Browsing by Author "Taifa, Ismail W.R."
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Item Critical analysis of material consumption and cost reduction techniques for the apparel cutting processes(CONAS, University of Dar es Salaam, 2021-12-01) Taifa, Ismail W.R.; Twaha, Ibrahim; Mwakibambo, Mboka ARevenues generation in the garment industry is synonymous with material consumption. This study thus analysed material consumption and cost reduction techniques in the Tanzanian garment industry. The research employed quantitative (experimentation) and qualitative approaches (document review and observation technique) in the apparel cutting processes. Experimental results of material consumption from ten tests averaged efficiency of 78.67%, the wasted pieces (19.2%), and unnoticed waste (2.03%). Essential considerations to reduce material waste include: digitalising the fabric cutting processes; providing workers training; deploying appropriate practices in the cutting room (e.g. pattern engineering and pattern accuracy); considering the quality of the procured fabric and fabric efficiencies relative to different human body shapes and proportions; and considering the separation process rather than extending facings, splitting substantial components, slight reductions in a flare, and seam displacements. The study implies that apparel enterprises can benchmark their actual material consumption circa 50-70% of their total garment manufacturing costs.Item Deployment of the Taguchi technique for surface roughness optimisation(Inderscience, 2021-09-10) Deshpande, Vivek; Taifa, Ismail W.R.; Deresse, Nesredin ChekoleThe aim is to investigate the machining parameters that are important to optimise surface roughness (Ra) through experimentation for EN45 steel material (AISI 9260). Optimisation of the machining parameters for a cylindrical grinding operation helps to save time, cost, and influence to get better surface characteristics and surface finish. The study deployed the Taguchi technique. The scrutinised factors included the feed rate, work speed and the depth of cut (DOC). Experimental set up involved the L9 orthogonal array. Minitab® and Microsoft® Excel 2016 generated results after applying the design of experiment. The Ra was tested by using a portable surface roughness tester. The silicon carbide wheel and a hydraulic cylindrical grinder machine were used. After analysing the generated results, DOC was found to be statistically significant. The influential parameter of Ra was found to be DOC as it contributed to 45.3% and 58.6% before and after heat treatment processes, respectively.Item The development of an ergonomically designed product through an integrated product team approach(Taylor & Francis, 2021) Taifa, Ismail W.R.; Desai, Darshak A; Bulsara, Niravkumar MukeshPurpose. This article discusses the process of developing an ergonomic desk for students through an integrated product team approach. Methodology. Using an integrated product team approach, numerous quality tools, customization techniques, strategic tools and techniques including quality function deployment, ergonomic principles, Kano model, SCAMPER (substitute, combine, adapt, modify, put, eliminate, reverse), brainstorming, Pareto’s principle and cause-and-effect diagrams were systematically applied. In addition, for detailed designs, anthropometric measurements were considered. Results. Having identified various health problems associated with use of unergonomic furniture by students, this study developed an ergonomic desk using SolidWorks version 2016. The ergonomic student desk considered the design for adjustability principle which accommodates 90% of all students (5th percentile female to 95th percentile male). Conclusions. Data obtained from three colleges were systematically verified, validated and evaluated and a design for an ergonomic student desk was the result. Adoption of these systematic processes gives the design practical validity, and once the ergonomic student desk has completed the manufacturing process its use is expected to lead to a reduction in the incidence of musculoskeletal disorders, neck problems, back pain and pressure on the hips. Ultimately, students having acquired a desk designed to fit their requirements will achieve comfort and satisfaction.Item Enabling manufacturer selection and an equitable order allocation amongst textiles and apparel manufacturers(Inderscience, 2021) Taifa, Ismail W.R.; Hayes, George S; Stalker, Ian DuncanSmall and medium-sized textile enterprises (SMTEs) contribute to the UK economy. Anecdotal evidence indicates that many SMTEs fail to secure enough orders from British retailers. So, this paper reports on the methodological decision analysis model and the qualitative linear weighted point method (LWPM) to develop the pertinent critical success decision criteria and virtually distribute the bulk orders equitably. The relevant decision criteria are stated for the SMTEs. The criteria are crucial as they were consolidated from the textiles and apparel manufacturers only, contrary to other several studies that established generic decision criteria. The criteria consist of corporate social responsibility, economic and environmental factors. The results indicate the opportunity to execute order quantities equitably after having ranked the collaborating SMTEs. LWPM assisted to rank SMTEs in selecting the right manufacturers. Since the criteria are from the SMTEs only; the generalisability of the results to other industries may need further research.Item Production quality improvement for the soft drinks bottling industry through six sigma methodology(2022-01-28) Taifa, Ismail W.R.; Makundi, Ebenezer D; Mwaluko, George SIncrease of rejection rate (percentage) in the production process of soft drinks is one of the chronic problems in the soft drinks industry. Over four months, the production rejection rate (PRR) increased up to 12.62%. This resulted in an estimated loss of 93,412,800 Tanzanian Shilling (TZS) at X-Company. Therefore, this study explored how to improve the quality of production in the manufacturing process of the Tanzanian soft drinks industry. The Six Sigma methodology - define-measure-analyse-improve-control (DMAIC) - was employed. DMAIC considers existing products, process and improves the same. An in-depth insight into PRR and speed of acquiring such insight while increasing the problem diversification was successfully performed. Still, soft drinks companies face high PRR. The critical reasons occur during bottle filling and crowning operations. The sigma level was found to be 4.9 with the cost of poor quality being 12.62%. This study achieved a potential annual saving of 280,238,400 TZS.Item Quality 4.0 conceptualisation: an emerging quality management concept for manufacturing industries(Emerald, 2023-01-26) Maganga, Deusdedith Pastory; Taifa, Ismail W.R.Purpose Quality 4.0 refers to a modern quality management approach that uses Industry 4.0 technologies, integration and digitalisation. This research explores the current understandings of Quality 4.0 in various publications. The focus is on Quality 4.0 concepts or explanations, available models, motivation and readiness factors for adoption, enablers and technologies that can be leveraged. Design/methodology/approach A qualitative approach was deployed to collect the findings. This paper employs bibliometric, scientometric and visual analytic tools to identify and analyse articles from Scopus, Web of Science (WOS), Google Scholar databases and other sources such as ScienceDirect and Taylor and Francis. Findings The bibliometric results revealed that Quality 4.0 publications began in 2016 and increased dramatically in 2020 and 2021, with India leading the way while scientometric analysis found no clear definition of Quality 4.0 hitherto. However, several authors have defined the concept of Quality 4.0, arguing that it is characterised by digitalisation and integration, Industry 4.0 technologies applications and big data management. Some of the Quality 4.0 models published in the theoretical underpinnings include total quality management (TQM) in the basis of Industry 4.0 model, the European Foundation for quality management model, Quality 4.0 model combining operational technology (OT) and information technology (IT) through digital transformation and the LSN Research eleven axes of Quality 4.0 model. The research highlights key enablers of Quality 4.0 adoption, such as enabling technologies, big data capability, skilled and competent workers, collaboration and leadership support. Research limitations/implications The findings can benefit Quality 4.0 researchers and practitioners on the available Quality 4.0 models, motivation and readiness factors for Quality 4.0 adoption, enablers and leveraged technologies in Quality 4.0. Originality/value This study attempted to explore the current understandings of Quality 4.0 concepts to sediment these emerging quality management concepts for manufacturing industries.Item Quality 4.0 transition framework for Tanzanian manufacturing industries(2022-05-31) Taifa, Ismail W.R.; Maganga, Deusdedith PastoryPurpose This research aimed at developing the Quality 4.0 transition framework for Tanzanian manufacturing industries. Design/methodology/approach The survey method was used in this study to gather practitioners' perspectives. The approach included open-ended and closed-ended structured questionnaires to assess respondents' perceptions of Quality 4.0 awareness and manufacturers' readiness to transit to Quality 4.0. The study's objective was to adopt non-probability and purposive sampling strategies. The study focused on fifteen Tanzanian manufacturing industries. The data were analysed qualitatively and quantitatively using MAXQADA 2020 and Minitab 20 software packages, respectively. Findings The study demonstrated a high level of awareness of Quality 4.0 among Tanzanian manufacturing industries (i.e. 100% in Quality 4.0 traditional attributes and 53% in Quality 4.0 modern attributes). Individuals acquire knowledge in various ways, including through quality training, work experience, self-reading and Internet surfing. The result also revealed that most manufacturing industries in Tanzania use Quality 3.0 or a lower approach to manage quality. However, Tanzanian manufacturing industries are ready to embrace Quality 4.0 since practitioners are aware of the concepts and could see benefits such as customer satisfaction, product improvement, process and continuous improvement, waste reduction and decision support when using the Quality 4.0 approach. The challenges hindering Quality 4.0 adoption in Tanzania include reliable electricity, high-speed Internet and infrastructure inadequacy to support the adoption, skilled workforces familiar with Quality 4.0-enabled technologies and a financial set-up to support technology investment. Moreover, the study developed a transition framework for an organisation to transition from traditional quality approaches such as quality control, quality assurance and total quality management to Quality 4.0, a modern quality approach aligned with the fourth industrial revolution era. Research limitations/implications The current study solely looked at manufacturing industries, leaving other medical, service, mining and construction sectors. Furthermore, no focus was laid on the study's Quality 4.0 implementation frameworks. Originality/value This is probably the first Quality 4.0 transition framework for Tanzanian manufacturing industries, perhaps with other developing countries.Item A student-centred design approach for reducing musculoskeletal disorders in India through Six Sigma methodology with ergonomics concatenation’(Elsevier, 2022-03) Taifa, Ismail W.R.Classroom-related musculoskeletal disorders (CMSDs) rates in low- and middle-income countries (LMICs) are increasing despite the ever-collective interest in occupational health and safety (OHS) and succeeding developments over time. To explore the problem (i.e., OHS) with its proposed solutions, this study integrated the Six Sigma methodology with ergonomics principles to eliminate the CMSDs. Participants were 478 students from India as a country amongst the LMICs. The age range, mean, and standard deviation were 17–37, 20.28, and 2.348 for male students and 17–26, 19.57, and 2.163 for female students, respectively (units in years). The study found that students are prone to high risks of getting CMSDs due to prolonged usage of poorly designed furniture. The CMSDs results are as follows: fatigue joint and muscle pain (71%), shoulder and neck tension (70%), headache (63%), neck pain (53%), back pain (51%), legs’ joints pain (46%), shoulders and muscles pain (42%), elbow pain (42%), sleeplessness (insomnia) (40%) and hand pain (39%). The proposed solutions include the two ergonomically designed students’ desks; students’ requirements and anthropometric measurements consideration; occupational health and safety workshops and/or seminars preparation; administration interventions; behavioural (personal) interventions, and other engineering interventions.Item Sustainable industrialisation for luxury products: Manufacturers and retailers must commit to tackling modern slavery in Africa(Springer, 2021-07-26) Taifa, Ismail W.R.Globally, there is high pressure concerning sustainability. This requires designers, manufacturers, distributors, and consumers to have obligations of looking at sustainability tenets: social (people), economic (profit) and environment (planet). Researchers have been exploring economic and environmental issues in several sectors. It is the sustainability age where people must now look at contemporary issues in the manufacturing (production) processes of luxury goods. One of the critical problems in today’s supply chain of industrial luxury products is modern slavery issues (MSIs) (or neo-slavery or contemporary slavery). MSIs mostly refer to slavery that continues to occur in private individuals, groups, institutions, organisations, companies, on engaging child labour, human trafficking, forced labour, long working hours, among other forms, in manufacturing products. This study focuses on Africa regarding manufacturing and retailing of luxury products. Africa is focused because the 2018 Global Slavery Index ranked Africa number one concerning MSIs; several African countries produce precious (valuable) metals; and, many African societies cannot notice much about how critical the MSIs are. The production processes and other sustainability issues were thus explored. The findings suggest the need for Africa to strengthen consolidative interventions to fight the diverse environment that results in MSIs.