The drawbacks of the mechanical linear actuator which is applied to punch flexible printed circuit boards(FPCBs), are many components involved, low transmission efficient, and high proportion of energy consumption. In order to design and manufacture a device that can generate a rapid and high quality punching processes, the fundamental rules that can be followed are to use few parts with light weight design, good working piece, energy conserved, and perfect efficient. To improve the kinematic and dynamic characteristics of the existing mechanism, design, manufacture, and assessment are to be taken for developing new linear actuated mechanisms. The first step is to analyze the performance of the existing linkage actuator . The second step is to design a over-head cam mechanism of non-constant rotational speed to substitute the pulley and the rock arm according to the design specifications. The performance of the new type actuated device is superior to the existing mechanism, and this research had preliminary verified the viewpoint of the energy in high speed punching. The achievements of this research also provide references for linear actuator designers and high speed punching producers.

Master of Science / Department of Industrial & Manufacturing Systems Engineering / Todd Easton / This thesis introduces the Bay Crane Scheduling (BCS) problem and related BCS algorithm. The purpose of this algorithm is to optimize the assignment of jobs to overhead cranes as well as the sequence in which each crane performs its assigned jobs. This problem is unique from other Overhead Crane Scheduling (OCS) problems through its increased complexity. Up until now, OCS problems involve a set number of cranes operating in a single common area, referred to as a bay, and are unable to pass over each other. The BCS problem involves a varying number of active cranes operating in multiple bays. Each crane is allowed to move from one bay to the next, through specific locations called bridges. This is crucial to completing certain “special” jobs that require two cranes operating in unison to transport an item. The BCS algorithm employs two continuous time simulations in conjunction with an initial job-assignment algorithm and a Simulated Annealing (SA) improvement heuristic in order to minimize the non-productive crane time, while avoiding overloading any crane. To the extent of the author’s knowledge, this is the first time a continuous time simulation has been used to model an OC system. The BCS algorithm was originally developed for a large manufacturing facility, and when it was tested against the facility’s current scheduling methods, it shows a 20% improvement in the overall active crane time required to complete equivalent set of jobs. This improved efficiency is crucial to the manufacturing facility being able to increase its production rate without the addition of new cranes. In addition, BCS is statistically shown to be superior to the current strategy. The results from BCS are substantial and practitioners are encouraged to utilize BCS’s methodologies to improve other overhead crane systems.

Technology is the answer to most of our human needs but every technology is often accompanied by other challenges which often lead to the evolvement of another technology. One of the technologies that have greatly impacted our world is that of energy development out of which the petro–chemical industry is an important one. The petro–chemical industry remains the main energy hub for our world today through ranges of products coming from its ambit but not without its own challenges too. One of which is the issue of breakdown or shut down which always require maintenance. Shutdown, many a times, may be planned (annual, quarterly, condition–based, time–based, preventive and so on) or unplanned (run–to–failure). In any case, maintenance personnel (mechanical, electrical and instrument) must perform their duties to fix it. In the process of fixing the equipment several factors affect the effectiveness of the personnel. To improve maintenance activities, factors affecting its effectiveness should be addressed. Some of the factors that are already been considered are; Overall Equipment Effectiveness(OEE), Precision maintenance, Maintainability, Computerized Maintenance Management System (CMMS), Work Order management, Equipment, Logistics, Process optimization, Supply chain management, Maintenance strategies, Continuous Improvement Hours and so on. (Taylor, 2000; Siemens.com, 2010) Of those factors, many people hardly think of ergonomics as a factor of reckoning with maintenance activities. Ergonomics is mostly thought of in relation to operators and office workers. According to National Institute for Occupational Safety and Health in U.S.A (2009), ergonomic injuries are the most common cause of workplace illness and injury in the United States. Back injuries and cumulative trauma disorders (CTDs) such as carpal tunnel syndrome, tendinitis, bursitis and epicondylitis form the majority of non–fatal occupational injuries and illnesses, costing employers more than 12 billion dollars per year in lost work time, workers compensation payments and medical expenses. Of the cost implication of ergonomics ailment reported above, how much of it is related to maintenance activities? Is there any relationship between maintenance activities andergonomics? In what direction is the relationship? positive or negative? How much is the impact in either direction? If it is negative, how can we mitigate it? Finally, what are the benefits, if any? These are some of the vital questions this dissertation is set to answer in relation to: physical, somatic, medical, overhead cost, production down–time and personnel morale. To achieve the afore–mentioned, several research instruments were employed which include; case studies, questionnaires, physical observations, interviews, literature reviews, internet resources, journals and other sources (industry experts and professionals). Relevant keywords and concepts were thoroughly researched in the literature review which serves as a base for the dissertation. Two hundred technical personnel (maintenance) serve as the population sample and questionnaires were administered to them. Technical personnel with appreciable number of years of experience occupying managerial positions were also interviewed. The outcomes of all the interviews, observations and questionnaires were analysed and interpreted accordingly to verify how ergonomics impact maintenance. This dissertation based on findings, was able to establish that ergonomics impact the activities of maintenance personnel culminated in proposing an E4M (Ergonomics for Maintenance) assessor. The assessor alongside utilization guidelines and a training matrix will help to effectively mitigate the impact of ergonomics on maintenance activities. There is room for further development of the tool into a computer based package for real–time assessment and mitigation. The assessor and its instruments cannot work alone without the commitment of stake–holders in the industry. That is why recommendations were included for effective application of the tool. The dissertation did not overlook the good works the industry has been doing in the area of creating awareness about repetitive stress injuries among its workforce but only complement its efforts in areas they might not look into. That is in a bid to improve the effectiveness of its workforce which will directly increase productivity, profit and stakeholders confidence. On the other hand, it will reduce their indirect losses through; production down–time, medical cost and over–head costs. However, the application of the E4M assessor is not limited to the petro–chemical industry only but finds its applicability in other industries like; manufacturing, aviation, automobile and any other field where maintenance activities take place particularly in third world countries. / Thesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2011.

Technology is the answer to most of our human needs but every technology is often accompanied by other challenges which often lead to the evolvement of another technology. One of the technologies that have greatly impacted our world is that of energy development out of which the petro–chemical industry is an important one. The petro–chemical industry remains the main energy hub for our world today through ranges of products coming from its ambit but not without its own challenges too. One of which is the issue of breakdown or shut down which always require maintenance. Shutdown, many a times, may be planned (annual, quarterly, condition–based, time–based, preventive and so on) or unplanned (run–to–failure). In any case, maintenance personnel (mechanical, electrical and instrument) must perform their duties to fix it. In the process of fixing the equipment several factors affect the effectiveness of the personnel. To improve maintenance activities, factors affecting its effectiveness should be addressed. Some of the factors that are already been considered are; Overall Equipment Effectiveness(OEE), Precision maintenance, Maintainability, Computerized Maintenance Management System (CMMS), Work Order management, Equipment, Logistics, Process optimization, Supply chain management, Maintenance strategies, Continuous Improvement Hours and so on. (Taylor, 2000; Siemens.com, 2010) Of those factors, many people hardly think of ergonomics as a factor of reckoning with maintenance activities. Ergonomics is mostly thought of in relation to operators and office workers. According to National Institute for Occupational Safety and Health in U.S.A (2009), ergonomic injuries are the most common cause of workplace illness and injury in the United States. Back injuries and cumulative trauma disorders (CTDs) such as carpal tunnel syndrome, tendinitis, bursitis and epicondylitis form the majority of non–fatal occupational injuries and illnesses, costing employers more than 12 billion dollars per year in lost work time, workers compensation payments and medical expenses. Of the cost implication of ergonomics ailment reported above, how much of it is related to maintenance activities? Is there any relationship between maintenance activities andergonomics? In what direction is the relationship? positive or negative? How much is the impact in either direction? If it is negative, how can we mitigate it? Finally, what are the benefits, if any? These are some of the vital questions this dissertation is set to answer in relation to: physical, somatic, medical, overhead cost, production down–time and personnel morale. To achieve the afore–mentioned, several research instruments were employed which include; case studies, questionnaires, physical observations, interviews, literature reviews, internet resources, journals and other sources (industry experts and professionals). Relevant keywords and concepts were thoroughly researched in the literature review which serves as a base for the dissertation. Two hundred technical personnel (maintenance) serve as the population sample and questionnaires were administered to them. Technical personnel with appreciable number of years of experience occupying managerial positions were also interviewed. The outcomes of all the interviews, observations and questionnaires were analysed and interpreted accordingly to verify how ergonomics impact maintenance. This dissertation based on findings, was able to establish that ergonomics impact the activities of maintenance personnel culminated in proposing an E4M (Ergonomics for Maintenance) assessor. The assessor alongside utilization guidelines and a training matrix will help to effectively mitigate the impact of ergonomics on maintenance activities. There is room for further development of the tool into a computer based package for real–time assessment and mitigation. The assessor and its instruments cannot work alone without the commitment of stake–holders in the industry. That is why recommendations were included for effective application of the tool. The dissertation did not overlook the good works the industry has been doing in the area of creating awareness about repetitive stress injuries among its workforce but only complement its efforts in areas they might not look into. That is in a bid to improve the effectiveness of its workforce which will directly increase productivity, profit and stakeholders confidence. On the other hand, it will reduce their indirect losses through; production down–time, medical cost and over–head costs. However, the application of the E4M assessor is not limited to the petro–chemical industry only but finds its applicability in other industries like; manufacturing, aviation, automobile and any other field where maintenance activities take place particularly in third world countries. / Thesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2011.

Many older bridges and tunnels were constructed using standards by now many decades out-of-date, at a time when trucks and other large vehicles were smaller. A bridge or tunnel strike is an incidence in which a vehicle, typically a lorry (truck) or double-decker bus, tries to pass under a bridge or tunnel that is lower than its height, subsequently colliding with the structure. These strikes lead to an increased cost of bridge repairs, clogged up roadways and increased potential for catastrophic events: hazardous spillage and/or total collapse. Today, Network Rail reports on average a strike every 4.5 hours. There are a number of reasons why strikes occur, and why drivers of heavy goods vehicles sometimes fail to recognise the warning signs, consequently striking the bridge or tunnel. At first glance, it may seem like the problem is a fairly easy one to solve; however, no matter how well planned the road system, human error is an ever-present risk. The research proposes to address the problem of bridge and tunnel strike prevention and management. The intent of the research is to develop an affordable, reliable and robust early warning over-height detection system bridge-owners can implement at locations with high strike occurrences. The research aims to test and validate a novel vision-based system using a single camera to accurately detect over-height vehicles using a set of optimised parameters. The system uses a camera installed at the offending height, which acts as an “over-height plane” formed by the averages of the maximum allowable heights across all lanes in a given traffic direction. Any vehicle exceeding this plane is analysed within a region of interest using a trigger-based approach for accurate detection and driver warning. If the vehicle is deemed to be over-height, a warning is issued to the driver. As a result, prolonging life expectancy of structures while decreasing the cost of repairs, maintenance and inspections.