such as 5S, standard operation, maintenance routine checklist, employee training, and quality control to reduce the wasted material. The achieved result showed that the glass waste is reduced from 30% to 15%, with total saving per year of approximately 9 Million LE.
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    Waste Reduction in a Corrugated Cardboard Factory
    (October university for modern sciences and arts MSA, 2024) Mohsen, Saif Tarek
    Universal Unipack has two branches specialized in packaging industry. It manufactures corrugated cardboard and prints on it. It was established in 1981, at the second industrial zone at 10th of Ramadan city-Egypt, the other branch is located in the Sadat city. After investigating the corrugated cardboard production line, it was found that there are two main problems in the factory. First, there are a lot of scrap that comes out from the production line, the average for production in a month is 2495.2 tons which has 290 tons waste from the production process which is about 12%. Secondly, the layers of cardboard peel off easily because of bad starch that they use to glue the layers with each other. This project aims to reduce waste in a corrugated cardboard factory from 290 (tons per month), which will reduce the material waste by almost 14 % and save them 920,000 L.E by using lean six sigma and 5s methodology. The achieved results will be increase the productivity of the corrugated cardboard by reducing the waste in the production line.
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    Waste Reduction in a Herbal and Tea Bags Factory
    (October university for modern sciences and arts MSA, 2024) Mohamed, Alaaeldin Ali; Abdulhakim, Mahmoud Ahmed
    The Royal Herbs Company is an Egyptian organization specialized in producing and exporting high-quality herbal products such as Mint, Anise and, green tea. There are 3 sizes of herbal bags packaging (25, 50 and 100) Pcs. The company was established in 1985, located in Shabramant - Giza Egypt. After investigating the herbal bags production line, observed a number of wastes. First, changeover time from one size to another is 8 hours for one machine. Second, there is 3.2% scrap out of 1 ton of daily production caused by cotton thread. Third, the waiting time of changing empty rolls with a new one takes around 407 sec. Fourth, the herbal and spices packaging machine breakdowns because of lack of lubrication on average three times a day. Fifth, there is an overproduction about 300 ton of Finished goods. The project aims to reduce production waste by implementing lean concepts in the production line Such as 5S, and pull system in the production line. The obtained results showed that changeover time from one size to another is reduced around 74%, by redesigning the machine. The overproduction was controlled, and the inventory was reduced by 40% by using pull system technique. The breakdown time is reduced from 163 min to 53 min by using preventive maintenance. The waiting time is reduced from 407 sec to 30 sec by using 5S methodology.