Faculty Of Engineering Graduation Project 2022- 2023

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    Improving the Productivity in an Animal Feed Production Factory
    (October University for Modern Science & Arts Faculty of Engineering, 2023) Magdi Hassan Al-Blbisi, Khalid; Ahmed Abdelkhalek, Seifeldin
    In the name of Allah, the Most Gracious and the Most Merciful, all praise to Allah for his strength and blessing in completing this project. This journey would not have been possible without the support of our families. To our families, thank you for encouraging us in all our pursuits and inspiring us through the whole journey. Dr. Nahed Sobhi and Dr. Sameh Ahmed, our project supervisors, deserve our sincere gratitude for their guidance and constant supervision; as well as for providing us with necessary information about this project. In addition, we would like to acknowledge Dr. Mohamed Hassan, who provided us with the insight and resources that enabled us to complete this project. It is our pleasure to acknowledge the efforts that have been made during this project by Eng. Ayman Shady the plant & operation manager of Aller Aqua Egypt, Eng. Said Mansour the production manager, and Mr. Mohammed Azzaz and Mss. Rehab Ali from the Human Resource Department
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    Improving Productivity in a Personal Care Company
    (October University for Modern Science & Arts Faculty of Engineering, 2023) Khaled Saeed, Ahmed; Mohamed Diab, Abdelaziz
    Scitra Contract Manufacturing factory is specialized in personal and home care in UAE since 1950’s. The Egyptian branch is in the industrial zone in 6th of October, since 2016. In addition, the factory has quickly earned the reputation as one of the highest quality manufacturers, it helps the other companies in increasing their productivity. Scitra is specialized in personal care and home care products like Nivea, Rexona, Tide and vanish. The project focuses on reducing problems affecting the productivity of Nivea production line in the factory. After investigating the production line, it was found that the packaging line is facing some problems. First, there is a high safety risk in the shrink wrap machine which cause a lot of rework products. Second, the shrink wrap machine has the longest cycle time 6.5 seconds per unit and this project is aiming to decrease it to 5 seconds. The aim of this project is increasing the productivity by reducing cycle time of the shrink wrap machine and reduce the safety risk of workers. This can be achieved by using industrial engineering techniques such as lean and value stream mapping, safety risk assessment. this reduction in time will lead to an improvement in productivity by 25%.
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    Improving Productivity in Chicken Bouillon Production Lines Using Lean Manufacturing Techniques
    (October University for Modern Science & Arts Faculty of Engineering, 2023) Mohamed, Adham; Sameh Sobhy, Hosam
    Nestlé is a multinational food and beverages corporation, originated from Switzerland. Nestlé has around 450 factories, operates in 189 countries, and employs around 339,000 people. Nestlé has multiple factories in Egypt, located in different governorates. This project focuses on the Maggi production line in Nestlé’s Dry Goods Factory which is in 6th of October Industrial zone, Giza, Egypt. Maggi is a culinary brand specialized in Chicken Bouillon, Soups and Seasoning. After observing the Maggi Soft bouillon production lines, several problems were noticed. The most prominent problems were the over filling of the cubes done by the workers and the jamming occurring at the nozzle, which is a source of unplanned stoppages. The lead time between the mixes’ production time and packaging time was also a contributing factor as the mix temperature cools down and cause stoppages in the machine. This project aims at improving the productivity of the production line, by applying the techniques learnt in Lean manufacturing, mainly the DMAIC approach and the fishbone technique to eliminate the major cause of unplanned stoppages; in addition, a new handover system will also be implemented to reduce the lead time between the production of the mixes and the time they are received on the packaging production lines which causes time waste and changes in the specifications of the mix. Furthermore, there was a significant improvement in productivity, increasing from 86.88% achievement of the planned production quantity to 98.32% in a period of 10 weeks of implementation. Results proved that the product machinability stoppage time was reduced by 94.5%, while the overfilling was reduced by 86.3% and the subsequent revenue lost reduced by approximately 85%. The waiting time between trollies was also reduced by 17 minutes, which meant the temperature of the mix no longer cooled down and cause changes in the specifications of the mix.
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    Improving the Productivity in a Clothes Manufacturing Factory
    (October University for Modern Science & Arts Faculty of Engineering, 2023) Gamal Ebrahim Haridy, Eissa; Sameh Thabit, Thabit
    GM group includes two factories specialized in clothes manufacturing. The two factories are located in the first industrial zone of Obour City, Egypt. The first factory was established in 1980, specialized in the manufacturing of clothes for adults and named as GM home wear. In 2005, a new branch was established which specialized in the manufacturing of kid’s clothes, named GM kids. After investigating the production line in one of the clothes factories, it was observed that there are a lot of defective products which requires rework due to imbalance in production line and it accounts for 10 percent of the total daily production and the daily production rate ranges from 60 to 70 percent. The imbalance in production line resulted from the wrong distribution of worker’s efficiency and lack of complete knowledge of the state of the machine in the production line. In addition to the existence of a problem in the machine maintenance system. There is also a problem with the productivity measurement system. The project aims to improve the productivity by reducing defective products to 1 percent, improve the daily productivity to be at least 95 percent ,and balancing the production line using industrial engineering techniques such as work analysis, quality control and preventive maintenance. This reduction in defective products and the balance in production line between workers efficiencies and the state of machine will lead to improvement in productivity and quality level
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    Design and Manufacturing of an Automated Bottle Filling & Capping Machine Prototype
    (October University for Modern Science & Arts Faculty of Engineering, 2023) SamyTahoun, Omar
    The Automation of business operations is no longer simply a luxury for larger companies; it is quickly becoming a vital requirement for companies of all sizes to ensure their sustained success. Automation is a method that entails carrying out a process using pre-programmed orders and automatic feedback control to verify that the instructions are carried out correctly. Manufacturing automation is regarded as a critical technology for increasing the quality and quantity of manufactured goods. Moreover, the rapid, reliable, and precise production flow helps to decrease production times, manufacturing costs, and labor costs, as well as human errors, maintaining consistency and quality of product. Although the similar production lines are imported from abroad, which leads to a rise in their prices in the market, but this project is trying to break the rule and provide a locally made product at the lowest possible cost. The aim of this project is to design and Manufacture an Automated Water Bottle Filling & Capping Machine Prototype. Empty bottles are pushed towards the filling head by a conveyor that runs the length of the assembly. The filling head is in charge of filling bottles with water; after that, the conveyor pushes the bottle through a circulating disc, which transports it to the capping station, where a cap is placed on the bottle, and then to the cap turning station, which is a motorized arrangement in charge of spinning and tightening the cap on bottles. The conveyor then pushes the bottle to the next step, where it is rolled down the system as a completed product
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    Design and Manufacturing of a Laser Engraving Machine
    (October University for Modern Science & Arts Faculty of Engineering, 2023) Mohsen Tawfiek, Ahmed
    In laser engraving, the laser beam burns the top layer of the surface to be engraved. The burned region stands out from the surrounding surface because it is uncolored. When engraving with a laser, the laser beam must penetrate the surface. This could be accomplished by focusing the beam on a specific location for an extended period. Gather the information required to learn more about this subject in depth, depending on the cutting material's strength. A working model of a laser engraving machine will be created as part of the project. This equipment is very useful in our division because it functions as a sort of rapid prototyping device. It may engrave thermoplastic sheets and paper to create the desired shape. It may engrave thermoplastic sheets and paper designs patterns to create the desired shape. We have gathered information on laser laser, and what engraving is up to this point. Laser engraving differs from laser cutting in that it uses a very low intensity, whereas laser cutting uses laser torches. We were given a quick overview of the laser, including how it works, what characteristics it has, how to produce it, and how to control its intensity. The machine is built with a 200mW red laser. It may be incapable of cutting through wood. The software "Solid Work" is used to run simulation analyses on each component of the machine. It was useful if necessary.