kaka shuaib - Academia.edu (original) (raw)
Papers by kaka shuaib
Journal of Applied Engineering Science
All over the world six sigma is being adopted as a quality improvement approach towards zero defe... more All over the world six sigma is being adopted as a quality improvement approach towards zero defects. Unfortunately, the adoption of six sigma methodology in manufacturing companies is very rare in developing countries due to various challenges. This study demonstrates the practical use of the six sigma Define, Measure, Analyze, Improve and Control (DMAIC) cycle by conducting a case study at a manufacturing company in Pakistan. The potential problem was the external leakage defect in the refrigerator during its production stage. The objective of this study was to improve the process by adopting six sigma DMAIC approach to identify and eliminate the root causes that produce defects in the final product. Project charter, Pie chart, Bar chart of faults, Suppliers Input Process Output (SIPOC), Voice of Customer (VOC) and flow process map were used to define the problem, its scope and process routing. Pareto chart was used to identify sub defects and sigma level was calculated for the ex...
This study examines the different risk assessment methods used in the oil and gas industry, recog... more This study examines the different risk assessment methods used in the oil and gas industry, recognizing that these approaches must be specific to effectively address complex challenges. The research encompasses qualitative, quantitative, and semi-quantitative techniques that reflect differing scopes and limitations. Key issues such as data uncertainties, dynamic risks, and interconnected systems are explored with emphasis on understanding their unique difficulties. The combined results of this analysis provide valuable guidance for those involved in the industry including policymakers. It outlines effective strategies for managing risks while promoting sustainability within energy operations by proposing innovative solutions like incorporating emerging technologies into risk management processes or enhancing existing data practices. In conclusion embracing forward-looking methodologies will enable professionals to better manage future threats which can lead towards safer more responsible energy exploration globally across industries despite adversity making it essential for everyone involved.
Risk analysis is playing a critical role for industries to evaluate and observe the incident/acci... more Risk analysis is playing a critical role for industries to evaluate and observe the incident/accidents. In today's competitive world industries are focusing on the best solution to evaluate the risk which may leads industry to loss their reputation. This research investigates the application of Mamdani and Sugeno Fuzzy Inference methodologies, incorporating various membership functions, for risk assessment within the oil and gas industry's case studies. The study emphasizes the economic significance of this sector, recognizing its essential role in supporting transportation, manufacturing, and energy sectors, while also addressing potential threats from hazardous facilities. Through a comprehensive Fuzzy Logic-based risk assessment model, with a focus on Mamdani and Sugeno interface systems, the research explores the qualitative and quantitative aspects of risk evaluation. The results indicate the consistent superiority of the Fuzzy Mamdani approach in terms of accuracy and efficiency over the Sugeno method. The model, comprising Likelihood and Consequence input variables and a Total Risk output variable, is evaluated through both qualitative and quantitative analyses. Whereas, the outcomes are based on different membership functions and showcases three case studies, each considering four key factors.
Nowadays to meet the production demand in textile industry, setup time reduction is a big challen... more Nowadays to meet the production demand in textile industry, setup time reduction is a big challenge for the companies. Moreover, product customization has been increasing which negatively affects the setup time. Thus, there is need of an effective technique which can reduce the setup time. Therefore, Single Minute Exchange of Die (SMED) has been proposed in this study, it allows to optimize the changeover activity. Moreover it helps these industries to have maximum production flow. To show the practical applicability of SMED, a case study has been carried out of the changeover activity of printing rotaries in processing department of a textile industry. The results of the study showed that, 36% reduction in setup time has been achieved i-e 7 minutes 42sec were reduced per change over. It increased the production by 2.21% per day, which benefited the company to achieve higher production.
All over the world six sigma is being adopted as a quality improvement approach towards zero defe... more All over the world six sigma is being adopted as a quality improvement approach towards zero defects. Unfortunately, the adoption of six sigma methodology in manufacturing companies is very rare in developing countries due to various challenges. This study demonstrates the practical use of the six sigma Define, Measure, Analyze, Improve and Control (DMAIC) cycle by conducting a case study at a manufacturing company in Pakistan. The potential problem was the external leakage defect in the refrigerator during its production stage. The objective of this study was to improve the process by adopting six sigma DMAIC approach to identify and eliminate the root causes that produce defects in the final product. Project charter, Pie chart, Bar chart of faults, Suppliers Input Process Output (SIPOC), Voice of Customer (VOC) and flow process map were used to define the problem, its scope and process routing. Pareto chart was used to identify sub defects and sigma level was calculated for the existing process. Feed rate, capillary action of filler material, cleanliness, visual inspection and unsuitable heat input were the major causes of external leakage. Cause and effect matrix was used to rank the identified causes. Further, design of experiment (DoE) was performed to improve the process by conducting different alterations in the parameters. In order to control the process, failure mode and effect analysis (FMEA) sheet was prepared to sustain the process improvements. The FMEA control plan needed to be revised at specific time intervals to attain continuous process improvement. This six sigma DMAIC cycle produced a 30% overall reduction of external leakage defect and service call rate (SCR) was improved with lower complaints from customers.
The qualitative risk matrix is used in oil and gas industries to evaluate hazard risk related to ... more The qualitative risk matrix is used in oil and gas industries to evaluate hazard risk related to health, safety, and environment (HSE). Traditional risk matrix processes may enhance the uncertainties in assessing the crucial factors regarding HSE. A better technique is needed to develop in order to overcome these uncertainties. Thus, this study has developed the Fuzzy Logic-Based Quantitative Risk Assessment (FLQRA) model to more accurately assess the HSE risks. In this approach, experts (decision-makers) provide their priority of risk assessment information for the severity of consequences and likelihood of HSE classifications in numerical scaling. Afterward, using a combination of consequence and likelihood associated with each category, the Fuzzy Logic approach is utilized to assess the risk level. MATLAB TM software is used to construct a Graphical User Interface (GUI) model to estimate the quantitative risk level, ranking, and priority for HSE categories according to the calculated risk scores for single and multi-expert inputs. Moreover, the weighted average factor is also introduced to measure the efficiency of experience of the expert in the final risk ranking. The effectiveness of the proposed FLQRA model is evaluated by three different case studies and the results from the model are compared with the existing method. FLQRA model has demonstrated to have the capability to facilitate decision-makers in evaluating the risk involved with HSE in oil and gas industry more effectively.
Risk assessment is a process of categorizing and measurement of risk related outcomes from a spec... more Risk assessment is a process of categorizing and measurement of risk related outcomes from a specific incident and in a particular scenario. While risk itself is considered as the combination of likelihood and severity of the consequences of hazards. Typically, the qualitative approach of risk based inspection (RBI) is applied in oil and gas industries to measure the risk levels of hazards. But with this qualitative approach sometime the risk ranking ties among the different factors can lead to problem in selecting the most critical factor. To address the problem, this study aims to develop a fuzzy logic-base risk assessment model using a quantitative approach of RBI that will assist to mitigate the risk ties in risk ranking process of hazard. In this proposed model, fuzzy membership functions and ranges have been assigned for likelihood, severity of consequences and for total risk levels. A case study on ammonia hazard is presented to demonstrate the vitality of the proposed fuzzy risk assessment model with samples of four categories (people, environment, asset and reputation) from an oil and gas industry. The outcomes of this study indicate that the developed model has a strong potential application in oil and gas industry in assessing the severity levels of risk, and resolving risk ranking ties.
Automation in Construction, 2012
Selecting an appropriate contractor is essential for the success of any construction project. Con... more Selecting an appropriate contractor is essential for the success of any construction project. Contractor prequalification procedure makes it possible to admit for tendering only competent contractor. Prequalification is a multi-criteria decision problem that is, in essence, largely dependent on the uncertainty and vagueness in the nature of construction projects and subjective judgement of the decision-maker. This paper presents a systematic prequalification procedure, based on Fuzzy Set Theory, whose main differences and advantages in comparison with other models are the use of an algorithm to handle the inconsistencies in the fuzzy preference relation when pair-wise comparison judgements are used and the use of linguistic assessment or exact assessment of performance of the contractors on qualitative or quantitative criterion, respectively. Finally, a case study for the rehabilitation project of a building at Technical University of Cartagena is presented to illustrate the use of the proposed model and to demonstrate its effectiveness.
Journal of Applied Engineering Science
All over the world six sigma is being adopted as a quality improvement approach towards zero defe... more All over the world six sigma is being adopted as a quality improvement approach towards zero defects. Unfortunately, the adoption of six sigma methodology in manufacturing companies is very rare in developing countries due to various challenges. This study demonstrates the practical use of the six sigma Define, Measure, Analyze, Improve and Control (DMAIC) cycle by conducting a case study at a manufacturing company in Pakistan. The potential problem was the external leakage defect in the refrigerator during its production stage. The objective of this study was to improve the process by adopting six sigma DMAIC approach to identify and eliminate the root causes that produce defects in the final product. Project charter, Pie chart, Bar chart of faults, Suppliers Input Process Output (SIPOC), Voice of Customer (VOC) and flow process map were used to define the problem, its scope and process routing. Pareto chart was used to identify sub defects and sigma level was calculated for the ex...
This study examines the different risk assessment methods used in the oil and gas industry, recog... more This study examines the different risk assessment methods used in the oil and gas industry, recognizing that these approaches must be specific to effectively address complex challenges. The research encompasses qualitative, quantitative, and semi-quantitative techniques that reflect differing scopes and limitations. Key issues such as data uncertainties, dynamic risks, and interconnected systems are explored with emphasis on understanding their unique difficulties. The combined results of this analysis provide valuable guidance for those involved in the industry including policymakers. It outlines effective strategies for managing risks while promoting sustainability within energy operations by proposing innovative solutions like incorporating emerging technologies into risk management processes or enhancing existing data practices. In conclusion embracing forward-looking methodologies will enable professionals to better manage future threats which can lead towards safer more responsible energy exploration globally across industries despite adversity making it essential for everyone involved.
Risk analysis is playing a critical role for industries to evaluate and observe the incident/acci... more Risk analysis is playing a critical role for industries to evaluate and observe the incident/accidents. In today's competitive world industries are focusing on the best solution to evaluate the risk which may leads industry to loss their reputation. This research investigates the application of Mamdani and Sugeno Fuzzy Inference methodologies, incorporating various membership functions, for risk assessment within the oil and gas industry's case studies. The study emphasizes the economic significance of this sector, recognizing its essential role in supporting transportation, manufacturing, and energy sectors, while also addressing potential threats from hazardous facilities. Through a comprehensive Fuzzy Logic-based risk assessment model, with a focus on Mamdani and Sugeno interface systems, the research explores the qualitative and quantitative aspects of risk evaluation. The results indicate the consistent superiority of the Fuzzy Mamdani approach in terms of accuracy and efficiency over the Sugeno method. The model, comprising Likelihood and Consequence input variables and a Total Risk output variable, is evaluated through both qualitative and quantitative analyses. Whereas, the outcomes are based on different membership functions and showcases three case studies, each considering four key factors.
Nowadays to meet the production demand in textile industry, setup time reduction is a big challen... more Nowadays to meet the production demand in textile industry, setup time reduction is a big challenge for the companies. Moreover, product customization has been increasing which negatively affects the setup time. Thus, there is need of an effective technique which can reduce the setup time. Therefore, Single Minute Exchange of Die (SMED) has been proposed in this study, it allows to optimize the changeover activity. Moreover it helps these industries to have maximum production flow. To show the practical applicability of SMED, a case study has been carried out of the changeover activity of printing rotaries in processing department of a textile industry. The results of the study showed that, 36% reduction in setup time has been achieved i-e 7 minutes 42sec were reduced per change over. It increased the production by 2.21% per day, which benefited the company to achieve higher production.
All over the world six sigma is being adopted as a quality improvement approach towards zero defe... more All over the world six sigma is being adopted as a quality improvement approach towards zero defects. Unfortunately, the adoption of six sigma methodology in manufacturing companies is very rare in developing countries due to various challenges. This study demonstrates the practical use of the six sigma Define, Measure, Analyze, Improve and Control (DMAIC) cycle by conducting a case study at a manufacturing company in Pakistan. The potential problem was the external leakage defect in the refrigerator during its production stage. The objective of this study was to improve the process by adopting six sigma DMAIC approach to identify and eliminate the root causes that produce defects in the final product. Project charter, Pie chart, Bar chart of faults, Suppliers Input Process Output (SIPOC), Voice of Customer (VOC) and flow process map were used to define the problem, its scope and process routing. Pareto chart was used to identify sub defects and sigma level was calculated for the existing process. Feed rate, capillary action of filler material, cleanliness, visual inspection and unsuitable heat input were the major causes of external leakage. Cause and effect matrix was used to rank the identified causes. Further, design of experiment (DoE) was performed to improve the process by conducting different alterations in the parameters. In order to control the process, failure mode and effect analysis (FMEA) sheet was prepared to sustain the process improvements. The FMEA control plan needed to be revised at specific time intervals to attain continuous process improvement. This six sigma DMAIC cycle produced a 30% overall reduction of external leakage defect and service call rate (SCR) was improved with lower complaints from customers.
The qualitative risk matrix is used in oil and gas industries to evaluate hazard risk related to ... more The qualitative risk matrix is used in oil and gas industries to evaluate hazard risk related to health, safety, and environment (HSE). Traditional risk matrix processes may enhance the uncertainties in assessing the crucial factors regarding HSE. A better technique is needed to develop in order to overcome these uncertainties. Thus, this study has developed the Fuzzy Logic-Based Quantitative Risk Assessment (FLQRA) model to more accurately assess the HSE risks. In this approach, experts (decision-makers) provide their priority of risk assessment information for the severity of consequences and likelihood of HSE classifications in numerical scaling. Afterward, using a combination of consequence and likelihood associated with each category, the Fuzzy Logic approach is utilized to assess the risk level. MATLAB TM software is used to construct a Graphical User Interface (GUI) model to estimate the quantitative risk level, ranking, and priority for HSE categories according to the calculated risk scores for single and multi-expert inputs. Moreover, the weighted average factor is also introduced to measure the efficiency of experience of the expert in the final risk ranking. The effectiveness of the proposed FLQRA model is evaluated by three different case studies and the results from the model are compared with the existing method. FLQRA model has demonstrated to have the capability to facilitate decision-makers in evaluating the risk involved with HSE in oil and gas industry more effectively.
Risk assessment is a process of categorizing and measurement of risk related outcomes from a spec... more Risk assessment is a process of categorizing and measurement of risk related outcomes from a specific incident and in a particular scenario. While risk itself is considered as the combination of likelihood and severity of the consequences of hazards. Typically, the qualitative approach of risk based inspection (RBI) is applied in oil and gas industries to measure the risk levels of hazards. But with this qualitative approach sometime the risk ranking ties among the different factors can lead to problem in selecting the most critical factor. To address the problem, this study aims to develop a fuzzy logic-base risk assessment model using a quantitative approach of RBI that will assist to mitigate the risk ties in risk ranking process of hazard. In this proposed model, fuzzy membership functions and ranges have been assigned for likelihood, severity of consequences and for total risk levels. A case study on ammonia hazard is presented to demonstrate the vitality of the proposed fuzzy risk assessment model with samples of four categories (people, environment, asset and reputation) from an oil and gas industry. The outcomes of this study indicate that the developed model has a strong potential application in oil and gas industry in assessing the severity levels of risk, and resolving risk ranking ties.
Automation in Construction, 2012
Selecting an appropriate contractor is essential for the success of any construction project. Con... more Selecting an appropriate contractor is essential for the success of any construction project. Contractor prequalification procedure makes it possible to admit for tendering only competent contractor. Prequalification is a multi-criteria decision problem that is, in essence, largely dependent on the uncertainty and vagueness in the nature of construction projects and subjective judgement of the decision-maker. This paper presents a systematic prequalification procedure, based on Fuzzy Set Theory, whose main differences and advantages in comparison with other models are the use of an algorithm to handle the inconsistencies in the fuzzy preference relation when pair-wise comparison judgements are used and the use of linguistic assessment or exact assessment of performance of the contractors on qualitative or quantitative criterion, respectively. Finally, a case study for the rehabilitation project of a building at Technical University of Cartagena is presented to illustrate the use of the proposed model and to demonstrate its effectiveness.