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International Conference on Smart
& Sustainable Manufacturing 2024
PROGRAMME & ABSTRACT BOOK
3 - 6 December 2024
Lagoon Beach Hotel, Milnerton,
Cape Town, South Africa
International Conference on Smart
& Sustainable Manufacturing 2024
Programme
Plenary Speakers
General Information
Welcoming message from the Local Organising Committee
Committees
Workshops
Keynote Speakers
Sponsors
Abstracts: Oral
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Session 1A:
Cyber Security and Industrial Internet of Things
Innovative Engineering Management
Session 6:
Manufacturing Processes
Session 4A:
Session 5A:
Session 1C:
Innovative Engineering Management
Virtual Session
Keynote
Energy-Conscious Manufacturing and Sustainable Energy Systems
Plenary
Session 3B:
Session 5B:
Session 1B:
Manufacturing Technology and Factory Automation
Session 2:
Smart Mobility and Sustainable Transportation
Energy-Conscious Manufacturing and Sustainable Energy Systems
Session 4B:
Session 4C:
Virtual Session
Session 7B:
Session 7C:
Engineering Design and Manufacturing Systems
Advanced Manufacturing and Infrastructure
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CONTENTS
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International Conference on Smart
& Sustainable Manufacturing 2024
Keynote
Manufacturing Processes
Keynote
Session 8:
Plenary
Session 9:
Session 10A:
Manufacturing Technology and Factory Automation
Session 10C:
Session 11A:
Session 11B:
Innovative Engineering Management
Session 14:
Keynote
Additive Manufacturing
Session 16A:
Session 10B:
Additive Manufacturing
Computing and Analytics
Session 16B:
Plenary
Renewable Energy Research and Waste Heat Recycling
Technological Applications in Sustainability
Session 13B:
Keynote
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Abstracts: Posters
CONTENTS
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WELCOMING MESSAGE
DR RAJESH RANSING
DR MUKONDELELI GRACE
KANAKANA-KATUMBA
International Conference on Smart and Sustainable Manufacturing 2024 (ICSSM 2024).......................
It is with great pleasure that we welcome you to the International Conference on Smart and Sustainable
Manufacturing 2024 (ICSSM 2024). This conference serves as a pivotal platform for fostering
collaboration and sharing insights into advancing manufacturing in a connected and sustainable world.
This year’s theme, “Engineering Solutions for a Sustainable Future,” underscores the urgency of
a double-blind peer-review process. This review process was managed via an online conference system,
which allowed reviewers to provide feedback and documented all reviewer comments and editorial
decisions. Each paper was reviewed by at least two reviewers to ensure a robust peer-review process.
Only papers that successfully passed this review process are included in the conference proceedings.
industry workshops, and collaborative engagement meetings over the past two years..........
redefining approaches to manufacturing and sustainability.......................................................
invited to submit a full-length paper. These submissions were screened using Turnitin plagiarism
software to uphold academic integrity. Submissions that passed this screening process underwent
our mission as engineers, researchers, and innovators. In a world marked by rapid technological
advancement and mounting environmental challenges, our role in designing and implementing
smart, sustainable manufacturing solutions has never been more critical. The conference explores
cutting-edge research, ground-breaking technologies, and innovative practices that are
partnerships between Swansea University, UNISA, and TUT, enabling academic exchange visits,
The conference represents the culmination of the unwavering dedication of the local organising
We extend our sincere gratitude to the Royal Academy of Engineering for their support through the
Transforming Systems through Partnerships (TSP1255) project, titled “Smart Manufacturing and
Product Development in a Connected Environment.” This initiative has facilitated robust
committee and a thorough review process. Prospective speakers could submit either full papers or
abstracts only. All Abstracts submitted were screened for suitability, and successful authors were
International Conference on Smart
& Sustainable Manufacturing 2024
5
International Conference on Smart
& Sustainable Manufacturing 2024
Nampuraja Enose, Industrial Engineering and Management, Lappeenranta-Lahti University of
abstracts, we are pleased to include 75 oral presentations and 16 virtual presentations.
and Dr. Constance Mafuwane for their exceptional eorts in managing the review process. We also
We are privileged to welcome an outstanding lineup of plenary speakers: Ms. Cordelia Burch, Senior
Manager – Programmes, Engineering X, Royal Academy of Engineering, UK; Prof. Sebastian
Special acknowledgement is extended to Dr. Boitumelo Innocent Ramatsetse, Dr. Genevieve Bakam,
The conference proceedings feature contributions from 13 countries, as well as authors with
ailiations in industry and international academic institutions. From a total of 131 submitted
Skoczypiec, Chair of Production Engineering, Cracow University of Technology, Poland; and Mr.
Technology, Finland. This is further enriched by keynote addresses from Prof Glen Bright, Peter
express our deepest gratitude to Thereza Botha (TechnoScene) for her tireless eorts in coordinating
this event and securing an outstanding venue in the vibrant city of Cape Town..................................
We warmly invite you to participate in the planned social activities, where you can experience South
gatherings promise to inspire new research ideas and collaborations that will shape the future of
We look forward to your active participation and hope this conference marks the beginning of
many such enriching events in the years to come...............................................................................
smart and sustainable manufacturing.....................................................................................................
Brookstein, Prof Marlien Herselman, Prof Neelesh Kumar Jain and Ilse Karg........................................
Warm regards,.................................................................................................................
African hospitality, sample the finest local wines, and build lasting professional connections. These
Rajesh Ransing and Mukondeleli Grace Kanakana-Katumba...............................................................
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International Conference on Smart
& Sustainable Manufacturing 2024
IMPORTANT INFORMATION
REGISTRATION
The conference will be held in the conference centre of the Lagoon Beach Hotel.
Registration
Monday 2 December 16:00 – 18:00
Tuesday 21 December from 07:30
The registration desk will be open every day for the duration of the sessions.
VENUES
Breakaways
Tea/coee
Main conference room for plenary sessions
Registration desk
Posters
Workshops and Virtual sessions
Exhibitions
Conference dinner
Atlantic Foyer
Atlantic Foyer
Atlantic Foyer
Atlantic 1
Atlantic 2 and Baltic
Atlantic 1
Atlantic Foyer
Atlantic Foyer
Atlantic 1
Atlantic Foyer
MEALS
INTERNET ACCESS
Complimentary Wi-fi is available in the rooms and conference area.
Please note that the Lagoon Beach Hotel is a cashless environment, and only credit/debit
cards are accepted for payment.
All registered delegates are welcome to enjoy the refreshments in the morning and
afternoon, as well as lunch on the days of the conference A soft drink will be served with
lunch. Please note that all additional food or drinks will be for the account of the delegate.
Special diets: If you have special dietary requirements, please enquire with the waiters
during the refreshment breaks and meals.
communicated to you.
Functions: Only delegates who have booked for the functions in advance are eligible to
attend the welcoming function on 3 December, the wine tasting on 4 December and the
Conference dinner on 5 December. If you have booked and paid for the conference dinner,
you should have received a dinner ticket.
Dinners during the week: There is a restaurant on site where you can have dinner. These
dinners will be for your own account, unless alternative arrangements have been
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International Conference on Smart
& Sustainable Manufacturing 2024
IMPORTANT INFORMATION
Virtual sessions: The workshops, panel sessions and presentations to be presented virtually
are marked with a light yellow background on the conference programme. The link to these
presentations will not be communicated to delegates, only the presenters. These sessions
will be live streamed on the Atlantic 1. The presenter will be able to see the audience and the
audience will be able to join in a discussion with the author directly after each talk.
GENERAL SAFETY
Posters: All posters must be mounted by 12:00 on the day you are presenting. Only double-
sided Velcro tape should be used for mounting the posters. Please remove your poster after
the poster session, to free the boards for the poster session the next day.
Please feel free to contact Thereza Botha (+27 83 375 7373) should you have any queries.
Although various security measures are in place at the venue to ensure the safety of guests
and their property, you are encouraged to keep your valuables in a safe place.
CERTIFICATES OF ATTENDANCE
An electronic Certificate of Attendance/Presentation certificate will be sent to you by email
after the conference.
WE HOPE YOU ENJOY THE CONFERENCE!
PRESENTATIONS
Please make sure that you have loaded and tested your presentation on the laptop on the
venue either early morning or during the break before your talk. There are technicians in each
venue who will help you to load your presentation.
Drinks: Only selected wines, beer, soft drinks, ciders, soft drinks and water will be supplied
on the main account during the functions. Please use the vouchers you have received upon
registration to order drinks of your choice. All other drinks will be for your own account.
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Conference Chairs
Dr Mukondeleli Grace Kanakana-Katumba, Tshwane University of Technology, South Africa
Dr Rajesh Ransing, Swansea University, UK
Willy Ngetich, Cape Peninsula University of Technology, South Africa
Dr Kgabo Mokgohloa, UNISA, South Africa
Prof Kapil Gupta, University of Johannesburg, South Africa
Prof Timothy Laseinde, University of Johannesburg, South Africa
Dr Boitumelo Innocent Ramatsetse, Stellenbosch University, South Africa
Prof Ndivhuwo Ndou, UNISA, South Africa
Prof SJ Jacobs, Tshwane University of Technology, South Africa
Prof Rendani Maladzhi, Durban University of Technology, South Africa
Prof Mammo Muchie, Tshwane University of Technology, South Africa
Programme Committee
Dr Mukondeleli Grace Kanakana-Katumba Tshwane, University of Technology, South Africa
Dr Khumbulani Mpofu, Tshwane University of Technology, South Africa
Local Organising Committee
Prof Arnaud Malan, University of Cape Town, South Africa
Dr Boitumelo Innocent Ramatsetse, Stellenbosch University, South Africa
Dr Genevieve Bakam Tshwane, University of Technology, South Africa
Dr Constance Mafuwane, Tshwane University of Technology, South Africa
Dr Kgabo Mokgohloa, UNISA, South Africa
Dr Mammo Muchie, Tshwane University of Technology, South Africa
Prof Khumbulani Mpofu, Tshwane University of Technology, South Africa
Dr Ndivhuwo Ndou, UNISA, South Africa
Dr. Rajesh Ransing, Swansea University, UK
International Conference on Smart
& Sustainable Manufacturing 2024
COMMITTEES
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International Conference on Smart
& Sustainable Manufacturing 2024
COMMITTEES
Dr Tabbi Wilberforce, King’s College London, UK
Prof Xianming Ye, University of Pretoria, South Africa
Prof Bing Zhu, Beihang University, China
Prof Charlie Wang, The University of Manchester, UK
Dr Ahmed Al Hamadani, University of Birmingham, Dubai
Dr Kazeem Aderemi Bello, Federal University Oye Ekiti, Nigeria
Prof Shengzhi Du, Tshwane University of Technology, South Africa
Prof Josef Gochermann, University of Applied Sciences Osnabrueck, Germany
Dr Loice K Gudukeya, University of Zimbabwe, Zimbabwe
Dr Heather Beem, Ashesi University, Ghana
Dr Norman Gwangwava, Botswana Int. University of Science & Technology, Botswana
Dr Munish Kumar Gupta, Opole University of Technology, Poland
Dr Bolanle Tolulope Abe, Tshwane University of Technology, South Africa
Mr Nampuraja Enose Kamalabai, Infosys Ltd, Finland
Prof Anish Kurien, Tshwane University of Technology, South Africa
Dr Whisper Maisiri, University of Portsmouth, UK
Dr Vusi Malele, Dept of Science and Innovation, South Africa
Dr Rajesh Matai, Birla Institute of Technology and Science, Pilani, India
Prof Charles Mbohwa, University of Zimbabwe, Zimbabwe
Prof Thanyani Pandelani, UNISA, South Africa
International Scientific Committee
Dr Michael Adeyeri, The Federal University of Technology, Akure, Nigeria
Organiser
Thereza Botha TechnoScene (Pty)Ltd
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SPONSORS
International Conference on Smart
& Sustainable Manufacturing 2024
DIAMOND SPONSOR DIAMOND SPONSOR
PLATINUM SPONSOR GOLD SPONSOR
BRONZE SPONSOR
EXHIBITOR
PRIZE SPONSOR
We would like to acknowledge the support of the
following companies and institutions with thanks:
communications
& digital technologies
Department:
Communications & Digital Technologies
REPUBLIC OF SOUTH AFRICA
12
International Conference on Smart
& Sustainable Manufacturing 2024
WORKSHOPS
WORKSHOP 1
WORKSHOP 2
workflow which includes data preparation, labelling, training, testing and deployment.
we have built for clients using computer vision. We will then work through the entire
AI For Visual Inspection............................................................................
Presenters:Nur’ain Are & Jason Miskin.............................................................................
The workshop will contain an introductory talk including real world applications that
Research ethics: Authorship, Conflicts of Interest & AI
Presenters:Dr Fulu Akinduro-Aje (Taylor & Francis) & Prof Mammo Muchie (Tshwane
University of technology and Editor of theAfrican Journal of Science, Technology, Innovation
and Development)
This session will explain:
• How we define authorship for Taylor & Francis Journals, including the responsibilities of
the author & corresponding author.
• How to recognise and avoid problems with ghost authorship, gift authorship, and even
authorship for sale.
• How to define and declare any competing interests behind your authorship.
• Taylor & Francis’ policy on Artificial Intelligence & Authorship.
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International Conference on Smart
& Sustainable Manufacturing 2024
How will I benefit from this? You will gain a clear understanding of how we define and
handle authorship disputes in our journals. You’ll also feel more equipped on how to
avoid problems with authorship in your articles & how to solve them should you find
yourself in a situation of concern.....................................................................................
AI Prompt Engineering for FMEA Systems.................................................................
Presenters:Dr Rajesh Ransing & Dr Meghana Ransing, Swansea University, UK,.//....,,,,,,,,,,,
This workshop aims to equip participants with practical skills in designing eective GPT
methods that rely on expert judgment and Risk Priority Numbers (RPN), the new AIAG-VDA
Objective:..................................................................................................................
management. The focus will be on reducing AI hallucinations and improving the accuracy
of FMEA documentation, specifically for Process Step (PS) and Process Work Element
Group Discussion:....................................................................................................
A discussion on how conversational AI has the potential to disrupt traditional root cause
analysis approaches, emphasising how these tools can streamline and improve FMEA
processes..............................................................................................................
Introduction to the latest AIAG-VDA FMEA guidelines and their role in AI-assisted systems for
risk management. Key concepts will include Process Steps (PS), Process Work Elements
(PWE), failure modes, root causes, Key Process Variables (KPVs), and detection/prevention
controls...........................................................................................................
(PWE) functions, failure modes, and controls..................................................................
prompts for automating FMEA documentation. With the shift from traditional FMEA
FMEA guidelines are optimized for AI-driven systems, enabling more eicient risk
AIAG-VDA FMEA Overview:.......................................................................................
Key Topics Covered:..........................................................................................................
WORKSHOP 3
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International Conference on Smart
& Sustainable Manufacturing 2024
Hands-On Exercise:.........................................................................................................
Participants will practice GPT-based prompt engineering to generate FMEA
adjusting their prompts to produce more accurate results.............................................
Students will work in teams to identify AI-generated hallucinations and errors,
explanations. Understand how to structure prompts to define PS and PWE functions
Teams will present their generated FMEA sheets, explaining the role AI played in
Learn how to design prompts that link root causes with failure modes using scientific
using information from existing FMEA files.........................................................................
Designing Eective GPT Prompts:.........................................................................
documentation. This exercise will focus on automating the creation of PS and PWE
functions while identifying and reducing AI hallucinations................................
Group Activity:..........................................................................................................
Group Presentation:........................................................................................................
enhancing their documentation and discussing the accuracy of the results................
15
in partnership with
The TUT Hub of
the AI Institute of South Africa
The TUT Hub of
the AI Institute of South Africa
Building and
Equipping
the Future
Workforce
in AI
• TheTUTHuboftheArtificialIntelligenceInstituteofSouthAfrica(AIISA)was
launchedonthe24thofMarch2024.
• TheTUTHubofAIISAwasestablishedasakeyrecommendationthatwasmade
fromthePresidentialCommissionon4IR(PC4IR)ontheestablishmentofa
NationalInstituteinAI.
• TheTUTHubofAIISAiscontributingtotheTshwaneUniversityofTechnology’s
VisionandMissionaimedatsolvingpressingsocietalproblemsandensuringthat
ourgraduatesareproductiveandactivecitizens.
• TheTUTHuboftheAIinstituteofSouthAfricaiscontributingtopreparingFuture-
readygraduatesintheareaofAI.
Focus of the TUT Hub of AIISA
ThefocusoftheTUTHubiscentredoneight areasthatithasexpertiseon.
Table 1 – TUT Focus Areas
Item No. Focus Area Link to Government Catalytic Projects
1 AIforAutomotiveSector AIMotorIndustryInfrastructure
EnhancementProgramme
2AIinTransport(inclusiveof
theusageofDrones)
AIMotorIndustryInfrastructure
EnhancementProgramme
34IRinManufacturing
(value-chain)
AIMotorIndustryInfrastructure
EnhancementProgramme
4AITourism(inclusiveof
VirtualReality) ModernisingPublicservice
5
AIinFarmingandFood
processing(Agriculture
5.0)
AIinFarmingandFoodproduction
6 AIforTelecommunications ModernisingPublicservice
7 AIinHealthcare ModernisingPublicservice
8 AIinEducation ModernisingPublicservice
Alltheabove8areascontributetoAICapacitybuildingforPublicServants.
Contact: Prof. AM Kurien, kurienam@tut.ac.za
1.PresidentialCommissionon4IRReport,availableonline:https://www.dcdt.gov.za/documents/reports.html
International Conference on Smart
& Sustainable Manufacturing 2024
CORDELIA BURCH
PLENARY SPEAKERS
Senior Manager – Programmes, Engineering X, Royal Academy of Engineering, UK
Cordelia Burch is an experienced program and senior manager with a wealth of
experience in overseeing international projects, grant management, and
stakeholder engagement. As a Senior Manager for Programmes at Engineering X,
part of the Royal Academy of Engineering, she has led multiple global initiatives
focusing on safety and sustainability challenges. Cordelia has successfully
managed multi-million GBP budgets, navigated the complexities of pandemic
preparedness, and fostered collaborations across continents. In her previous
role as Programme Manager, International Entrepreneurship, also at the Royal
Academy of Engineering, Cordelia spearheaded the Africa Prize for Engineering
Innovation, providing crucial commercialization support to African innovators.
She adeptly handled significant budgets, organized numerous training events
across diverse locations, and maintained high levels of engagement even during
the COVID-19 pandemic. Her extensive background includes roles such as
Programme Coordinator & Development Oicer at the Unite Lebanon Youth
Project, where she managed EU-funded initiatives for Palestinian youth, and
various volunteer positions where she supported educational and psychological
programs in the Middle East and Greece.Cordelia holds an MA in Development
Studies with distinction from the Institute of Development Studies, Sussex
University, and a BA in Arabic and Spanish from The University of Edinburgh.
Professor Sebastian Skoczypiec graduated from the Faculty of Mechanical
Engineering at the Cracow University of Technology. His scientific discipline is
mechanical engineering, with a focus on electrophysical and chemical methods
of manufacturing machine parts and tools, such as electrochemical machining
(ECM), electrical discharge machining (EDM), or laser machining (LBM). Prof.
Skoczypiec’s research focuses on integrating machining processes into
sequential and hybrid technologies, including selected additive manufacturing
technologies. The research also addresses the challenges of adapting these
processes for micromachining. Prof. Sebastian Skoczypiec has authored or co-
authored over 140 publications and has spoken at numerous international
conferences. He has been involved as a contractor in 16 research and
development projects. Currently holds the position of Head of the Department of
Production Engineering at the Cracow University of Technology, President of the
Production Engineering Committee of the Polish Academy of Sciences and Vice-
President of the Polish Academy of Engineering.
PROF SEBASTIAN SKOCZYPIEC
Chair of Production Engineering, Cracow University of Technology, Krakow, Poland
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MR NAMPURAJA ENOSE
Industrial Engineering and Management, Lappeenranta-Lahti University of Technology, Finland
Nampuraja Enose is acknowledged as a thought leader in the industry, focusing
on leveraging the transformative potential of Fourth Industrial Revolution (4IR)
technologies that are reshaping global industrial landscapes. Currently, he is
pursuing doctoral research focused on ‘Industrial Sustainability’ at LUT
University in Finland. With over two decades of diverse cross-industry
experience, he heads the ‘Industry 4.0 Centre of Excellence’ at Infosys Limited.
His involvement extends beyond corporate realms; he is deeply committed to
bridging academia, industry, and policy domains through innovative
collaboration models. Notably, he played a pivotal role in conceiving the Industry
4.0 Maturity Index, a collaborative endeavour with ‘acatech’ (the German
academy for Science and Technology), as well as esteemed scientific partners
and industry stakeholders. Moreover, he plays an active role in the World
Economic Forum’s ‘Shaping the Future of Advanced Manufacturing and Value
Chains’ initiative. Beyond that, he shares his expertise with specialized agencies
dedicated to development eorts across dierent countries and sectors.
International Conference on Smart
& Sustainable Manufacturing 2024
PLENARY SPEAKERS
19
PROF GLEN BRIGHT
Dean of Engineering, University of KwaZulu Natal, Durban, South Africa
Leader and supervisor of the Mechatronics and Robotics research Group,
(MR2G) since 1995 at UKZN. Research objectives are to provide industry with
‘state of the art’ solutions for Advanced Manufacturing Systems
Graduated with a BSc (Mechanical Engineering), MSc (Engineering) and PhD
(Engineering) degree at the Ex-University of Natal in the area of Mechatronics,
Robotics and Advanced Manufacturing Systems. Professor of Mechatronics,
Robotics and Advanced Manufacturing Systems since 2002. Held the following
leadership positions since 2002: Major Leader and Head of the Mechatronics
degree program at Massey University, Auckland, New Zealand, Head of School
for Mechanical Engineering UKZN, Dean of Research and now Dean of
Engineering at UKZN since 2018.
Holder of the James Fulton Chair based in Mechanical Engineering since 2008.
Graduated with an MBA degree at UKZN, Durban, in 2011. Lecture courses in
topics associated with Mechatronics, Robotics and Advanced Manufacturing
Systems. Teaching and learning objectives are to provide quality education to
students at undergraduate and post graduate level.
PETER BROOKSTEIN
DataProphet, Cape Town, South Africa
Peter Brookstein is an experienced software engineer currently leading the
CONNECT Platform Team at DataProphet. He holds both a BSc in Electrical
Engineering (Information Engineering) and MSc in Electrical Engineering from the
University of Witwatersrand.
Over the past eight years at DataProphet, Peter has led the design and
development of software, APIs, tooling, infrastructure, automation, and
platforms that facilitate the deployment & application of AI and ML systems
within the manufacturing industry.
Prior to joining DataProphet, Peter spent several years developing secure and
encrypted communication systems. His extensive experience encompasses
cloud computing, networking, security, software engineering and product
development.
International Conference on Smart
& Sustainable Manufacturing 2024
KEYNOTE SPEAKERS
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PROF MARLIEN HERSELMAN
Next Generation Enterprises and Institutions, CSIR, Pretoria South Africa
Prof. Marlien Herselman (F) is a Chief Researcher at the Council for Scientific and
Industrial Research (CSIR) in Pretoria, South Africa. She leads complex projects
in the Innovation Ecosystems domain. She is ailiated with various universities
as an adjunct/associate professor (UNISA, Rhodes, University of Stellenbosch,
University of Pretoria, and Regenesys) where she does supervision and co-
supervision at Masters and PhD level. She was also Chairperson and founder of
the Living Labs Network in Southern Africa (LLiSA) since 2009. Herselman has
over 49 accredited journal articles, 3 books, 39 accredited conference papers,
cited over 2000 times and has delivered 45 Masters and 31 PhD students. Areas
of expertise: Innovation ecosystems; Mobile and digital Health; Rural
communities and ICT4D; Applying Design Science as a Research Methodology
ILSE KARG
International Conference on Smart
& Sustainable Manufacturing 2024
KEYNOTE SPEAKERS
Ilse Karg has been serving the government for more than 35 years, mainly in
National Treasury and public finance. Ms Karg was responsible for programme
and project financing, national budgets, legal work, institutional reviews,
governance and compliance, as well as government policy reviews and
evaluations in the areas of trade, industry, innovation, state-owned enterprises,
science, technology, education, environmental aairs and tourism.
Her economics qualification and her experience have prepared her for
establishing a new 4th Industrial Revolution (4IR) chief directorate in the
Department of Trade, Industry and Competition. She has been appointed to
ministerial task teams, steering committees, boards and councils, such as the
Ministerial Task Team on 4IR for Post-School Education and Training and the
Intsimbi Future Production Technologies board, among others. She has
participated in international forums such as the BRICS Partnership on New
Industrial Revolution Advisory Group (4IR) and the World Economic Forum's
Advanced Manufacturing and Value Chains. Ms Karg's current work is focused on
developing the South African digital manufacturing policy and strategy. Her work
also involves building industrial capacity and skills for the industrial
internet; identifying and enabling technological change and capabilities,
knowledge diusion and data governance; and promoting innovation and
knowledge intensification in the South African manufacturing sector.
The Department of Trade, Industry and Competition (the dtic), South Africa.
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PROF MARLIEN HERSELMAN
Next Generation Enterprises and Institutions, CSIR, Pretoria South Africa
Prof. Marlien Herselman (F) is a Chief Researcher at the Council for Scientific and
Industrial Research (CSIR) in Pretoria, South Africa. She leads complex projects
in the Innovation Ecosystems domain. She is ailiated with various universities
as an adjunct/associate professor (UNISA, Rhodes, University of Stellenbosch,
University of Pretoria, and Regenesys) where she does supervision and co-
supervision at Masters and PhD level. She was also Chairperson and founder of
the Living Labs Network in Southern Africa (LLiSA) since 2009. Herselman has
over 49 accredited journal articles, 3 books, 39 accredited conference papers,
cited over 2000 times and has delivered 45 Masters and 31 PhD students. Areas
of expertise: Innovation ecosystems; Mobile and digital Health; Rural
communities and ICT4D; Applying Design Science as a Research Methodology
PROF NEELESH KUMAR JAIN
Mechanical Engineering, Indian Institute of Technology Indore, India
Prof. Neelesh Kumar Jain did PhD from IIT Kanpur in 2003. He is an expert in Micro-
plasma based additive manufacturing (AM) of metallic materials; Development
of biomaterials, HEA, FGM, SMM, MMC via AM route; Solid-state AM of thermally
challenging materials, Sustainable hobbing of gears; Net-shape manufacturing
of miniature and non-circular gears; High quality gear finishing; Non-contact
flank modifications of gears; Modeling and optimization of the manufacturing
processes; Micro-joining of thin sheets. He has developed 10 innovative
technologies of which two technologies have been granted Indian patents. He
has more than 200 publications which includes 6 authored and 2 edited books,
25 book chapters, 137 journal and 32 conference papers. He has guided 16 PhD
and 29 MTech theses. He has developed Center of Excellence in Gear
Engineering, 6 state-of-art research and teaching labs, Central workshop. He has
delivered many expert lectures on international and national fora. He has been
conferred many awards and honors. He served as Oiciating Director for 25
months, Acting Director for 19 months, and founding Dean of Academic Aairs of
IIT Indore for 8 years and 8 months.
International Conference on Smart
& Sustainable Manufacturing 2024
KEYNOTE SPEAKERS
22
Tuesday 3 December 2024
07:30
Registration desk opens
08:30
Workshop 1
Facilitator: Dr Boitumelo Ramatsetse Atlantic 1
AI For Visual Inspection
Opti-Num Solutions
Nur’ain Areff
Jason Miskin
Virtual
10:30
Refreshment break
11:00
Workshop 2
Facilitator: Dr Genevieve Bakam Atlantic 1
Research ethics: Authorship, Conflicts of Interest & AI
Taylor & Francis Group
How to successfully navigate the publishing process
Prof Mammo Muchie (Tshwane University of Technology and Editor-in-Chief of the African Journal of Science, Technology, Innovation and Development)
Research ethics
Dr Fulu Akinduro-Aje (Taylor & Francis)
Hybrid
13:00
Lunch
14:00
Workshop 3
Facilitator: Dr Rajesh Ransing Atlantic 1
AI Prompt Engineering for FMEA Systems
Swansea University
Dr Rajesh Ransing
Dr Meghana Ransing
Hybrid
15:30
Refreshment break
16:00
AI Prompt Engineering for FMEA Systems (continued)
18:00
Welcoming function Adriatic Suite
PROGRAMME
23
Wednesday 4 December 2024
07:30
Registration desk opens
Opening Atlantic 1
08:30
Welcoming
Prof Mukondeleli Grace Kanakana-Katumba
Co-chair of the Organising Committee
08:40
Welcoming message: Prof Simi Dube
Deputy Executive Dean, CSET, UNISA
Session 1A
Manufacturing Processes
Chair:Prof Rendani Maladzhi Atlantic 1
Session 1B
Manufacturing Technology and Factory
Automation
Chair: Prof SJ Jacobs Atlantic 2
Session 1C
Energy-Conscious Manufacturing and
Sustainable Energy Systems
Chair: Prof Josiah Munda Baltic
09:00
Productivity and quality issues in the
manufacturing of ceramic refractory and wear
lining materials
Steadyman Chikumba
University of South Africa
IoT device integration on legacy production
systems
Kobus Vorster
Tshwane University of Technology
Simulation of bulk tanker truck loading
operations at a new fly ash plant: a case of coal
fired power station
Asser Letsatsi Tau
University of Johannesburg
09:15
Computer aided modelling and simulation of
carbon fibre for aircraft’s wing application
Festus Fameso
Tshwane University of Technology
Increasing the accuracy of position and
orientation estimates in image processing for
asymmetric profile shapes
Momina Malik
Durban University of Technology
Utilizing kitchen and organic waste for biogas
production in multi-family housing units:
Innovation, opportunities, and challenges
Mariam Adeoba
University of South Africa
09:30
Sustainable manufacturing of stainless steel
elliptical gears and study of their tribological
behaviour
Neelesh Kumar Jain
Indian Institute of Technology Indore, India
The Impact of rapid prototyping on modern
product development
Rendani Wilson Maladzhi
Durban University of Technology
Integration of advanced fiber-reinforced
composite materials in energy-efficient
transportation: Challenges and opportunities
Idowu David Ibrahim
Vaal University of Technology
09:45
Vision-based monitoring of sheet metal welding
process
Yongwa Chuengwa
Tshwane University of Technology
Revolutionizing manufacturing [unleashing AI
for enhanced efficiency and resilience]
Kemlall Ramdass
University of South Africa
10:00
Break
24
10:15
Session 2
Chair: Prof Mukondeleli Grace Kanakana-Katumba Atlantic 1
Plenary: Engineering and the SDGs: Spotlight on the Transforming Systems through Partnership programme (virtual presentation)
Cordelia Burch
Royal Academy of Engineering
10:45
Keynote: Innovation ecosystems and smart manufacturing in South Africa
Prof Marlien Herselman
Council for Scientific and Industrial Research
11:20
Refreshment break
Session 3A
Panel Discussion
Facilitator: Prof Tabbi Wilberforce Atlantic 1
Session 3B
Energy-Conscious Manufacturing and Sustainable Energy Systems
Chair: Dr Genevieve Bakam Atlantic 2
11:45
Skills needed by Engineers in the era of AI
Panel members
Prof Tabbi Wilberforce
Other participants to be confirmed
Virtual
Application of AI to sustainable design strategies for green roofs combined
with biogas systems in urban landscapes: Benefits and challenges
Mariam Adeoba
University of South Africa
12:00
Towards addressing skills shortage causing power outage execution in
South Africa
Kgashane Stephen Nyakala
Tshwane University of Technology
12:15
Analysis of variable optimization in manufacturing: A machine learning
approach to improving operational efficiency
Rajesh Ransing
Swansea University, UK
25
Session 4A
Cyber Security and Industrial Internet of Things
Chair: Dr Rajesh Ransing Atlantic 1
Session 4B
Innovative Engineering Management
Chair: Dr Kgashane Nyakala Atlantic 2
Session 4C
Smart Mobility and Sustainable Transportation
Chair: Dr Boitumelo Ramatsetse Baltic
12:30
Addressing personnel challenges and solutions
in securing industrial control systems
Thobeka Sishuba
University of Johannesburg
AI-driven root cause analysis utilising FMEA
based Knowledge Graphs
Meghana Ransing
Swansea University, UK
Investigating the constraints associated with
running traffic control systems effectively at
signalized intersections
Zanele Mpanza
University of South Africa
12:45
Influence of tool pin profile on the geometrical,
macrostructural and microstructural features of
friction stir processed pure aluminium based
composites: A zonal analysis
Tawanda Marazani
Tshwane University of Technology
GPT- 4.0 Assisted generation of PFMEA process
step & process work element functions
Meghana Ransing
Swansea University, UK
Smart mobility innovations and solar energy
towards sustainable transportation
Kyle Brand
Tshwane University of Technology
13:00
Cyber security standards for applying the
“Defense in depth approach" for industrial
control systems
Thobeka Sishuba
University of Johannesburg
Work measurement analysis: A survey of
literature
Thokozani Hlatshwayo
Tshwane University of Technology
An in-depth analysis of electric vehicle
technology, charging infrastructure, and grid
stability
Bolanle Abe
Tshwane University of Technology
13:15
Lunch
Session 5A
Virtual Session
Prof Rajesh Ransing Atlantic 1
Session 5B
Innovative Engineering Management
Chair: Prof Josef Gochermann Atlantic 2
14:00
Embedding project-based learning and design thinking in engineering
curricula: A review
Lebogang Bopape
Durban University of Technology, joining from Australia
Embracing the future of manufacturing [cyber-physical systems in
manufacturing]
Ngaka Mosia
University of South Africa
14:15
Application of FMEA techniques to improve plant maintenance strategy: A
case study on a metal granulation plant
Peter Muganyi
University of Johannesburg
Assessment of factors affecting project quality in the construction of
telecommunication towers
Adelegan Adeyeri Adewumi
University of Johannesburg
14:30
Feasibility study of sugarcane bagasse-based composites as sustainable
polymer alternatives
Harish Kumar Devarakonda
Wollega University, Ethiopia
Integration of electric vehicle technologies into engineering curricula
through project-based learning lessons learned
Rouxzeta van der Merwe
Tshwane University of Technology
14:45
Policy Considerations and recommendations for renewable energy
generation from waste (ReGen) and green growth technology in West
Africa
Opeyemi Amusan
Development of an agile supply chain network [A technology-driven
supply chain framework]
Zanele Mpanza
26
University of South Africa, joining from Nigeria
University of South Africa
15:00
Artificial intelligence overview for optimizing production scheduling in a
picture framing company
Jadwiga Worek
Cracow University of Technology, Poland
Evaluating technical proficiency and adoption trends of innovative
building technologies in South African homebuilding: A critical path and
gap analysis approach
Thokozani Hlatshwayo
Tshwane University of Technology
15:15
Energy efficiency amelioration endeavours in a commercial building
Peter Muganyi
University of Johannesburg
15:30
Refreshment break
Session 6
Virtual session
Chair: Prof Rajesh Ransing Atlantic 1
15:45
Exploration of the relationships between composition and properties of a nickel-based brazing alloy using experimental and thermodynamic
simulations
Samuel Ross
Swansea University, UK
16:00
Sustainable food-energy-waste nexus enhancement with renewable energy recovery system in Africa
Opeyemi Amusan
University of South Africa, joining from Nigeria
16:15
Renewable energy utilization in the manufacturing sector: Benefits, challenges, and solutions
Kazeem Aderemi Bello
Federal University Oye Ekiti, Nigeria
16:30
Effect of Industry 4.0 on social and environmental sustainability of manufacturing industries
Olufemi Oroye
Bells University of Technology, Nigeria
16:45
Frugal embedded service design framework for low-cost innovations in LMICs: Case of digital maternal and child health promotion in Kenya
Danny Nyatuka
Strathmore University, Kenya
17:00
Modeling and evaluating distributed renewable energy generating system in transmission expansion network
Nomihla Ndlela
Durban University of Technology
17:15
Status of centralized and decentralized solar and wind technology and performance potential in Sub-Saharan Africa: A review
Hulisani Matsila
Tshwane University of Technology
18:00
Wine tasting Atrium
27
Thursday 5 December 2024
08:00
Registration desk opens
Session 7A
Panel discussion
Facilitator: Prof Khumbulani Mpofu Atlantic 1
Session 7B
Advanced Manufacturing and Infrastructure
Chair: Dr Simon Phuluwa Atlantic 2
Session 7C
Engineering Design and Manufacturing Systems
Chair: Meghana Ransing Baltic
08:30
Bilateral funding for SMEs to support
research on 4IR
Panel members:
Prof Khumbulani Mpofu
Ms Ilse Karg
Department of Trade, Industry and
Competition
Prof Josef Gochermann
Hochschule Osnabrück, Germany
The use of powders in friction stir welding of
AA5083: the current state and future trends
Thato Ralebakeng
University of South Africa
Investigation of the effect of geometric and
operating parameters on thermal behaviour
latent heat energy storage systems
Thandiwe Radebe
Tshwane University of Technology
08:45
The influence of process parameters during
friction stir processing on corrosion properties of
titanium alloys: An overview
Shyline Chingowo
University of South Africa
Optimal decision-making approach for the
advancement of SMEs in transportation
manufacturing
Eriyeti Murena
Tshwane University of Technology
09:00
Sustainable Manufacturing of Stainless Steel
Elliptical Gears and Study of their Tribologic
riction stir welding of aluminium AA5083
Thato Ralebakeng
University of South Africa
Organisation resources and performance
measures to enhance productivity in the
manufacturing industry
Kgashane Stephen Nyakala
Tshwane University of Technology
09:15
Corrosive Behavior of Saltwater Phase-Change
Materials on Common Refrigeration Metals
Thandiwe Radebe
Tshwane University of Technology
09:30
Break
Session 8
Chair: Prof Ndivhuwo Ndou Atlantic 1
09:45
Plenary: The impact of Industry 4.0 technologies on the development of electrical discharge machining
Prof Sebastian Skoczypiec
Cracow University of Technology, Poland
10:35
Refreshment Break
28
Session 9
Chair: Prof Rendani Maladzhi Atlantic 1
11:00
Keynote: Recent technology developments in advanced manufacturing systems
Prof Glen Bright
University of KwaZulu-Natal
11:35
Keynote: Environment friendly additive manufacturing of thermally challenging materials
Prof Neelesh Kumar Jain
Indian Institute of Technology Indore, India
Session 10A
Manufacturing Processes
Chair: Dr Steadyman Chikumba Atlantic 1
Session 10B
Manufacturing Technology and Factory
Automation
Chair: Prof Bolanle Abe Atlantic 2
Session 10C
Additive Manufacturing
Chair: Willy Ngetich Baltic
12:10
Exploring the continuum of human-robot
collaboration and the impact on the
manufacturing process
Ndivhuwo Ndou
University of South Africa
Towards smart manufacturing: Integration of
computerized systems in the press tool industry
Moses Oyesola
Tshwane University of Technology
Lithography-based ceramic additive manu-
facturing of biodegradable bone regeneration
lattice structures
Morakane Moletsane
Central University of Technology
12:25
Influence of hybrid fillers on buoyancy and
thermal stability of epoxy-based foam composite
panels
Ayodele Ajayi
Durban University of Technology
Improving production throughput and reduction
of down time in automotive industry
Steadyman Chikumba
University of South Africa
Investigating the mechanical properties of
additively manufactured Al-Ti-Zr-Nb-V-Cr high
entropy alloys for multifunctional application
Adebayo Olutumbi Ogunyinka
Tshwane University of Technology
12:40
Low clinker cement production output and
carbon tax emission payable at a cement
blending operations
Asser Letsatsi Tau
University of Johannesburg
A dynamic and differentiated tool for assessing
the 4IR readiness of manufacturing companies
Josef Gochermann
Hochschule Osnabrück, Germany
Post-processing heat treatment analysis for
additively manufactured AlSi12
Alliance Bibili Nzengue
Tshwane University of Technology
12:55
Lunch
Session 11A
Technological Applications in Sustainability
Chair: Prof Ndivhuwo Ndou Atlantic 2
Session 11B
Renewable Energy Research and Waste Heat Recycling
Chair: Nampuraja Enose Kamalabai Baltic
14:00
Aptasensor platform based on carbon quantum dot-titanium dioxide
nanoparticles (CQD-TiO2) for the detection of Cryptosporidium in water
Indiphile Nompetsheni
University of South Africa
The current state of South Africa's transition to net zero emissions
Emmanuel Ogundimu
Tshwane University of Technology
14:15
Optimizing automotive injection molding processes through predictive
modeling techniques
Fikile Poswa
Tshwane University of Technology
Modelling and analysis of bidirectional converters and supercapacitors in
wind turbines for management of short-term voltage output variations
Banele Mbendane
University of South Africa /Tshwane University of Technology
29
14:30
Establishing resilience in manufacturing through smart technology
strategies
Ngaka Mosia
University of South Africa
The impacts of environmental conditions on the output power efficiency of
photovoltaic (PV) solar modules
Emmanuel Ogundimu
Tshwane University of Technology
14:45
A bibliometric analysis of Industry 4.0 technologies in sustainable
manufacturing
Charles Mothobiso
Tshwane University of Technology
Indigenous innovation way of turning waste from coal and cow dung to
manufacture bricks for sustainable use for bioresource
Tshifhiwa Nenzhelele
Tshwane University of Technology
15:00
Cyber defence mechanisms and digital customer experience for sustainable
manufacturing companies in South Africa
Genevieve Bakam
Tshwane University of Technology
15:15
Refreshment break
14:00
Session 12
Poster session
19:30
For
20:00
Gala dinner
30
Friday 6 December 2024
08:00
Registration desk opens
Session 13A
Panel discussion
Facilitator: Dr Randall Paton Atlantic 1
Session 13B
Innovative Engineering Management
Chair: Dr Tshifhiwa Nenzhelele Atlantic 2
08:30
Transformative era of engineering education
Panel members
Dr Randall Paton
University of the Witwatersrand
Prof Chris Von Klemperer
University of Cape Town
Eudes Tshitshonu
Vaal University of Technology
How to Train Tomorrow's Engineers [Empowering Education with Digital
Twins]
Kemlall Ramdass
University of South Africa
08:45
Assessment of a model for carbon emissions at the logistics and
transportation stage of conveyor belt procurement processes in a
manufacturing industry
Adefemi Adeodu
Bells University of Technology, Nigeria
09:00
Agent-based model detection of corrosion under insulation on the
condensate pipelines
Khumbulani Mpofu
Tshwane University of Technology
09:15
Dynamic smart service design for twin transformation in the packaging
industry
Maren Kobusch
Hochschule Osnabrück, Germany/Tshwane University of Technology
09:30
Implementation guidelines for total productive maintenance and reliability
centered maintenance
Festus Fameso
Tshwane University of Technology
09:45
Session 14
Chair: Prof SJ Jacobs Atlantic 1
Plenary: Industry 5.0 – A systematic and holistic approach to establish the current trends and guidance for future research
Mr Nampuraja Enose
Lappeenranta-Lahti University of Technology, Finland
10:35
Keynote: Unlocking the potential of Industrial Policy in a Digital Society
Ilse Karg
The Department of Trade, Industry and Competition, SA Government
11:10
Refreshment break
Session 15
Chair: Prof Mxolisi Shongwe Atlantic 1
31
11:40
Keynote: An industry perspective on deploying real-world AI & data systems in the manufacturing sector
Peter Brookstein
DataProphet
Session 16A
Computing and Analytics
Chair: Ngaka Mosia Atlantic 1
Session 16B
Additive Manufacturing
Chair: Dr Idowu Ibrahim Atlantic 2
12:15
Adaptive control of machining parameters in machine tools for enhanced
product accuracy using DDPG approach
Olugbenga Aderoba
Tshwane University of Technology
Influence of Laser cladding process parameters on hardness and wear
resistance of titanium alloys
Shyline Chingowo
University of South Africa
12:30
From analysis to action: Optimising FMEA processes for enhanced risk
management and continuous improvement
Rajesh Ransing
Swansea University, UK
Addressing polypropylene (PP) warping in fused deposition modelling (FDM)
Magadi Katuma
Tshwane University of Technology
12:45
Closing
13:15
Lunch & departure
POSTERS
1
Reverse engineering and rapid prototyping in product development
Steadyman Chikumba
University of South Africa
2
Understanding intrapreneurship: Definition, characteristics and importance
Tlotlo Ramasu
Tshwane University of Technology
3
Internet of Things (IoT) sensor development for real-time monitoring of water quality and distribution
Rendani Maladzhi
Durban University of Technology
4
Synthesis and characterization of silica-supported cobalt catalyst with different pore sizes using the Stber process for use in Fischer Tropsch synthesis
Nicholas Jim
ICES, University of South Africa
32
Session 1A: Manufacturing Processes
Productivity and Quality Issues in the Manufacturing of Ceramic
Refractory and Wear Lining Materials
Steadyman Chikumba
University of South Africa, Department of Industrial Engineering and Engineering Management,
Florida campus, Florida, South Africa, 1709
South Africa
Corresponding author: chikus@unisa.ac.za
Wear, excessive heat and corrosion cause considerable material loss and equipment damage in
manufacturing and material processing industries. Wear protection is important in such fields as
mineral processing, material handling in energy plants and furnace linings as well as other
operations where materials are abrasive e.g. cement manufacturing. To overcome loss due to
wear and corrosion, vulnerable components of exposed equipment such as chutes, bunkers and
pipes are protected using ceramic, metallic and non-metallic lining on equipment to effectively
resist abrasive and impact wear, limit dust generation, and reduce product degradation. This
paper focusses on ceramic wear and refractory materials commonly used for and wear
resistance applications. Manufacturing of such materials involves mixing of powders with water
into a slurry before drying and firing. Finishing can be achieved through machining and polishing.
Processes and procedures of ceramic and wear refractory materials are important in ensuring
high quality and functional liners. The aim is to investigate the factors affecting quality of
refractory wear lining manufacturing and develop how product quality and productivity is
improved. Using a literature and exploratory study the manufacturing steps and several
refractory materials and their functional requirements is carried out. The effect of manufacturing
steps on product quality and manufacturing productivity is discussed together with methods of
eliminating or reducing defects are proposed.
33
Session 1A: Manufacturing Processes
Computer Aided Modelling and Simulation of Carbon Fibre Utilization
for Light Aircraft Wing Application
1Ilesanmi Daniyan*, 2Festus Fameso, 3Julius Ndambuki, 4Lanre Daniyan, 5Kazeem Bello
1Department of Mechatronics Engineering, Bells University of Technology, Ota, Nigeria.
2,3Centre for Climate Change, Water Security and Disaster Management, Department of Civil
Engineering, Tshwane University of Technology, Pretoria, 0183, South Africa.
4Department of Instrumentation, Centre for Basic Space Science, University of Nigeria, Nsukka,
Nigeria.
5Department of Mechanical Engineering, Durban University of Technology, Durban, South
Africa.
*Corresponding author: Ilesanmi Daniyan (afolabiilesanmi@yahoo.com)
Light aircrafts play a significant role in climatic and disaster management operations such as in
aerial surveillance, mapping, monitoring, response etc. This study aims to contribute to
enhanced performance and sustainability of light aircraft operations through effective design of
its wing. Using commercial software code, computer aided modelling and simulation of carbon
fibre material-based application was carried out, to determine suitability for the development of
a light aircraft wing. The effect of different lengths of the wing (3500 mm, 5000 mm, 6500 mm,
7000 mm) on the performance of the aircraft was investigated with respect to the resulting stress
and strain induced, plastic strains and displacement. The results obtained indicated that the
maximum induced stress could reach 25.515 MPa, which is significantly lower than the yield
strength of the material (3.20 GPa). Furthermore, wing length of 5000 mm showed less strain
induced and thus more stability compared to others. Furthermore, the equivalent plastic strain
and resultant displacement for the various lengths of the aircraft wings at the root chord (central
axis) were found to be negligible. The outcome of this study can assist light aircraft developers to
optimally harness the potentials of carbon fibre for aircraft wing development.
Keywords: aircraft wing, carbon fibre, modelling and simulation, sustainability
34
Session 1A: Manufacturing Processes
Sustainable Manufacturing of Stainless-steel Elliptical Gears and
Study of their Tribological Behavior
Sandeep Gour 1, and Neelesh Kumar Jain1a
1 Department of Mechanical Engineering, IIT Indore, 453552 (MP), India
a Corresponding author: nkjain@iiti.ac.in
Elliptical gears are used effectively in automatic machines to generate variable gear ratios.
Manufacturing of elliptical gears is difficult due to their complex tooth design and non-standard
shapes. Wire spark erosion machining (WSEM) process has emerged as a sustainable alternative
for gear manufacturing because it does not emit any toxic gases due to the use of deionized water
as the dielectric (i.e., socially sustainable), consumes less power (i.e., environmentally
sustainable), and incurs less cost of dielectric, tooling, and maintenance (i.e., economically
sustainable). In this research, WSEM process has been used for net-shape manufacturing of
elliptical gears from stainless steel 304 using 250 µm diameter diffused brass wire as the tool and
deionized water as the dielectric fluid. Taguchi L9 orthogonal array approach has been used to
identify the optimum combination of WSEM process parameters namely, pulse on-time, pulse
off-time, wire tension, and wire feed rate as 2 µs; 40.5 µs; 420 g; and 2 m/minute respectively. Use
of this combination yielded maximum and average surface roughness values, and manufacturing
time as 11.73 µm, 1.67 µm, and 112 minutes respectively. Pulse-on time is found to be the most
influencing parameter for manufacturing of the elliptical gears followed by pulse-off time, wire
tension, and wire feed rate. The tribological behavior of the best quality elliptical gear
manufactured by WSEM process has been studied by conducting linear reciprocating wear tests
at an applied load of 20N, 30N, and 40N on its flank surfaces. A maximum reduction of 48.2% in
coefficient of friction has been observed at the flank surfaces of WSEM manufactured best
quality elliptical gear as compared to the gear blank surfaces. This research establishes the
WSEM process as a sustainable alternative for manufacturing good-quality elliptical gears.
Keywords: Sustainability; Elliptical Gears; WSEM; Tribological Behavior; Taguchi Orthogonal
Array
35
Session 1A: Manufacturing Processes
Vision-based monitoring of sheet metal welding process
Thierry Yonga Chuengwa
Industrial Engineering, Tshwane University of Technology, Pretoria, South
Africa
Product quality is an important aspect of industrial manufacturing operations. The
manual measurement of production parameters has increasingly created a bottleneck in
maintaining small and medium enterprises (SMEs) competitive. The main challenge in
using manual inspection to evaluate manufacturing quality is the time taken and labour
wasted. However, SMEs often encounter challenges stemming from limited resources and
technical expertise, which impede the adoption of advanced quality inspection
systems. Thus, resulting in inconsistencies in finished-product quality. Recent
advancements in the era of Industry 4.0 and sensing technology present promising solutions
for manufacturing engineers. In this scenario, the work addresses the problem of automated
visual inspection of structural weld defects. This innovation enables the effective analysis of
diverse product parameters based on functional and graphical information extracted from
images. Taking advantage of deep learning methods, the outcome of the proposed framework
is demonstrated by a case study of automatically detecting four types of industrial weld
defects. Leveraging an image-based pretrained Convolutional Neural Network (CNN)
architecture, specifically ResNet-50, along with the fc1000 extraction layer, the framework
achieves 100% classification accuracy across all target classes. This approach to quality
inspection enhances product quality through superior defect detection capabilities,
significantly reducing inspection times and increasing operational efficiency.
36
Session 1B: Manufacturing Technology and Factory Automation
IoT Device Integration on Legacy Production Systems
Kobus Vorster1, a), SJ Jacobs1, b), Wayne Rabe1, c), and Antony Douglas Smith1, d)
1Technology Station in Electronics, Faculty of Engineering and The Built Environment, Tshwane
University of Technology, 132 Staatsartillery Road, Pretoria, Gauteng, South Africa
a)Corresponding author: vorsterk1@tut.ac.za
b)jacobssj@tut.ac.za
c)rabew@tut.ac.za
d)smithad@tut.ac.za
The Internet of Things offers a valuable capability to businesses within the manufacturing sector
to obtain greater visibility of their data. This in turn improves decision making and ultimately has
an impact on the effectiveness of the manufacturing process. Many manufacturers are still
operating with legacy equipment that does not have built-in Internet of Things (IoT capabilities
and opportunities exist to develop customized hardware platforms that can act as data-gathering
points for IoT integration. This project was to assist a local electronics manufacturing company
in South Africa in implementing an IoT solution across their production facility that would give
decision-makers real-time data on products as they move through the production process. Due
to the nature of electronic manufacturing, various options had to be assessed that would not
interfere with the equipment or staff performing manufacturing operations. Custom electronic
and mechanical hardware was developed that utilised gesture-based inputs to count and upload
data to a cloud database where it could be displayed in real-time. This platform was installed and
operated for 6 months to demonstrate the data collection process on which the company could
scale up if the need arose in future. The project showed how effective the application of IoT to
legacy production systems are for companies considering implementation of a smart
manufacturing strategies.
37
Session 1B: Manufacturing Technology and Factory Automation
Increasing the accuracy of position and orientation estimates in image
processing for asymmetric prole shapes
Momina Malik 1* and Mark Gilpin1
1Durban University of Technology, Department of Mechanical Engineering, Durban, South Africa
Pick and place operations in assembly and manufacturing rely on accurately determining
component position and angular orientation. Image processing, often using the Principal
Component Analysis (PCA) method, analyses profile perimeters for this purpose. PCA calculates
a mean pixel value and determines the orientation of two principal axes of the profile. The values
are then used to determine profile characteristics of position and angular rotation. However,
using PCA alone may lead to inaccuracies in estimation of rotation angle, especially for profiles
lacking symmetry. This behaviour is readily observed and is the result of PCA using the principal
axis as a profile reference. This study highlights aspects of the PCA method and includes the
addition of a profile specific body vector for precise and consistent angular rotation
determination. The vector is established between the profile's centroid and the farthest point.
This provides direction by establishing both orientation and sense. Asymmetric 2D profile images
are analysed using the PCA algorithm from the OpenCV library, with additional Python code to
demonstrate the validity of the algorithm. The proposed method may be leveraged for the
machine assembly of stained glass or the laying of Penrose’ tiles. Identification and positioning
of laser or plasma cut profiles may be a further use case.
38
Session 1B: Manufacturing Technology and Factory Automation
The Impact of Rapid Prototyping on Modern Product Development
Kazeem Aderemi Bello1, a, Mukondeleli Grace Kanakana-Katumba2, and Rendani Wilson
Maladzhi3
1Department of Mechanical Engineering, Durban University of Technology, Durban, South Africa
2Faculty of Engineering and the Built Environment, Tshwane University of Technology, Pretoria,
South Africa
3Department of Mechanical Engineering, Durban University of Technology, Durban, South Africa
aCorresponding author: kazeemb@dut.ac.za
Rapid prototyping (RP) has emerged as a critical tool in modern product development in recent
years. This paper explores the impact of RP on the engineering industry and its influence on the
design and manufacturing processes. RP refers to the quick and cost-effective creation of
physical prototypes using computer-aided design (CAD) data. This technology has revolutionised
product development and assists engineers in iterating and refining designs faster. One
significant impact of RP is the reduction in development time. The concept of RP allows engineers
to test and validate their designs more frequently leading to faster product iterations and
ultimately shortening the time to market. RP enables engineers to identify design flaws and make
necessary modifications early in the development cycle. Additionally, RP allows for greater
design flexibility. Engineers can easily experiment with multiple design concepts and variations
evaluating their feasibility and performance. The flexibility encourages innovation and creativity
as designers are not limited to the constraints of traditional manufacturing processes. In
conclusion, PR has a profound impact on modern product development. Its ability to reduce
product development time, improve communication, enhance design validation, and increase
design flexibility makes it an invaluable tool in the engineering industry.
Keywords: Rapid prototyping, product development, product testing, short cycle time
39
Session 1B: Manufacturing Technology and Factory Automation
Revolutionizing Manufacturing Unleashing AI for Enhanced Efficiency
and Resilience
Ngaka Mosia1, a) and Kemlall Ramdass2, b)
1,2University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding author: mosian@unisa.ac.za
b) b)ramdakr@unisa.ac.za
Part design, process design, and execution are only a few of the stages that manufacturing processes
include. Traditional scientific computation and data processing techniques are important for automating
these steps, but they frequently can't solve all industrial problems. Human intervention has historically
been necessary to solve these problems, but the complexity of today's production systems is taxing
human reasoning capacity. Thankfully, a fresh wave of computational methods is beginning to surface,
providing a wider range of applications in addressing these intricate problems. This study presents an
Artificial Intelligence (AI) enhanced manufacturing model, emphasizing inefficiencies in traditional
computational methods. It then offers a range of interesting AI methods designed to tackle these issues
and a plethora of uses for resolving manufacturing-related issues. The goal of this study is to open the
door to automation that is more effective and efficient. The research adopts a qualitative research
approach to establish a framework and a guideline for transforming traditional manufacturing activities
into resilient and agile technology-enhanced processes.
Keywords: Manufacturing, Production, Automation, Computational. Artificial Intelligence.
40
Session 1C: Energy-Conscious Manufacturing and Sustainable Energy Systems
Simulation of Bulk Tanker Truck Loading Operations at a New Fly Ash
Plant: A Case of Coal Fired Power Station
Asser Letsatsi Tau 1,a), Emmanuel Innocents Edoun1, b), Nelson Sizwe Madonsela1, c) and Anup
Pradhan1, d)
1Department of Quality and Operations Management, University of Johannesburg, 55 Beit St,
Doornfontein, Johannesburg, 2028, South Africa
a) Corresponding author: lecturer.tau@gmail.com
b) eiedoun@uj.ac.za
c)nmadonsela@uj.ac.za
d) anupp@uj.ac.za
Coal is the dominant fossil fuel used during generation of electricity in South Africa contributing
to 80% of electricity generation mix. The combustion of coal results with fly ash and bottom ash
as by-products. A bulk tanker truck fly ash loading operation was studied for a new fly ash
plant. Arena simulation software was used to simulate the loading operations for current 8 hours
operations, and for suggested operating time of 24 hours and monthly operations at 22 working
days at 5 number of replication. According to the power station monthly emissions report, coal
received onsite is permitted to have a maximum of 38% ash content, meanwhile on average, the
actual monthly ash content in coal received was 28.67%. Based on the outcomes of modelling
results, it was noted that about 23, 62 and 1416 numbers of trucks can be potentially loaded at
8, 24 hours and 22 working days, respectively. At 38% maximum ash content in coal, the
estimated quantity of fly ash produced, percentage quantity of fly ash to be loaded by bulk
tanker and percentage amount of fly ash to be send to disposal site were 6 065 tons, 12.14%
and 87.86% (for current 8 hours operations); 18 195 tons, 10.90% and 89.10% (for 24 hours
operations), 564 046 tons, 8.03% and 91.97% ( for monthly operations at 22 working days) and
6.8 million tons, 7.33% and 92.67% (for yearly operations). Similar assessment was made in the
case of 28.67% average ash content in coal received at power stations where the annual fly ash
production was 5.3 million tons at 9.33% of fly ash being loaded by trucks and 90.67% fly ash
being sent to disposal sites. Full utilisation of resources was achieved. Based on these findings,
it can be noted that management of ash through usage of fly ash as a raw material in other
manufacturing processes such as cement, ready-mix concrete, brick and block as loaded by
trucks is not enough. This is because over 80% of fly ash produced still goes to approved disposal
sites. Further research needs to explore ash management strategy at power stations to further
attract fly ash utilization such as export market to neighboring countries to increase utilization.
Research on introducing another fly ash loading operations at the Power station needs to be
considered for purpose of meeting higher demand.
Key words. Fossil fuel, generation mix, coal fired power station, ash, and simulation
41
Session 1C: Energy-Conscious Manufacturing and Sustainable Energy Systems
Utilizing Kitchen and Organic Waste for Biogas Production in Multi-
Family Housing Units: Innovation, Opportunities, and Challenges
Mariam I Adeoba1, a) Thanyani Pandelani1 Harry Ngwagwa1Tracy Masebe11, 2
1UNISA Biomechanics Research Group, Department of Mechanical, Bioresources and
Biomedical Engineering, College of Science Engineering and Technology (CSET) University of
South Africa, Florida 1710, South Africa, South Africa
2Department of Life and Consumer Sciences, College of Agriculture and Environmental
Sciences, University of South Africa (UNISA), Florida 1710, South Africa
a) Corresponding author: Mariam Iyabo Adeoba 0000-0002-3392-2365
(mariamsalami@yahoo.co.uk: adeobmi@unisa.ac.za)
The growing concerns over waste management and renewable energy sources have
increased interest in biogas production from kitchen and organic waste, especially in
urban settings like multi-family housing units. This review explores the potential of utilizing
kitchen and organic waste for biogas production, focusing on innovative approaches,
opportunities, and challenges. Biogas, a renewable energy source derived from the
anaerobic digestion of organic materials, offers significant environmental benefits by
reducing greenhouse gas emissions and diverting waste from landfills. Innovations in
biogas technology, such as advanced anaerobic digesters and smart monitoring systems,
have made it feasible to implement biogas production in densely populated areas. These
technological advancements, coupled with efficient waste pre-treatment processes and
integration of compact, modular biogas plants, enable the effective conversion of organic
waste into valuable biogas and byproducts like compost. The opportunities presented by
biogas production in multi-family housing units are multifaceted. Environmentally, it
contributes to waste reduction and lowers the carbon footprint. Economically, it offers
cost savings on waste disposal and potential revenue streams from the sale of biogas and
compost. Socially, it fosters community engagement and promotes energy independence.
However, several challenges must be addressed to realize these opportunities. Technical
challenges include biogas systems' high initial setup costs, maintenance, and operational
complexities. Regulatory barriers involve obtaining necessary permits and ensuring
compliance with health and safety standards. Social and behavioral challenges, such as
community acceptance and participation, require effective education and awareness
campaigns. Addressing these challenges and leveraging the opportunities, biogas
production from the kitchen and organic waste can significantly contribute to sustainable
urban living.
Keywords: Biogas production, Kitchen waste, Organic waste, multi-family housing
42
Session 1C: Energy-Conscious Manufacturing and Sustainable Energy Systems
Integration of Advanced Fiber-Reinforced Composite Materials in Energy-
Efficient Transportation: Challenges and Opportunities
Idowu David Ibrahim1 and Stephen C Agwuncha2,3
1 Vaal University of Technology, Department of Industrial Engineering, Operations Management
and Mechanical Engineering, Andries Potgieter Blvd, Vanderbijlpark, 1900, South Africa
2 North Carolina State University, Department of Forest Biomaterials, Raleigh, USA
3 Federal University, Lokoja, Department of Industrial Chemistry, Lokoja, Nigeria
The use of advanced fiber-reinforced composite (AFRC) materials has great potential in
transforming and revolutionizing energy-efficient transportation systems across diverse modes
of mobility. The study explores the challenges and opportunities of incorporating fiber-reinforced
composite materials into vehicles' design and manufacturing processes to enhance energy
efficiency and sustainability. Using fiber-reinforced composites in the transportation sector
offers several advantages, including improved structural performance, reduced weight,
enhanced fuel efficiency, and extended battery span and range in electric vehicles (EVs).
However, several challenges must be addressed to realize the full potential benefits. These
challenges involve material development, characterization, cost-effectiveness, manufacturing
scalability, durability, and end-of-life concerns. This study highlights the significance of
interdisciplinary research in bridging the gap between material science, engineering, and
transportation design to overcome these challenges. By overcoming these challenges,
integrating advanced fiber-reinforced composite materials can open up new avenues for
developing energy-efficient transportation solutions, mitigating environmental impact, and
improving the sustainability of global transportation networks.
43
Session 2
The Royal Academy of Engineering and the SDGs: Spotlight on
Transforming Systems through Partnership
Cordelia Burch
Royal Academy of Engineering
The Royal Academy of Engineering is the UK’s national engineering academy, it is also a
charity and a fellowship organisation, bringing together over 1500 of the top engineers
from industry and academia in the UK, and a select group of international fellows.
Although we are the UK’s national academy, we have a global outlook; our mission is to
advance engineering’s contribution to a safer, inclusive, more sustainable world, tackling
the global challenges of our time.
Through our activities, we have supported research, innovation, and skills building in
more than 60 countries, funding more than £26million GBP to change makers delivering
transformative solutions.
This presentation will touch on some of the Academy’s main initiatives supporting
excellent engineers to address global challenges and contribute to the UN SDGs. There
will be a focus on the Engineering X - Transforming Systems through Partnership
programme. Running since 2015, this programme has funded 300 bilateral research
partnerships between the UK and nine countries, all working towards the SDGs. This
includes funding for a UK-South Africa collaboration on smart manufacturing and
manufacturing systems, which has led to this conference. Finally, the presentation will
mention some current international opportunities at the Academy.
44
Session 2
Innovation Ecosystems and Smart manufacturing in South Africa
Marlien Herselman
Next Generation Enterprises and Institutions, CSIR, Pretoria South Africa
The keynote aims to discuss the relationship between innovation ecosystems and smart
manufacturing, which is increasingly important in driving technological and socio-
economic growth, particularly in emerging markets like South Africa. Innovation
ecosystems involve networks where various agents collaborate and compete to foster
innovation. These ecosystems rely heavily on knowledge management to optimize
resources, contributing to both technological advancements and regional development.
Emerging technologies, including the Internet of Things (IoT), articial intelligence (AI),
and data analytics, are pivotal in advancing smart manufacturing. These technologies
enhance production through cyber-physical systems and data-driven intelligence,
fostering new opportunities for collaboration within innovation ecosystems. Smart
manufacturing practices, exemplied by the concept of smart factories, integrate these
technologies to improve processes, robotics, and digital manufacturing.
Innovation ecosystems and smart manufacturing are key to economic growth and
sustainability in South Africa. The country is striving to upgrade its traditional industries
to meet global sustainability goals, but faces challenges such as a power supply
imbalance and environmental standards. Smart manufacturing technologies, such as
automation, AI, and IoT, can help reduce energy consumption, emissions, and improve
industrial competitiveness, thereby supporting South Africa’s transition to a more
productive and sustainable economy. Examples of how innovation ecosystems can
enhance smart manufacturing will also be provided.
45
Session 3B: Energy-Conscious Manufacturing and Sustainable Energy Systems
Application of AI to Sustainable Design Strategies for Green Roofs
Combined with Biogas Systems in Urban Landscapes: Benets and
Challenges
Mariam I Adeoba1, a) Thanyani Pandelani1 Harry Ngwagwa1Tracy Masebe1,2
1UNISA Biomechanics Research Group, Department of Mechanical, Bioresources and
Biomedical Engineering, College of Science Engineering and Technology (CSET) University of
South Africa, Florida 1710, South Africa, South Africa
2Department of Life and Consumer Sciences, College of Agriculture and Environmental
Sciences, University of South Africa (UNISA), Florida 1710, South Africa
a) Corresponding author: Mariam Iyabo Adeoba 0000-0002-3392-2365
(mariamsalami@yahoo.co.uk: adeobmi@unisa.ac.za)
Urban areas are increasingly confronted with environmental and sustainability issues such as
waste management, air pollution, and energy consumption. The integration of green roofs and
biogas systems presents a unique solution to tackle these problems by combining renewable
energy production with ecological improvement. Combining green roofs and biogas systems in
urban environments offers an exceptional method to promote sustainability, tackle waste
management, and enhance energy efficiency. Applying Artificial Intelligence (AI) in this context
can improve the efficiency of design, operation, and maintenance, resulting in substantial
environmental, economic, and social advantages. This review paper examines the application of
AI to sustainable design strategies for combined green roofs and biogas systems in urban
environments, highlighting the potential benefits and obstacles. The paper utilizes collated case
studies from existing literature to delineate optimal strategies and suggestions for harnessing AI
to optimize the efficiency of these integrated systems. It discusses explicitly the system's
environmental, economic, and social advantages and the associated difficulties. By analyzing
existing literature and examining real-life examples, we can identify the most effective strategies
and offer suggestions for successful implementation.
Keywords: Green Roofs, Biogas, Articial Intelligence, Urban Sustainability, Renewable Energy,
Sustainable Design, Waste Management
46
Session 3B: Energy-Conscious Manufacturing and Sustainable Energy Systems
Towards Addressing Skills Shortage Causing Power Outage Execution
in South Africa
Thembeka Behrens1, Ilesanmi Daniyan2, Felix Ale3, Olugbenga Adegbemisola Aderoba1
Kgashane Stephen Nyakala4
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, South
Africa.
2Department of Mechatronics Engineering, Bells University of Technology, Ota, Nigeria.
3Engineering & Space Systems, National Space Research and Development Agency, Abuja,
Nigeria.
4Department of Mathematics & Statistics, Tshwane University of Technology, Pretoria, South
Africa.
Corresponding author: Ilesanmi Daniyan (afolabiilesanmi@yahoo.com)
There is a growing concern in South Africa about power outage and its effect on the economy.
This study employs a mixed method approach to probe the root causes of power outage in South
Africa. The survey was carried at company X, one of the subsidiaries of Eskom that is saddled
with the responsibilities of equipment maintenance using a structured questionnaire as the
survey instrument. The customer satisfaction scores are calculated from the feedback
periodically received from the various power stations where company X carries out maintenance
outages to obtain the customer satisfaction index which reflects the quality of the skills engaged
in the power stations. The results obtained indicated that there is a growing amount of rework
and skills shortage in the organisation. The results further show that the unavailability of the
power station units for the power generation often result in load shedding amongst other factors.
At the heart of these challenges lies the issue of the lack of the required skills to execute the
maintenance outage work. In view of these challenges, a framework is proposed for addressing
skills shortages. This work has identified the skills shortage gap and has established the root
cause of skills shortage. It has also developed a framework aimed at addressing the skills
shortage causing outage execution.
Keywords: Maintenance, Power generation, Power outage, Rework, Skills shortage
47
Session 3B: Energy-Conscious Manufacturing and Sustainable Energy Systems
Analysis of variable optimization in manufacturing: A machine learning
approach to improving operational efficiency
Rodolfo Gonzalez-Benedetto1, Philip Pe1, Raed Batbooti2, Meghana Ransing3, Grace Kanakana-
Katumba4, and Rajesh S. Ransing1*
1Department of Mechanical Engineering, Swansea University, Swansea, UK.
2Department of Mechanical Engineering, Southern Technical University, Iraq.
3p-matrix Ltd, Swansea, UK.
4Tshwane University of Technology, South Africa
This paper focuses on reducing the variability present in manufacturing techniques by using a
machine learning algorithm to identify and predict optimal operating ranges for the variables
related to the output response. Additionally, investigating how adjusting specific variables affect
the response and quantifying this influence. Focusing on a more data-driven manufacturing
practice that will foster innovation and technological advancements for the evolving market. The
landscape of modern manufacturing is increasing in complexity and competitiveness daily,
urging the need for an enhancement in efficiency and standards when optimising manufacturing
parameters - to stay up to date with the demanding global market. The application of machine
learning algorithms presents as a transformative tool for the manufacturing sector.
48
Session 4A: Cyber Security and Industrial Internet of Things
Addressing Personnel Challenges in Securing Industrial Control
Systems: Strategies and Solutions
Thobeka Sishuba1, a) and Dr Emmanuel Innocents Edoun 2, b)
1 Ph.D. student in Quality & Operations Management, University of Johannesburg,
South Africa, 2001
2 Ph.D. student supervisor, Quality & Operations Management, Engineering and the Built
Environment, University of Johannesburg , South Africa, 2001
a) Corresponding author: thobz77@gmail.com
b) eiedoun@uj.ac.za
The era of digital transformation or Industry 4.0 has come with substantial benefits for industrial
areas, including critical and vital infrastructures. These benefits include remote monitoring,
increased production, reduced downtime, and reduced errors and waste. Along with these
benefits come challenges, such as integrating information technology (IT) and operational
technology (OT) due to digital transformation, which has increased cyber incidents such as
physical attacks on infrastructure, Denial-of-Service, and ransomware attacks in the OT
network. IT manages the information, while OT controls the physical environment in business
operations. The OT network consists of industrial control systems that must be protected from
these cyber-attacks. Cyber security in the OT network is a relatively new subject compared to IT
security, and the critical priority for OT is production; this has led to challenges in securing
industrial control systems. This paper addresses personnel challenges in securing industrial
control systems; these challenges include identifying the best approach to meeting cyber
security compliance for industrial control systems, departmental silos between IT and OT
departments, and skills. The study investigates how frameworks and standards such as NIST and
IEC 62443 can deal with the personnel challenges of securing industrial control systems. A
survey conducted reveals that the main challenge for personnel working with industrial control
systems is a lack of knowledge and support in meeting cyber security compliance, departmental
silos between IT and OT departments, and a lack of skills in OT cyber security. The study
introduces the IEC 62443, NICE Framework, and NIST CSF standards and frameworks to reduce
these challenges.
Keywords: Industrial Control Systems, Operational Technology, Informational Technology,
Cybersecurity
49
Session 4A: Cyber Security and Industrial Internet of Things
Based Composites: A Zonal Analysis
Tawanda Marazani1*, a) Samson Olaitan Jeje1, b) Mxolisi Brendon Shongwe1, c) Nicholus Malatji1, d)
Daniel Makundwaneyi Madyira2, e) and Esther Titilayo Akinlabi3, f)
1Department of Chemical, Metallurgical and Materials Engineering, Tshwane University of
Technology, P.O. Box X680, Pretoria, South Africa.
2Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park
Kingsway Campus, Johannesburg, 2006, South Africa.
3Faculty of Engineering and Environment, Northumbria University, Newcastle, United Kingdom.
a) Corresponding author: tmtmarazani@gmail.com
b)JejeSO@tut.ac.za
c)ShongweMB@tut.ac.za
d)MalatjiN@tut.ac.za
e)dmadyira@uj.ac.za
f)etakinlabi@gmail.com
The use of different tool pin profiles for friction stir processing is a common practise. Generally,
the pin is responsible for material breaking, initial heating, mixing and transportation. Attainment
of different zonal features by different pin profiles is therefore highly expected. The present work
utilized H13 tool steel tools with square (SQ), cylindrical threaded (CT) and taper threaded (TT)
pin profiles of sides 7×7 mm, diameter 7 mm, and 7 mm major diameter and 5 mm minor
diameter respectively, all being 5 mm in length, with a common shoulder diameter of 21 mm. The
study sought to map the stir zone (SZ), thermo-mechanically affected zone (TMAZ), and the heat
affected zone (HAZ) geometrical, macrostructural and microstructural features. The SZ widths
attained by the pins were 9.433 mm for the CT pin, 10.185 mm for the TT pin and 10.34 mm for
the SQ pin. The attained TMAZ thickness for the CT and TT pins were 0.568 mm and 0.214 mm,
while the SQ pin had no visible TMAZ. The CT, TT, and SQ pins had particle sizes of 17-88 µm, 23-
135 µm, and 9-73 µm respectively. The macrostructural and microstructural results revealed
fingerprint or onion ring features for the TT and CT pins, with pronounced zonal features, while
the SQ pin had no visible onion rings and zonal features. The obtained results show the capability
of the CT and TT pins to severely stir and mix the matrix with the reinforcements better than the
SQ pin, which on the other hand attained the best grain refinement.
50
Session 4A: Cyber Security and Industrial Internet of Things
Cyber Security Standards for Applying The "Defense-in-Depth
Approach" For Industrial Control Systems
Thobeka Sishuba1, a) and Dr Emmanuel Innocents Edoun 2, b)
1 Ph.D. student in Quality & Operations Management, University of Johannesburg,
South Africa, 2001
2 Ph.D. student supervisor, Quality & Operations Management, Engineering and the Built
Environment, University of Johannesburg, South Africa, 2001
a) Corresponding author: thobz77@gmail.com
b) eiedoun@uj.ac.za
Industry 4.0, or digital transformation, has led to the convergence of Information Technology (IT)
and Operational Technology (OT). Due to the convergence of IT and OT, cyber security incidents
that were previously only found in the IT network are now affecting industrial control systems
found in the OT network. Industrial control systems (ICS) are critical to the OT network as they
are responsible for production. Apart from the loss of output and data, the risk of cyber security
incidents in the OT network has more devasting outcomes as these cyber-attacks can affect the
safety of personnel with the possibility of death. The Defense-in-Depth (DiD) approach is a
strategy used in IT networks to implement multiple layers of security to reduce cyber risks in the
IT network. This paper investigates how the DiD approach can be implemented using existing OT
or ICS cyber security standards in OT networks. This study will examine whether the DiD
approach is good enough for the OT network.
Keywords: Industrial Control systems, Defence in Depth Approach, Cyber security, Standards
51
Session 4B: Innovative Engineering Management
AI-driven rootcause analysis utilising FMEA based knowledge graphs
Ollie Rees1, Philip Pe1, Meghana Ransing1,2, Grace Kanakana-Katumba3, and Rajesh S. Ransing
1Department of Mechanical Engineering, Swansea University, Swansea, UK.
2p-matrix Ltd, Swansea, UK.
3Tshwane University of Technology, South Africa
This paper explores the integration of Root Cause Analysis (RCA) and Knowledge Management
(KM) within the framework of Failure Mode and Effects Analysis (FMEA)-based AI-driven digital
twin technology, to enhance business processes and minimise risks in manufacturing.
Highlighting the application of classic RCA techniques such as the "5 Whys" and Ishikawa
analysis in tandem with AI capabilities to pinpoint failure origins accurately. The study
emphasises the significance of creating a comprehensive knowledge repository through process
work elements (PWE) and enriched functions, enabled by AI technologies such as Large
Language Models (LLMs) and vector embeddings. These technologies not only facilitate the
centralisation of knowledge storages but also significantly enhancing search capabilities and
data retrieval speed. By deploying a detailed case study, this paper demonstrates the practical
benefits of merging AI-driven digital twins with traditional RCA and KM practices, presenting a
pathway towards improved operational efficiency and a competitive advantage in today’s
contemporary manufacturing landscape.
Keywords: Artificial intelligence; root cause analysis; FMEA; knowledge graph; large language
model; vector embedding
52
Session 4B: Innovative Engineering Management
GPT- 4.0 assisted generation of PFMEA process step & process work
element functions
Philip Pe1, Meghana Ransing1, Aditya Parkhi3, Grace Kanakana-Katumba4, and Rajesh Ransing1
1Department of Mechanical Engineering, Swansea University, Swansea, UK.
2p-matrix Ltd, Swansea, UK.
3Department of Biomedical Engineering, Indian Institute of Technology, Jodhpur, India
4Tshwane University of Technology, South Africa
Existing Failure Mode and Effects Analysis (FMEA) documents have information on process step
name, failure modes and rootcauses. However, process step (PS) function and process work
element (PWE) functions are not normally defined as per recent VDA-AIAG guidelines. This
research paper explores the role of generative AI models such as GPT-4o, by taking inputs such
as multiple failure modes and root causes for each process step name to generate Process Step
(PS) functions and Process Work Element (PWE) functions. Utilising this information, GPT-4o
updates failure modes if necessary and predicts detection controls for PS functions, as well as
detection and prevention controls for PWE functions, forming a comprehensive pipeline of step-
by-step interactions. The paper demonstrates the implementation of this pipeline on two FMEA
sheets used as case studies: a polymerisation process and a machining process involving a 5-
axis precision drilling machine, showcasing the efficient conversion from the old format to the
new guidelines using self-designed prompts. Users have access to these prompts, allowing them
to input their own data and generate their own results. This approach is particularly beneficial for
process and quality engineers who have limited time, as it significantly reduces the effort
required for FMEA updates as it provides them with a practical and time-saving solution for
maintaining high-quality standards.
Keywords: Generative AI, FMEA, Quality Control, Risk Management, 7Epsilon.
53
Session 4B: Innovative Engineering Management
Work measurement analysis: A survey of literature
Emmanuel Basitere1, Felix Ale2, Ilesanmi Daniyan3, Adefemi Adeodu4, Thokozani Hlatshwayo1
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, South
Africa.
2Engineering & Space Systems, National Space Research and Development Agency, Abuja,
Nigeria.
3Department of Mechatronics Engineering, Bells University of Technology, Ota, Nigeria.
4Department of Project Management, Bells University of Technology, Ota, Nigeria.
Corresponding author: Ilesanmi Daniyan (afolabiilesanmi@yahoo.com)
There are many techniques involved in measuring work, especially in the current digital world.
These include using educated guesses, stopwatches and applying predetermined time
standards. Regardless of the selected technique, it is essential to implement the procedure
correctly to improve work efficiency. This study conducts a literature review on work
measurement analysis. A total number of 80 articles were initially obtained using different search
engines but only 22 articles were reviewed due to their relevance to the topic. The findings show
the Modular Arrangement of Predetermined Time Standard (MODAPTS) is an effective method of
conducting work measurement, which is due to its minimalistic coding mechanism and
framework when compared with other time standards for instance Methods Time Measurement
(MTM), Maynard Operations Sequence Technique (MOST). MODAPTS can be applied in many
industries and its methodology can be extended to analyse supporting factors such as
ergonomics, fine and gross motor skills.
Keywords: MODAPTS, MOST, MTM, Time Standards, Work measurement
54
Session 4C: Smart Mobility and Sustainable Transportation
Investigating the Constraints Associated with Running Traffic Control
Systems Effectively at Signalized Intersections
Zanele Mpanza 1, Robert Mutyavavire2
1Department of Industrial & Engineering Management, University of South Africa, South Africa
2Department of Mechanical & Industrial Engineering, University of Johannesburg, South Africa
Intersections are a critical element of a road section. They are critical locations in the road
network in terms of capacity, level of service and safety. In intersections, opposing streams of
traffic compete for space and time and road users are required to use the same space.
Controlling the order in which the traffic streams from the opposing directions interact becomes
imperative to reduce conflict between vehicles and other traffic; including pedestrians and
cyclists, to improve the traffic handling capability or capacity of the road network, to enable the
pedestrians to cross the road safely, and to reduce delay and stops to side road. Different traffic
control types and technologies were implemented in South Africa but were “switched off” at
some point. This study investigates the constraints associated with running traffic control
systems effectively at signalized intersections in South Africa.
55
Session 4C: Smart Mobility and Sustainable Transportation
Smart Mobility Innovations and Solar Energy Toward Sustainable
Transportation
Christiaan Oosthuizen 1,a) and Kyle Brand 2,b) and David Richards 3,c) and Andrew Cruden 3,d)
1Department of Mechanical and Mechatronics Engineering, Tshwane University of Technology,
Pretoria, 0183, South Africa
2Department of Architecture and Industrial Design, Tshwane University of Technology, Pretoria,
0183, South Africa
3School of engineering, University of Southampton, Southampton, SO17 1BJ, United Kingdom
a)oosthuizencc@tut.ac.za
a) Corresponding author: brandkg@tut.ac.za
c) djr@soton.ac.uk
d) a.j.cruden@soton.ac.uk
The adoption of Solar Electric Vehicles (SEVs) for everyday use is becoming more feasible due to
advancements in lightweight material composites and the increasing efficiency of photovoltaic
panels (per unit surface area). This is particularly true in regions with high annual solar irradiance,
such as South Africa. The integration of Internet of Things (IoT) devices enables these vehicles to
connect to the Internet, providing drivers with critical information services like weather updates,
traffic conditions, drivable range, and various vehicle safety system alerts. By embedding
sensors throughout the vehicle, researchers can perform data analytics using both machine
learning and analytical modelling to enhance driver safety and vehicle performance and conduct
preventative failure analysis. The solar vehicle team at Tshwane University of Technology is
developing such a technology platform and aims to have a skeletal “rolling chassis” by the end
of 2024. This will demonstrate the feasibility of a multi-seater solar electric vehicle for smart
mobility and sustainable transport, with the capability to participate in local events and meet
homologation standards for regular road use.
56
Session 4C: Smart Mobility and Sustainable Transportation
An in-depth analysis of electric vehicle technology, charging
infrastructure, and grid stability
Adeniyi Kehinde Onaolapo1, * and Bolanle Tolulope Abe2
1,2Electrical Engineering Department, Tshwane University of Technology, Witbank, 1034, South
Africa
1Corresponding author: adeniyi.onaolapo@egmail.com
2btabe@tut.ac.za
Abstract. An extremely efficient method for reducing dependence on fossil fuels and greenhouse
gas emissions is using Electric vehicles (EVs). Notwithstanding, restricted driving range, high
initial cost, lack of or insufficient charging infrastructure, battery technology constraints,
overloaded power grids, and insufficient rare earth metals required for EV infrastructures are the
challenges associated with EV technology. Currently, there has been much research on the
charging infrastructure as a major driver of EV technology. This research investigates the charging
infrastructure in islanded, grid-connected, and hybrid modes. Microgrid architectures of
charging stations and charging methods are also explored to improve EV efficiency and lifespan.
The impact of EV charging on the grid is assessed to improve grid reliability and prevent the grid
from collapsing.
57
Session 5A: Virtual Session
Embedding Project-Based Learning and Design Thinking in Engineering
Curricula: A Review
Lebogang Bopape1
Department of Electronic and Computer Engineering, Durban University of Technology, South
Africa
Corresponding author: lebogangb@dut.ac.za
This paper reviews the integration of Project-Based Learning (PBL) and Design Thinking (DT) in
engineering education, emphasizing their role in enhancing student engagement, creativity, and
practical problem-solving skills. Through a comprehensive review of academic literature, the
study identies how these pedagogical approaches foster innovation and better prepare
students for real-world engineering challenges. The paper also addresses the challenges in
implementing these methodologies, including the need for faculty training, resource limitations,
and institutional support. Recommendations are provided to overcome these obstacles,
focusing on interdisciplinary collaboration, continuous evaluation, and leveraging industry
partnerships. The review concludes that the strategic implementation of PBL and DT can
signicantly enhance the quality of engineering education, equipping students with the
competencies needed for future engineering careers.
Keywords: Design Thinking, Engineering Education, Project Based Learning, Student
Engagement.
58
Session 5A: Virtual Session
Application of FMEA Techniques to Improve Plant Maintenance
Strategy: A Case Study on a Metal Granulation Plant
Peter Muganyi 1, Tebello Ntsiki Don Mathaba 1, and Lebogang. Relela2
1Department of Post Graduate Studies, University of Johannesburg, Johannesburg, 2028, South
Africa
2Postgraduate School of Engineering Management, Faculty of Engineering and the Built
Environment, University of Johannesburg, Johannesburg 2028, South Africa
The improved process plants reliability plays an important role in ensuring that organizations can
meet their targets. However, the designs of these plants have become complex over years, by
introducing automation and less labour-intensive systems. Equipment maintenance is therefore
essential to maintaining effective plants. This study incorporates the use of operational data,
literature review, equipment manuals and subject matter experts’ inputs into Failure Mode and
Effect Analysis (FMEA) method to identify and prioritise critical failures. The research focused on
the metal granulation plant case study by quantifying the Occurrence (O), Detectability (D),
Severity (S) of potential failure modes, and the associated Risk priority number (RPN). The highest
priority failures were drawn from the results. In addition, the suitable maintenance strategies
were proposed for such failures. This research gives insight of critical failures pertaining to the
granulation plant for the metal industry. The application of FMEA offered an opportunity to utilize
the existing maintenance data to examine the current equipment performance and identification
improvements.
59
Session 5A: Virtual Session
Feasibility Study of Sugarcane Bagasse-Based Composites as
Sustainable Polymer Alternatives
Devarakonda Harish Kumar1, a)
1Meachnial Engineering Department, Associate professor, Wollega university, Ethiopia
a)*Corresponding Author: dharishkumar03@gmail.com
The increasing interest in composites stems from their remarkable attributes, including
durability, affordability, and their potential to replace conventional engineering materials. This
paper delves into the exploration of a novel composite material comprising a blend of
biodegradable polymers and natural fibers, with a particular focus on sugarcane bagasse fiber.
Unlike traditional polymer composites, this composite offers a sustainable alternative, mitigating
the adverse environmental impacts associated with plastics. By leveraging the mechanical and
chemical properties of sugarcane bagasse fiber and ABS (Acrylonitrile butadiene styrene), our
research aims to develop a composite material that exhibits comparable qualities to plastic. The
investigation delves into the mechanical characteristics, including tensile strength, of sugarcane
bagasse fiber, as well as the mechanical properties of bagasse fiber reinforced with ABS. Through
the compression molding technique, fabricated composite materials with varying fiber volume
fractions ranging from 40% to 50% and curing temperatures ranging from 120°C to 140°C. The
evaluation of tensile strength revealed promising results, with an average strength of 40 MPa
observed at a 50% fiber volume fraction and 125°C curing temperature. Furthermore, the study
highlights the superiority of bagasse/ABS composites over bagasse fiber alone, indicating the
potential for their application instead of polymer composites. These findings underscore the
viability of sugarcane bagasse fiber as a raw material for commercial applications.
Keywords: Acrylonitrile butadiene styrene, mechanical properties, natural material, Sugarcane
Bagasse, Tensile strength.
Theme: Energy-Conscious Manufacturing and Sustainable Energy Systems
60
Session 5A: Virtual Session
Policy Considerations and Recommendations for Renewable Energy
Generation from Waste (ReGen) and Green Growth Technology in West
Africa
Opeyemi Amusan1,2, a) and Charles Mbohwa1, b)
1University of South Africa, Mechanical Engineering Department, Sustainability Engineering
and Future Technologies (SEFT), CSET, P.O. Box 392, UNISA 0003, South Africa.
2Development Impact West Africa - Waste and Bio Recycling Associates League WABRAL - C12
Intercontinental,
Amiesol Resources Konsult / Mechanical Engineering - CPEEL University of Ibadan (UI),
P.O. Box 23039 UI Post,Ibadan, Nigeria
a) Corresponding author: amusanopeyemi@yahoo.com;
b)mbohwc@unisa.ac.za
Increasing waste, population and urbanisation among scarce resources informed this research
to evaluate the potential impact of managing waste using waste-to-energy-recovery-generation
(ReGen) technology in Nigeria, and how waste-to-energy (WtE), environmental quality (EQ), and
sustainable development (SD) are related. This brief presents the literature reviewed in
summary, ReGen design concept-note, and policy considerations and recommendations of this
climate-environment-friendly (ReGen Technology) development in Nigeria. Theoretical
framework used was Environmental Kuznets Curve. Data on indicators of WtE in Nigeria were
sourced from the World Development Indicators (1981-2017). Secondary series methodology
described as Autoregressive Distributive Lag was used to estimate he short and long run
relationships among WtE, EQ, and SD. Techno-economic viability of ReGen was evaluated with
Cost Benefit Analysis. Literature were reviewed for some theories and empirical findings on WtE
development and its relationship with EQ and SD globally. Proceeding to the review of theories
of the structural change models, after which the empiric of previous studies on the subject
matter were reviewed. A table was used to summarize the theoretical and empirical review.
ReGen generating cost was $0.71/kWh with 6-8years payback period and better environmental-
socioeconomic benefits than equivalent diesel generators. ReGen reduce waste by 90.0% with
332kW net-energy-output from 980kg waste/hour. Successful ReGen development in Nigeria
requires good financial investment, information and understanding of future change, knowledge
about adaptation options, and the capacity to implement the most suitable interventions
nationally. The following policy considerations and recommendations will address such
concerns and will foster sustainable development of ReGe-technology in Nigeria and Africa:
(1.)Establish Tech-Funds/Financial Instruments for ReGen; (2.)Incorporate Coping Mechanisms;
(3.)Diversify into Circular Economy; (4.)Enforce Polluters-Pay-Principle; (5.)Enforce Sustainable
Waste and Energy Recovery Management; (6.)Invest in Food-Water-Energy Nexus Research and
Development; (7.)Adopt Renewable Technology Incentives; (8.)Implement Climate Smart Energy
Recovery Concept; and (9.)Develop and Implement a National Waste-to-Energy Strategy. For
effectiveness, appropriate technologies like waste-to-energy recovery generation must be
climate and environment friendly, covering all the waste management value-chain. Policies that
would facilitate a de-carbonized energy transition, unlock waste waste potentials and enhance
its sustainability through circular economy are also recommended. Government should provide
enabling environment for increased investment in waste-to-energy-recovery-generation.
Keywords: Circular economy, Climate protection, Green environment, Nigeria, Waste-to-Energy
recovery generation.
61
Session 5A: Virtual Session
Articial Intelligence Overview for Optimizing Production Scheduling in
a Picture Framing Company
Jadwiga Krupnik-Worek1, a), Sebastian Skoczypiec1 and Jacek Habel1
1 Tadeusz Kosciuszko Cracow University of Technology, Faculty of Mechanical Engineering,
Chair of Production Engineering, al. Jana Pawla II 37, 31-864, Krakow, Poland.
a) Corresponding author: jadwiga.krupnik-worek@doktorant.pk.edu.pl
Artificial Intelligence (AI) is dynamically transforming manufacturing, impacting warehouse
planning, production management, operations and logistics. The article provides an overview of
AI applications in these areas, using examples from different industries. In warehouse planning,
AI optimises inventory placement, automates processes and enables predictive infrastructure
maintenance. In production management, AI optimises schedules, predicts machine failures
and personalises products. AI improves operations management by analysing sensor data to
predict failures and schedule maintenance. In logistics, AI optimises transport routes,
automates shipping processes and manages inventory. This paper addresses the scheduling
problem using established methods, including priority rules, complete search and genetic
algorithms. These methods have been implemented in the program and tested on data from a
picture framing company, which is characterised by individual, make-to-order production. The
quality of the schedule was determined using the criterion of minimising the makespan. Since
time is a crucial factor in production, the time needed for the program to solve the problem using
the chosen method was also compared. The results demonstrate that the genetic algorithm
consistently outperformed the complete search method in terms of minimising the makespan.
Although both approaches provided optimal solutions, the genetic algorithm executed the
scheduling task for 70 orders on 10 machines in just over 500 ms, showcasing a significant
reduction in computational time compared to the complete search. This efficiency is particularly
advantageous when dealing with larger problem sizes, where the complete search becomes
computationally prohibitive.
62
Session 5A: Virtual Session
Energy Efficiency Amelioration Endeavours in a Commercial Building
Peter Muganyi1, Tebello Ntsiki Don Mathaba1 and Nelson Sizwe Madonsela 2
1Department of Post Graduate Studies, University of Johannesburg, Johannesburg, 2028,
South Africa
2Department of Quality and Operations Management, Faculty of Engineering and the Built
Environment, University of Johannesburg, Johannesburg 2028, South Africa
Worldwide, buildings are numerous and it comes as no surprise that around 40% of primary
energy requirements in South Africa, the EU and other regions is attributed to buildings. Many
nations have promulgated legislative directives aimed at energy efficiency amelioration, and
these encompass African, European, Asian and American countries. Energy efficiency
amelioration initiatives take different approaches, which may be influenced by factors such as
prevailing climatic conditions, building architecture and the equipment in use in the building.
Literature is awash with energy efficiency amelioration endeavours that capitalize on the likes of
the application of appropriate insulation and glazing systems, lighting initiatives, architectural
and equipment modifications, and all these being paramount to energy efficient buildings.
Contemporary structures as influenced by prevailing architectural standards incorporate
buildings that may be visually disconnected with the exterior, centred on the option of
substituting natural lighting and heating/cooling for artificial options even during the day. This
has culminated in retrofitting endeavours being undertaken to heighten the overall energy
efficiency of buildings.
Keywords: energy, efficiency, retrofit
63
Session 5B: Innovative Engineering Management
Embracing the Future of Manufacturing
(Integrating Cyber-Physical Systems in Manufacturing)
Ngaka Mosia1, a)
1,2University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding authosr: mosian@unisa.ac.za, b)ramdakr@unisa.ac.za
The integration of cyber-physical systems (CPS) in manufacturing has emerged as a pivotal
research area, promising to revolutionize traditional industrial practices. This research delves
into the integration, challenges, and future perspectives of CPS in manufacturing. Focusing on
intelligent factory automation, real-time data analytics, and their impact on manufacturing
efficiency and sustainability. Integrating CPS involves merging physical machinery with
intelligent software systems, enabling real-time data exchange and decision-making. Challenges
such as interoperability, cybersecurity, and workforce readiness hinder seamless integration.
However, future perspectives are promising, with CPS driving automation, optimization, and
sustainability across the manufacturing value chain. Real-time data analytics will facilitate
predictive maintenance and customization, while digital twins will revolutionize product
development. Addressing these challenges and harnessing the potential of CPS in
manufacturing requires collaboration among industry stakeholders and academia. Embracing
CPS not only augments competitiveness but also paves the way for a more resilient and
sustainable manufacturing ecosystem. The research report adopts a qualitative approach to
explore and explain the integration of CPS in manufacturing. The output of the research report is
a thought paper that explores the integration of CPS in manufacturing, addressing the pros and
cons of CPS, and offering insights into future perspectives and areas of further research.
Keywords: CPS, Manufacturing, Industrial, Automation, Factory.
64
Session 5B: Innovative Engineering Management
Assessment of Factors Aecting Project Quality in the Construction of
Telecommunication Towers
Adelegan Adeyeri Adewumi1, a, Emmanuel Emem-Obong Agbenyeku2, b, Takalani Musundwa
Tshabalala1, c and Nelson Siswe Madonsela1, d
1Department of Quality and Operations Management, University of Johannesburg, South Africa
2Department of Construction Management, University of Johannesburg, South Africa.
a)adeyarey@gmail.com
b)emmaa@uj.ac.za
c)tnemarumane@uj.ac.za
d)nmadonsela@uj.ac.za
The telecommunication tower is an important infrastructure in the promotion of the evolved
industrial revolution by accommodating the hardware required for eective communication in
this era, connecting people and sharing data through improved quality tower construction to
reduce safety and failure-related issues that arise. Plummeting telecommunication tower
construction failure has now become imperative for construction sustainability, communication
eectiveness and overall safety reasons. Hence, this study aimed to identify associated quality
factors that impact the telecommunication tower construction stability, safety and improved
planned life cycle. The study was conducted in the Gauteng province of South Africa using
exploratory and conrmatory factors analyses. The results revealed that major factors aecting
the construction of telecommunication towers are associated with humans (the project people
- stakeholders). The objective was satised by establishing that factors that aect the project
quality of telecommunication towers are associated with the construction stakeholders – the
client, contractors and suppliers’ attitude and commitment to the project plans. The outcome
also mentioned geotechnical and structural issues that need to be taken care of to achieve
project success with an emphasis on poor concrete reinforcement and weakness of concrete
mix and curing processes. The client was found to aect construction project quality more by
making changes to plans and lacking adequate provisions for structural maintenance after
commissioning. The contractors were majorly not following the due processes especially in the
selection of suppliers and not practicing eicient communication with the client and other
project stakeholders.
Keywords: Construction Quality; Telecommunication Tower; Construction Sustainability; Tower
Quality.
65
Session 5B: Innovative Engineering Management
Integration of E-Mobility Technologies into Engineering Curricula
Through Project-Based Learning: A Case study
Grace Kanakana-Katumba1), Rouxzeta Van der Merwe1, a), Tabbi Wilberforce2) and Thierry Chuengwa1
1Tshwane University of Technology (SOUTH AFRICA)
2College London (UNITED KINGDOM)\
a) Corresponding author: VandermerweR1@tut.ac.za
The urgent need for clean energy and reduction of carbon emissions has spurred innovative technologies
in the automotive industry, with E-Mobility Technologies (EMT) being one of the most signicant
advancements. This shift towards EMT has revolutionised the automotive sector and highlighted a critical
skills gap in EMT that must be addressed to sustain global EMT adoption. EMT relies on electric
powertrains, including batteries, motors, and power electronics. The novelty of these components
necessitates a workforce skilled in their design, manufacturing, and maintenance. Addressing this gap is
essential for the sustained growth of the EMT market. Hence, this study examines the benets of
integrating EMT into engineering curricula through the use of project-based Learning, using Tshwane
University of technology’s (TUT) faculty of engineering and the built environment, as case study. The
progressive focusing methodology was used to achieve the aim of this study. This methodology required
that the study is started with no prior assumptions, then the gathering of data, updating of data, correcting
etc. The results obtained indicated that students developed better communication skills, capacity for
teamwork, problem-solving skills, and project management skills. Furthermore, the study underscored
the potential for industry-academia collaboration in curriculum development. It was therefore
recommended that partnerships with automotive companies and technology rms will provide TUT
students access to cutting-edge resources and real-world applications during their learning.
Keywords: Project-based Learning, Electric Vehicle, Engineering Curricula, Sustainable development
goals
66
Session 5B: Innovative Engineering Management
Development of an Agile Supply Chain Network Model
Ngaka Mosia1, a) Zanele Mpanza2, b)
1,2University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding author: mosian@unisa.ac.za, b)mpanzzp@unisa.ac.za
The increasing global interconnectedness and inter-dependency demands a dynamic
technological innovation process for Supply Chain Management (SCM). Technology brings
a new evolution that requires a different type of analysis and a management process. This
new paradigm is a technology-driven model integrating supply chain management
activities and manufacturing. The paradigm comprises the original two-way
communication between the original three tenants of a supply chain. This research
addresses the increasing global interconnectedness and interdependency by developing
a theoretical adaptive and responsive supply chain model for manufacturing SCM
systems. The objective is to explore and explain how a technology-driven paradigm can
enhance supply chain management by integrating traditional supply chain elements
(suppliers, manufacturing, and customers) with modern components such as high-speed
technology, the Internet of Things (IoT), and big data, in an external environmental factor
paradigm (PESTE). Through a qualitative research approach, this study seeks to establish
a model that improves the supply chain’s ability to adapt to dynamic changes in demand,
ensuring greater responsiveness and efficiency in manufacturing supply chain
management systems.
Keywords: SCM; Purchasing; Technology; Procurement; Manufacturing
67
Session 5B: Innovative Engineering Management
Evaluating Technical Proficiency and Adoption Trends of Innovative
Building Technologies in South African Homebuilding: A Critical Path
and Gap Analysis Approach
1Thokozani Hlatshwayo, 2Ilesanmi Daniyan*, 3Kemlall Ramdass, 3Humbulani Simon Phuluwa
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, South Africa.
2Department of Mechatronics Engineering, Bells University of Technology, Ota, Nigeria.
3Department of Industrial Engineering & Engineering Management, University of South Africa, South
Africa.
*Corresponding author: Ilesanmi Daniyan (afolabiilesanmi@yahoo.com)
This study evaluates the technical proficiency of homebuilders and adoption trends of innovative building
technologies (IBTs) in the South African homebuilding industry using a Critical Path Method (CPM) and
gap analysis approach. Using secondary data from scholarly publications, industry reports, and
government publications, the study conducted a thorough desktop analysis comparing present practices
against accepted technical norms. Results show notable differences in technical competency between
urban and rural homebuilders; urban areas show higher levels of competency because of better
availability to tools and training. Driven by aspects including financial constraints, legal obstacles, and
labour skills, the trend study shows a rising but unequal acceptance of IBTs. The gap analysis exposes
significant problems with digital infrastructure, workforce development, and resource allocation,
therefore preventing the effective integration of IBTs. Among the suggestions for business people aimed
to increase technical knowledge and increase IBT adoption are policy reforms, financial incentives, and
targeted training programmes. The study underscores the need for continuous professional development
as well as of longitudinal research to track development and manage fresh challenges. These disclosures
aim to encourage sustainable expansion of the homebuilding industry in South Africa by highlighting a
more technologically advanced and competent construction sector.
Keywords: Construction management, Critical path method, Gap analysis, Homebuilding, Innovative
building technologies, Technical proficiency
68
Session 6: Virtual Session
Exploration of the relationships between composition and properties
of a nickel-based brazing alloy using experimental and thermodynamic
simulations
Samuel Ross 1, Daniel Butcher1, Shahin Mehraban1, Peter Cookson2, Caroline Goddard2, and
Nicholas Lavery1
1 Swansea University, MACH 1, Faculty of Science and Engineering, Swansea, United Kingdom
2 Reaction Engines Ltd, Building F5, Culham Science Centre, Abingdon, Oxon, OX14 3DB,
United Kingdom
Nickel based llers are used extensively to vacuum braze high temperature nickel, steel and
cobalt alloys for components in applications such as lightweight compact heat exchangers in
advanced aeroengines. An example of these llers is the BNi 2 brazing ller from the NicoBraze®
family which is based on a 5-element system (Ni-Cr-B-Si-Fe). This research takes a combinatorial
approach to the baseline composition of BNi 2 with the aim of getting a better understanding of
what each element contributes to the mechanical properties at a specic target brazing
temperature. From a preliminary large set of elemental combinations, a smaller number of
optimal compositions are down selected for further mechanical testing by considering measured
properties including solidus, liquidus and micro-hardness. Alongside this, ThermoCalc
simulations were carried out to validate the eectiveness of using greater computational
methods in brazing alloy design and optimisation of processing temperatures for tailored
properties.
69
Session 6: Virtual Session
Sustainable Food-Energy-Waste Nexus Enhancement with Renewable
Energy Recovery System in Africa
Opeyemi Amusan1,2, a)
1University of South Africa, Mechanical Engineering Department, Sustainability Engineering and
Future
Technologies (SEFT), CSET, P.O. Box 392, UNISA 0003, South Africa.
2Development Impact West Africa - Waste and Bio Recycling Associates League WABRAL - C12
Intercontinental,
Amiesol Resources Konsult / Mechanical Engineering - CPEEL University of Ibadan (UI),
P.O. Box 23039 UI Post, Ibadan, Nigeria
a) Corresponding author: amusanopeyemi@yahoo.com
The need to enhance the food-energy-waste nexus in Africa cannot be over-emphasized. A major
uptake has occurred in the last decade in various forms of renewable energy as a viable
commercial alternative to the common fossilfuel-based energy generation. Water can be
substituted for petroleum fuels and/or coal in energy recovery generation from waste materials
which are readily available and even problematic in many rural and semi-urban settlements
worldwide. The recycling nature of this water-run renewable energy system makes it
simultaneously solve the problems of waste pollution and electricity generation with a low
carbon footprint from fossil-fuel substitution, with major contribution to a sustainable and food-
energy-waste nexus. Its independence from uctuating fossil fuel prices makes it economical
and exible with the possibility of hybridization for peak demand from its reliable base load
supply. While some countries in other continents: Europe, North America, Australia, Asia, and
South America have used this emerging clean climate-friendly technology, Africa the most
vulnerable to climate change is yet to adopt this renewable power generation. This study details
the design methods or features, environmental implications, resource conservation, and
investment analysis for this redeployable energy generation (ReGen). Within this decade, there
are new investments in renewable energy by over 25% increase by the end of 2023, with many
countries now coming to clearly understand the benets of utilizing renewable energy as a
source of meeting o-grid and distributed demand. The study revealed some special features of
this ReGen power system as; redeployable, robust multi-fuel grates, low-pressure operation (5
bar) through ORC system, low water consumption and high reliability, with on/o-grid power
supply application. The theory of change for the food-energy-waste nexus, and the sustainable
development goals achieved, was also analysed. A comparable analysis shows that ReGen
electricity business is protable economically and environmentally. Since ReGen power-
systems facilitate alternative energy supplies to both households and industries, enhance
circular economy growth and improve food-resource eiciency, a national Waste-to-Energy
Strategy should be collaboratively developed and implemented by relevant Stakeholders in
Africa to accelerate access to sustainable food, energy and environment for all.
70
Session 6: Virtual Session
Renewable Energy Utilization in the Manufacturing Sector: Benefits,
Challenges, and Solutions
Omojola Awogbemi1, Kazeem Aderemi Bello2, a, Ayodeji Usman Akerele3, Mukondeleli Grace
Kanakana-Katumba4, and Rendani Wilson Maladzhi5
1Department of Mechanical Engineering, Ekiti State University, Ado Ekiti, Nigeria
2Department of Mechanical Engineering, Durban University of Technology, Durban, South Africa
3Institute of Energy, Ceramic and Polymer Technology, Faculty of Materials and Chemical
Engineering, University of Miskolc, Miskolc 3515, Hungary
4Faculty of Engineering and the Built Environment, Tshwane University of Technology, Pretoria,
South Africa
5Department of Mechanical Engineering, Durban University of Technology, Durban, South Africa
aCorresponding author: kazeemb@dut.ac.za
The global energy setting has been dominated by fossil-based (FB) energy sources, over the past
few decades, resulting in the emission of unwanted gases and the escalation of climate change.
The continued reliance on FB energy sources to power the manufacturing sector escalates
dangerous emissions impacts energy security, contaminates ecosystems, and is unsustainable.
To reverse this trend, concerted efforts are needed to significantly increase the share of
renewable energy (RE) in the manufacturing sector. The study highlights the benefits derivable in
RE integration in the manufacturing sector, interrogates the challenges hindering the effective
and efficient use of RE technologies in manufacturing operations, and proffers implementable
prospects for RE integration in the manufacturing sector. The benefits of the integration of RE in
the manufacturing sector include energy cost reduction, environmental sustainability,
emissions reduction, and employment generation. For these benefits to be feasible, the
identified technical, economic, regulatory, lack of government support and incentives, and weak
advocacy and awareness must be confronted. The study recommends forming and
strengthening strategic partnerships, employing appropriate energy storage infrastructure,
onsite energy generation, adopting energy-efficient measures, and using customized microgrid
energy systems to facilitate timely RE integration in the manufacturing sector towards achieving
sustainable manufacturing.
Keywords. Renewable Energy, Manufacturing sector, Bioenergy, Hydropower, Emissions
reduction, Sustainable manufacturing
71
Session 6: Virtual Session
Effect of industry 4.0 on social and environmental sustainability in
multinational manufacturing industries
Olufemi A. Oroye1, a) and Joseph E. Egbekun2, b)
1, 2 Management Technology Department, Bells University of Technology Ota, Ogun State Nigeria
a) Corresponding author: oaoroye@bellsuniversity.edu.ng
b)joseph.egbekun@outlook.com
The manufacturing industry stands on the cusp of a transformative era, propelled by the rapid
advancements of Industry technologies. Embracing Industry 4.0 technologies offers a myriad of
advantages, making the adoption of these innovations not just advantageous but imperative for
the manufacturing sector. This transformative shift does not only optimize resource utilization
but also minimizes waste, its environmental impact and enhance social performances, thereby
aligning manufacturing practices with sustainable development goals. This research delves into
the pivotal role of industry 4.0 in the context of multinational manufacturing companies in Lagos,
Nigeria, focusing on their impact on social and environmental sustainability. The rate of
implementation of industry 4.0 was also, investigated. Partial Least Square Structural Equation
Modeling approach was employed to examine the relationship between Industry 4.0
technologies, social and environmental sustainability of the multinational manufacturing
companies. The findings depicts that 60.5% of the multinational manufacturing companies
consulted have implemented industry 4.0. With Cloud Computing been the most implemented
and Artificial Intelligence been the least implemented. This is an indication of the relatively
average adoption of digital technologies by manufacturing companies in Lagos State, Nigeria.
Also, the finding indicates a significant positive relationship between Industry 4.0, Environmental
and Social Sustainability Practices thus, leading to the acceptance of the proposed null
hypothesis. Therefore, manufacturing industries may both improve their competitiveness and
contribute to a more sustainable and inclusive future by embracing Industry 4.0 technology.
Keywords: Digital Technology, Sustainable Manufacturing, Fourth Industrial Revolution, Smart-
Pls Structural Equation Model
72
Session 6: Virtual Session
Frugal Embedded Service Design Framework for Low-cost Digital
Health Innovations in LMICs: Case of Maternal and Child Health
Promotion in Kenya
Danny Nyatuka
Strathmore University, Kenya
Targets 3.1 and 3.2 of SDG 3 aims to reduce global maternal mortality to 70 per 100,000 ratios of
live births by 2030. As part of strategies to achieve this goal, there has been increased adoption
of digital technologies to promote healthcare. Still, unfortunately, digital interventions in low and
middles-income countries (LMICs) have underperformed. This is attributed to resource-
limitations hence the need to rethink their design and nature to align them to the context of use.
The aim of the study was to propose a novel research framework to guide the designing of
efficacious low-cost digital health innovations to mitigate resource-limitations to enhance
maternal and child health (MCH) promotion an LMIC setting such as Kenya. This is to be achieved
through leveraging service design (SD) and frugal innovation (FI) principles to deliver affordable
context-specific solutions. A mixed methods approach was used, with a total sample size of 32
participants (n=32). The study was executed in two phases: stage 1- used eight (8) theoretical
themes to explore the research phenomenon; and stage 2 - a field study conducted to engage
the stakeholders. Resources, information, and social protection were among the most critical
factors in enhancing MCH promotion in the LMIC context. We propose a frugally embedded
service design framework to create simple, affordable, and sustainable digital health innovations
to improve delivery and access to MCH services. This will go a long way in overcoming resource
limitations towards better health outcomes.
73
Session 6: Virtual Session
Modeling and Evaluating a Distributed Renewable Energy Generating
System in a Transmission Line Expansion Network
Nomihla Ndlela
Durban University of Technology
Renewable generation enhances eco-friendly power accessibility. Furthermore, they have the
potential to enhance the eiciency and reliability of transmission lines when eectively
integrated into the network. Renewable Energy (RE) technologies such as Photovoltaic (PV) and
wind energy oer economic and nancial benets since they are environmentally friendly, safe,
and pollution-free. Consequently, the design of PV power plants and wind farms has become
indispensable in the energy sector. The importance of expanding the transmission network
cannot be overstated. Transmission Network Expansion Planning (TNEP) is a periodic necessity
driven by dynamic civilizations with increasing energy demands. To enhance the system's
Reliability, it is necessary to carry out generation and transmission expansion planning
concurrently. This approach ensures the investment cost is economical and the reliability criteria
are met. A method was created for determining the voltage level, based on economic and
technological parameters. Various voltage level alternatives were considered. Various factors
were considered to establish the economic voltage, line-loading limit, N-1 contingency, transient
stability, voltage stability, and small signal stability. The present study on DigSilent PowerFactory
utilizes the South African transmission line network and integrates it with both Solar PV and Wind
farm technologies to enhance power supply in the transmission line, ensuring that the demand
is met while maintaining grid reliability.
74
Session 6: Virtual Session
Status of Centralized and Decentralized Solar Photovoltaics and Wind
Technologies and their Performance Potential in the African sub-
Saharan Region – A Review
Hulisani T. Matsila
Department of Electrical Engineering, Tshwane University of Technology, South Africa
Corresponding author: matsilaht@tut.ac.za
The electricity generation sector is experiencing exponential growth of grid-integrated solar
photovoltaic (PV) and wind technologies, including distributed generations. Continents
like Asia, Europe, North America, South America, and Oceania have seen rapid growth in
the connection of solar and wind plants to the grid for the last decade. This growth is
inspired by the need to achieve the Sustainable Development Goal 7 (SDG-7) and global
zero net emissions by 2050. Africa is also partaking in the transition towards clean energy
but as of 2023, the continent has only tapped into a fraction of its renewable energy
potential, especially in the sub-Saharan region. This study uses a systematic review
method approach to address the status of grid-tied and distributed generation solar PV and
wind technologies in sub-Saharan Africa. Also included in this study are current renewable
projects, challenges, and renewable energy performance potential. The focus is on solar
PV and wind technologies as they are currently the fastest-growing clean energy sources
around the world. Different literature sources have been reviewed extensively to collect
recent data on the status of solar PV and technology adoption in all 51 countries of the sub-
Saharan region. Only data on grid-tied and decentralized renewable energy sources have
been covered in this study. Findings show that as of 2023 and 2024, most countries in the
sub-Saharan region are still with very little or no access to clean and sustainable energy
from solar PV and wind technologies despite targeting SDG-7. Although there are various
political, economic, and other social factors affecting access to renewable energy sources
in many sub-Saharan African countries, solutions are required to ensure social
development in this region. There is a lack of literature that addresses the status of
renewable energy for all the sub-Saharan continents, including its small island members.
75
Session 7B: Advanced Manufacturing and Infrastructure
The use of powders in friction stir welding of AA5083: the current state
and future trends
Thato Ralebakeng
A solid-state green technology method called friction stir welding (FSW) is utilized to join both
similar and dissimilar materials of aluminium alloys and other metals together. Because of its
excellent strength-to-weight ratio, good corrosion resistance, and reasonable formability,
AA5083 is widely used in the automotive and aerospace industries. This review examines the
effect of adding powder on the friction stir welding quality of AA5083, utilizing various powders
such as TiC, TiO₂, SiC, Al₂O₃, B₄C, CNTs, and Al-ZrO₂ in both nano and micron scales, but SiC
powder is the most used powder. The current state and future trends are discussed. It has been
demonstrated that the use of powders has an impact on the resulting properties of the joints.
Numerous researches have explored the possibility of enhancing FSW of AA5083 joint qualities
by the use of powders. However, process variables including tool geometry, axial force, traverse
speed, and rotational speed also play crucial roles. It has been observed that microstructural
changes contribute to improved microhardness and tensile. Nonetheless, the powders
appeared to affect microhardness and tensile strength differently. Studies focused on micron
and nanoparticle powders, and it was found that joints strengthened with nanoparticles had
better tensile strength and reduced grain size. It was also be noted that the role played by
process parameters and tool design may not be ruled out. More research must be undertaken
to determine how powder particles may further enhance the properties of the weld and the
benefits of powder particles linked to the AA5083 friction stir welding process parameters.
Keywords: FSW, AA5083, Powders, Microstructure, Mechanical properties, Corrosion
resistance
76
Session 7B: Advanced Manufacturing and Infrastructure
The inuence of process parameters during Friction Stir Processing on
corrosion properties of titanium alloys: an overview
Shyline Chingowo1*, Mukuna Patrick Mubiayi 2 and Ndivhuwo Ndou3
1Department of Mechanical, Bioresources, and Biomedical Engineering, College of Science,
Engineering and Technology, University of South Africa, Florida, Johannesburg 1709, South
Africa.
2 Department of Industrial Engineering and Engineering Management, University of South
Africa, South Africa
3 Institute for Nanotechnology and Water Sustainability, College of Science, Engineering and
Technology, University of South Africa, Florida, Johannesburg 1709, South Africa
Titanium alloy's light-to-weight ratio and excellent resistance to corrosion and wear have led to
their increasing appeal in the biomedical and aerospace industries. On the other hand,
corrosion resistance is lowered when highly acidic environments. For long-term application of
titanium in biomedical applications where toxicity and implant failure rates need to be
minimized, they must have increased corrosion resistance. Friction stir processing (FSP) is a
solid-state process that involves severe plastic deformation resulting in enhanced surface
properties such as hardness, wear resistance, and reduced defects. Previous studies have
mostly concentrated on the influence of FSP on increased hardness and wear, and there isn't
much clear knowledge of how FSP affects corrosion characteristics. The review’s objective is to
understand the effects of the FSP process parameters on the corrosion behavior of titanium
alloys. A comprehensive literature review will provide an in-depth analysis of prior studies on
the connection between corrosion resistance and FSP. Potentiodynamic polarization and
electrochemical spectroscopy results were utilized to evaluate the titanium alloys' corrosion
behavior. Following FSP, an equiaxed grain size forms, and increasing the number of passes
reduces the grain size and raises high-angle grain boundaries, improving corrosion resistance.
Keywords: Friction Stir Processing, corrosion, Titanium
77
Session 7B: Advanced Manufacturing and Infrastructure
Sustainable Manufacturing of Stainless-steel Elliptical Gears and
Study of their Tribological Behavior
Sandeep Gour 1, and Neelesh Kumar Jain1a
1 Department of Mechanical Engineering, IIT Indore, 453552 (MP), India
a Corresponding author: nkjain@iiti.ac.in
Elliptical gears are used effectively in automatic machines to generate variable gear
ratios. Manufacturing of elliptical gears is difficult due to their complex tooth design and
non-standard shapes. Wire spark erosion machining (WSEM) process has emerged as a
sustainable alternative for gear manufacturing because it does not emit any toxic gases
due to the use of deionized water as the dielectric (i.e., socially sustainable), consumes
less power (i.e., environmentally sustainable), and incurs less cost of dielectric, tooling,
and maintenance (i.e., economically sustainable). In this research, WSEM process has
been used for net-shape manufacturing of elliptical gears from stainless steel 304 using
250 µm diameter diffused brass wire as the tool and deionized water as the dielectric
fluid. Taguchi L9 orthogonal array approach has been used to identify the optimum
combination of WSEM process parameters namely, pulse on-time, pulse off-time, wire
tension, and wire feed rate as 2 µs; 40.5 µs; 420 g; and 2 m/minute respectively. Use of
this combination yielded maximum and average surface roughness values, and
manufacturing time as 11.73 µm, 1.67 µm, and 112 minutes respectively. Pulse-on time
is found to be the most influencing parameter for manufacturing of the elliptical gears
followed by pulse-off time, wire tension, and wire feed rate. The tribological behavior of
the best quality elliptical gear manufactured by WSEM process has been studied by
conducting linear reciprocating wear tests at an applied load of 20N, 30N, and 40N on its
flank surfaces. A maximum reduction of 48.2% in coefficient of friction has been
observed at the flank surfaces of WSEM manufactured best quality elliptical gear as
compared to the gear blank surfaces. This research establishes the WSEM process as a
sustainable alternative for manufacturing good-quality elliptical gears.
Keywords: Sustainability; Elliptical Gears; WSEM; Tribological Behavior; Taguchi
Orthogonal Array
78
Session 7C: Engineering Design and Manufacturing Systems
Investigation of the effect of geometric and operating parameters on
thermal behavior of latent heat energy storage systems
Thandiwe Bongani Radebe1, Lethukuthula Vilakazi1, Lekwetje Maureen Ramaube 2, Asasei
Unarine Casey Ndanduleni1, and Zhongjie Huan1
1 Department of Mechanical and Mechatronics Engineering, Tshwane University of Technology,
Pretoria 0001, South Africa.
2 Applied Fluid and Thermal Engineering Laboratory (@FTERLab), Howard University,
Washington, DC 20059
Thermal energy storage systems (TESS) integrated into home refrigerators can reduce energy
consumption and preserve perishable food products during power outages. This study
investigates the optimal shape design and configuration of TESS incorporated into a refrigerator.
Experiments were conducted on a household refrigerator using five liters of saltwater solutions
of potassium chloride (KCl) and sodium chloride (NaCl) as phase-change materials (PCMs). The
experimental results were validated with numerical simulations using ANSYS Fluent, with a focus
on optimizing the geometry and positioning of the containers to achieve a uniform temperature
distribution within the compartment. The phase of the KCl PCM changed at -11°C and the NaCl
PCM at -21°C, both maintaining the compartment below 5 °C for 20 hours. Energy savings of
0.567 kWh were observed every third and sixth day for KCl and NaCl PCM, respectively. The study
highlights the potential of PCM-based TESS in domestic refrigerators while emphasizing the need
for further optimization to enhance energy savings.
79
Session 7C: Engineering Design and Manufacturing Systems
Optimal Decision-Making Approach for the Advancement of SMEs in
Transportation Manufacturing
Eriyeti Murena1, a) Khumbulani Mpofu1, b) Vennan Sibanda2, c) , Gift Tshiwa Nenzhelele1, d)
1Tshwane University of Technology, Pretoria, South Africa
2National University of Science and Technology, Bulawayo Zimbabwe
a) Corresponding author: murenaeri@gmail.com, murenae@tut.ac.za
b)mpofuk@@tut.ac.za
c)vennan.sibanda@@nust.ac.zw
d)nenzhelelet@tut.ac.za
Slow-growing organisations and SMEs in the manufacturing industry are lured into investing in
smart manufacturing technologies because of the need to improve their manufacturing
processes and systems. Due to the harsh competition in the global market, local manufacturing
companies have been forced to produce customised solutions. Hence the a need to provide
guidelines to determine whether investing in custom-made smart systems in manufacturing is
more advantageous than off-the-shelf solutions. In this light, this article compares two methods,
MAKE (Alternative A) and BUY (Alternative B), to help both SMEs and slow-growing large
enterprises make the right decision when investing in smart manufacturing technologies. The
Fuzzy Analytical Hierarchy Process (FAHP) technique was utilised to rank the two criteria. A
cloud-based process plan was offered as a case study. This study focuses on the twelve major
attributes, these being Cost, Quality and Control, Strategic Objectives, Capacity and Expertise,
Flexibility and Responsiveness, Innovative Technology, Intellectual Property, Risk, Return on
Investment, Long-term, Short-term, and Market Acceptance. The report offers a concrete path
ahead for investing in and procuring cloud-based technologies. Results show that Alternative B
is the best alternative. SMEs and slow-growing organisations need to purchase smart
technologies and then later modify them so that they are compatible with the available
resources. From this research, organisations can make an informed decision about whether to
build or purchase not only cloud-based systems but also other smart manufacturing
technologies. For further work, the cost-benefit analysis for each alternative will be conducted.
A MAKE and BUY framework which can be adopted by SMEs will be developed.
80
Session 7C: Engineering Design and Manufacturing Systems
Adaptive Control of Machining Parameters in Machine Tools for
Enhanced Product Accuracy Using DDPG Approach
Olugbenga Adegbemisola Aderoba 1,2,a) and Khumbulani Mpofu1
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, SOUTH
AFRICA
2Department of Mechanical Engineering, Landmark University, Omu-Aran, NIGERIA
a) Corresponding author: olugbenga.aderoba@gmail.com
Conventional machining operations using pre-determined machining parameters neglect the
dynamic nature of manufacturing operations leading to increased scrap rates and suboptimal
accuracy levels of manufactured components. This study leverages the Deep Deterministic
Policy Gradient (DDPG) algorithm, a deep reinforcement learning technique for adaptive control
of cutting speed, feed rate, and depth of cut parameters based on varying machining conditions
and material properties. The algorithm uses the actor-critic approach to autonomously learn
from and adjust machining parameters dynamically using environmental feedback for improved
product accuracy. The test results obtained from the experiment conducted on a Computer
Numerical Controlled (CNC) lathe machine at Company "A" Engineering workshop indicate that
the proposed method works better in achieving superior accuracy, surface finish quality and
machining efficiency than old static settings. This study gives practical solutions to
manufacturing plants to make high-quality component parts that meet strict tolerances.
81
Session 7C: Engineering Design and Manufacturing Systems
Corrosive Behavior of Saltwater Phase-Change Materials on Common
Refrigeration Metals
Thandiwe Bongani Radebe1*, Asasei Unarine Casey Ndanduleni1, Zhongjie Huan1, Lehlogonolo
Rudolf Kanyane2, Boingotlo Innocentia Sehlabi2, James Molelekoa Mosesane2
1Department of Mechanical and Mechatronics Engineering, Tshwane University of Technology,
Pretoria, South Africa.
2Department of Chemical and Metallurgical Engineeirng; Pretoria, South Africa.
Cold Thermal Energy Storage (CTES) systems often utilize phase-change materials (PCMs) such
as potassium chloride (KCl) and sodium chloride (NaCl) to enhance cooling applications.
However, the corrosive nature of these PCMs on common refrigeration metals, including
stainless steel (St), copper (Cu), and aluminum (Al), poses a critical challenge. This study
investigates the corrosion resistance of these metals in KCl and NaCl solutions (19.5% and
22.4% w/w, respectively) over a four-week period using mass loss measurements and
potentiodynamic polarization tests. The results revealed that Cu demonstrated acceptable
performance as an evaporator coil material, with a corrosion rate below 50 mg/cm²/year in both
solutions. Conversely, Al proved unsuitable for prolonged exposure, particularly in NaCl
solutions, exhibiting corrosion rates exceeding 100 mg/cm²/year. Stainless steel showed high
resistance to pitting corrosion, with corrosion rates stabilizing below 100 mg/cm²/year after
initial exposure. These findings offer crucial insights for optimizing material selection in CTES
systems, enhancing their longevity and operational efficiency.
82
Session 8
The Impact of Industry 4.0 Technologies on the Development
of Electrical Discharge Machining
Sebastian Skoczypiec 1
1 Tadeusz Kosciuszko Cracow University of Technology, Faculty of Mechanical Engineering,
Chair of Production Engineering, al. Jana Pawla II 37, 31-864, Krakow, Poland
Electro-discharge machining (EDM) is one of the most common and widely used non-
conventional machining processes. In EDM, electrical energy is converted into thermal energy
during a series of discrete electrical discharges that occur between two electrodes (workpiece
and tool) immersed in a dielectric medium. The material is removed by melting and vaporisation,
and the dielectric medium between the tool and the workpiece provides the optimum conditions
for spark generation, regulates the thermal conditions and ushes the debris formed in the gap.
The physical phenomena of material removal in EDM make the process very complex to control
and EDM technology is not easy to master. Despite the continuous development of EDM
technology, the current challenges are related to ensuring consistent and reproducible quality.
The presentation will highlight the potential and importance of applying Industry 4.0 technologies
in the recent development of EDM technology. Industry 4.0 technologies are revolutionising the
way companies manufacture their products. Modern manufacturing systems are associated with
the use of advanced sensors, increased automation, embedded software and robotics that
collect and analyse data and enable better decision-making. These trends are also reected in
recent innovations in electro-discharge machining. EDM machines are actually 80 per cent pure
electronics and computers, which makes them predestined for Industry 4.0. It is also worth
emphasising that the EDM process is very complex to monitor and control. It is estimated that
about 20 parameters need to be controlled in real time during the operation of the machine tool,
and this is beyond the capabilities of a human operator. Therefore, recent advances in EDM are
related to the following areas: increasing automation and robotization of the process, real-time
data analysis, adaptive control and application of articial intelligence, use of advanced sensors
(especially machine vision systems), improvement of communication between machine tool and
operator (i.e. voice-operated assistant technology), IoT and application of additive manufacturing
to shaping electrodes.
The discussion of selected examples in this area will be preceded by a brief overview of the history
of EDM, the idea of Industry 4.0 and its main pillars, and concluded with advantages connected
with application of technologies of Industry 4.0 in EDM. The following benets connected with
application of technologies of Industry 4.0 in EDM should be highlighted: reduction of lead times
(reduction of non-productive machine tool downtime, more eicient management and increased
availability of production resources), increase of productivity, improvement of process
repeatability, reduction of incidents due to human errors, freeing up of operator time,
improvement of quality of manufactured parts and electrodes, increase of exibility in
production.
In recent years, EDM has become a more eicient and reliable process, increasing equipment
utilisation by up to 90% and the number of unattended machining hours. In addition, the quality
of machining improves and ner surface nishes can be achieved without additional nishing
operations. It should be clearly stated that Industry 4.0 technologies play a key role in this
progress.
83
Session 9
Recent Technology Developments in Advanced Manufacturing
Systems
Glen Bright
University of KwaZulu Natal, Durban, South Africa
Disruptive technologies play a transformative role in engineering by revolutionizing
traditional processes. They enable automation, reducing human intervention while
improving eiciency and speed. Advanced sensors and AI-powered analytics enhance
precision in design and manufacturing, minimizing errors. Real-time decision-making is
facilitated through IoT and big data, optimizing workows and resource utilization. Additive
manufacturing, like 3D printing, enables complex, customized designs, reducing material
waste. Furthermore, robotics and machine learning improve quality control and adaptability
in dynamic environments, driving innovation and competitiveness in engineering sectors.
84
Session 9
Environment Friendly Additive Manufacturing of Thermally Diiculty
Materials
Neelesh Kumar Jain
Mechanical Engineering, Indian Institute of Technology Indore, India
This keynote lecture will give a brief introduction of additive manufacturing and their
classications. It will highlight dierent problems/challenges faced during fusion based
additive manufacturing (FBAM, which require melting of the deposition material) of
thermally diicult materials i.e., alloy and metal matrix composites (MMCs) of Al, Cu, Mg,
Zn due to their higher thermal conductivity and thermal diusivity. It will give a glimpse of
how solid state additive manufacturing (SSAM) processes can overcome these problems.
It will give details of dierent SSAM processes explaining their unique features and their
environment-friendly nature. It will provide summary research ndings of the friction stir
powder additive manufacturing (FSPAM) process which has been developed at IIT Indore
during 2019-2022.
85
Session 10A: Manufacturing Processes
Exploring the continuum of human-robot collaboration
Ngaka Mosia1, a) and Ndivhuwo Ndou2, b)
1,2University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding author: mosian@unisa.ac.za, b)nndou@unisa.ac.za
Understanding the dynamics of human-robot collaboration is essential for maximizing
possible benefits and resolving potential issues as robot integration into all facets of
human life becomes more commonplace. This study explores the range of human-robot
cooperation, offering a thorough examination that covers the ground from minimum
interaction to smooth cooperation. The first part of the study looks at how human-robot
collaboration has historically changed, following the advancement of robotics from
standalone automation to interactive systems that can carry out intricate tasks. The study
employs a mono-qualitative methodology to examine the psychological, social, and
ethical aspects of human-robot collaboration. The findings provide insights into the
variables that impact user acceptance, trust, and flexibility. Case studies and empirical
evaluations of collaborative systems from a variety of industries, including manufacturing,
healthcare, and service industries. This paper adopts a qualitative research approach and
provides a nuanced understanding of the continuum of human-robot collaboration,
offering insights into the evolving nature of this relationship. The findings contribute to the
ongoing discourse on the future of robotics, informing researchers, policymakers, and
industry professionals on navigating the complexities of integrating robots into diverse
aspects of human society.
Keywords: Robotics, Artificial Intelligence, Automation, Manufacturing, Machine
Learning.
86
Session 10A: Manufacturing Processes
Influence of hybrid fillers on buoyancy and thermal stability of epoxy-
based foam composite panels
Ayodele Abraham Ajayi1,a, Mohan Turup Pandurangan2,b and Kanny Krishnan3,c
1,a Composite Research Group, Department of Mechanical Engineering, Durban University of
Technology. South Africa, 22176175@dut4life.ac.za
2,b Composite Research Group, Department of Mechanical Engineering, Durban University of
Technology. South Africa, mohanp@dut.ac.za
3,c Composite Research Group, Department of Mechanical Engineering, Durban University of
Technology. South Africa, kannyk@dut.ac.za
Background
In recent years, there has been a significant increase in interest in epoxy-based foam composite
materials due to their wide range of applications in the maritime and aerospace industries.
These foam composite panels with an epoxy foundation and hybrid fillers were fabricated as a
solution to the thermal stability issue. Therefore, the goal of this research is to enhance the
buoyancy behavior and the thermal stability of epoxy-based foam composite panels utilizing
nanoclay particles(25A) and hollow glass microspheres (HGM) to create a hybrid-filled foam
panel.
Research questions
Can hybridization of fillers in epoxy-based foam composites enhance its thermal stability?
Methodology
The HGM was varied with different weight percentages of HGM as 0%, 1%, 3%and 5% in the foam
composite panel while the amount of nanoclay in each HGM-filled series of foam composite
panels was also varied as 0%, 1%, and 5%, this foam composite panel was fabricated by
employing a traditional resin casting technique as shown in Figure 1. The thermal conductivity
and buoyancy of hybridized foam composite panels were examined and contrasted with neat
epoxy.
Figure 1: Processing sequence of hybrid-filled foam composites
87
Session 10A: Manufacturing Processes
Results
The findings of this research revealed that foam composite panels made of hybrid fillers had
better thermal stability and buoyancy than neat epoxy material as a significant decrease in
thermal conductivity was observed in the foam composites containing a hybrid filler
1%wt.HGM+5%wt.Clay with a decrease from 3.73 W/m*K to 0.33 W/m*K as seen in Figure 2
while the highest buoyancy was observed in foam composite with 5%wt.HGM which could be
because of its higher concentration of HGM than all other foam composites which is evidence in
Figure 3.
Figure 2: Thermal conductivity of hybrid-filled foam composites
Figure 3: Buoyancy of hybrid-filled foam composites
Conclusion
By hybridizing HGM and nanoclay fillers with epoxy resin, the foam composite materials revealed
thermally stable foam composites with enhanced buoyancy. This enhanced thermal stability and
88
Session 10A: Manufacturing Processes
buoyancy behavior may indicate that this material is appropriate for use in applications requiring
lightweight materials with good thermal behavior, particularly in the aerospace and marine
industries. Using hybrid fillers to improve thermal properties, opens up new research
opportunities in the field of foam composite fabrication.
Keywords: Buoyancy, Fillers, HGM, nanoclay, thermal properties
89
Session 10A: Manufacturing Processes
Low Clinker Cement Production Output and Carbon Tax Emission
Payable at a Cement Blending Operation
Asser Letsatsi Tau 1,a), Emmanuel Innocents Edoun1, b) and Anup Pradhan1, c)
1Department of Quality and Operations Management, University of Johannesburg, 55 Beit St,
Doornfontein, Johannesburg, 2028, South Africa
a) Corresponding author: lecturer.tau@gmail.com
b) eiedoun@uj.ac.za
c) anupp@uj.ac.za
Production of low clinker cements are encouraged to reduce the carbon dioxide emissions. A
cement blending operation was studied with respect to production of eco-blended cement.
Monthly demand forecasting was quantified for one year using potential customers’ historical
cement requirements. Simulation modelling using Arena Software was then used to predict the
potential number of cement bags that be produced. Annual production of 30900 tons CEM V/A(S-
V) 42.5N and 124414 tons CEM V/B(S-V) 32.5N were associated with annual carbon dioxide
emission of 32401 tons at minimum percentage total clinker utilization and 583367 tons at
maximum percentage total clinker utilization for production of the two cement products. The
year 2024 carbon tax rate is ZAR 190/ton CO2. The associated annual carbon tax bill payable at
better case scenario of carbon tax rate of ZAR 37.00/870 kg CO2 emission and worst case
scenario on carbon tax rate of ZAR 165.30/870 kg CO2 emission for minimum and maximum
clinker utilization in CEM V/A(S-V) 42.5N and CEM V/B(S-V) 32.5N was ZAR 2.88 million, ZAR 1.39
million and ZAR 5.36 million, ZAR 9.64 million, respectively. This further indicated an additional
cost of ZAR 2.15 for CEM V/A(S-V) 42.5N and CEM V/B(S-V) 32.5N each for 50kg bag production
under carbon tax payable better case scenario. Meanwhile, the worst-case scenario of carbon
tax payable is associated with a production cost increase by ZAR 9.50 for both 50kg cement bag.
These carbon tax payables are charged to customers as part of the cement product selling price.
These propelled customers to purchase the 32.5N cement as an environmentally friendly
product. Furthermore, these were also noted on the forecasted annual demand mix of 19.90%
42.5N cement and 80.10% 32.5N cement. Production of CEM V/B(V-S) 32.5N by SANS50197-1
was recommended due to its low clinker content, thus with reduced carbon footprint for
sustainable environmental management. Future research was recommended for investigation
on availability of supplementary cementitious materials for production of low carbon footprint
cements in South Africa.
Keywords: carbon dioxide, carbon tax, simulation modelling and carbon footprint
90
Session 10B: Manufacturing Technology and Factory Automation
Towards Smart Manufacturing: Integration of Computerized Systems in
the Press Tool Industry
Moses Oyesola1, Mukondeleli Grace Kanakana-Katumba1, Khumbulani Mpofu1
1Tshwane University of Technology, Staatsartellerie Road, Pretoria 0001, South Africa.
In the global manufacturing landscape, industries are increasingly turning to strategic suppliers
to expedite pre-production processes and minimize costs. The press tool industry, essential for
mass production, is no exception. Press tools cut and shape blanks into precise components per
design specifications. To meet the demands of Original Equipment Manufacturers (OEMs) and
reduce export costs, press tool firms must evolve from manual to automated processes. This
transition requires meticulous planning to ensure seamless integration of computerized
systems. This research addresses the core challenge of facilitating this transition while
enhancing manufacturing capacity and maintaining quality standards. Through an examination
of the press tool industry, this study explores a system that optimizes production efficiency,
embraces technological advancements, and meets OEM needs. Using a machine press tool as
a case study, the research offers insights into the opportunities and challenges of integrating
manufacturing support systems and automation, presenting strategies for achieving smart
manufacturing in the press tool sector.
91
Session 10B: Manufacturing Technology and Factory Automation
Improving Production Throughput and Downtime Reduction in the
Automotive Industry
Steadyman Chikumba
University of South Africa, Department of Industrial Engineering and Engineering Management,
Florida campus, Florida, South Africa, 1709
South Africa
Corresponding author: chikus@unisa.ac.za
Manufacturing companies are fighting stiff competition within their sectors due to the existence
of various factors. Complex supply chains, technological and operational factors processes and
procedures affect productivity in automotive manufacturing. The aim of this research is to study
factors affecting productivity and throughput of automotive manufacturing and assembly
companies and come up ways of improving methods for improving productivity. Study of
automotive manufacturing of components and assembly. Causes of down times and their
effects of the stoppages. Identification of the enabling technologies and industrial engineering
techniques for production streamlining. The study discusses ways of reducing times and
improving productivity and sustainable continuous improvement.
92
Session 10B: Manufacturing Technology and Factory Automation
A dynamic and differentiated tool for assessing the Industry 4.0
readiness of manufacturing companies
Chantel Botha1, and Josef Gochermann2,3
1 Simera Innovate, Somerset West, Cape Town, South Africa
2 Osnabrück University of Applied Sciences, Faculty of Management, Culture and Technology,
Lingen (Ems), Germany
3 Tshwane University of Technology, Department of Industrial Engineering, Pretoria, South Africa
A wide variety of methods and tools has been developed in the last decade to determine a
company's digital maturity. Most of these tools determine the overall maturity without a deeper
level of detail. A differentiated assessment of the company's I4.0 readiness is not possible. In
addition, static target values are specified for a desired state, which implies that the highest state
is also the most desirable for the company, which is not always the case. Although most models
also evaluate organisational statuses, there is weak integration of the business model and the
company's strategy. Moreover, many models are generalised and do not take into account the
specific requirements of manufacturing companies. The Industry 4 Organisational Readiness
Assessment tool (I4ORA) was developed in a South African-German co-operation, focussing on
manufacturing companies. It allows a differentiated assessment of the current and the preferred
state of any dimension. Also it is integrating the Organisation of the company including the
business model and the strategy. This method allows both a dynamic view on the desired target
status and a company-specific, differentiated view and evaluation. The model was developed on
the basis of existing methods and verified by companies in Germany, Saudi Arabia and South
Africa.
Keywords: Industry 4.0, digital maturity, readiness assessment tools, digital business
models, manufacturing companies
93
Session 10C: Additive Manufacturing
Lithography-based ceramic additive manufacturing of biodegradable
bone regeneration lattice structures
Morakane Moletsane, Willie Bouwer du Preez2, Deon de Beer3 and Shathani Nkhwa4
1Department of Mechanical and Mechatronics Engineering, Faculty of Engineering, Built
Environment and Information Technology, Central University of Technology, Free State, South
Africa
2,3 Centre for Rapid Prototyping and Manufacturing, Faculty of Engineering, Built Environment
and Information Technology, Central University of Technology, Free State, Bloemfontein, South
Africa
4Department of Biomedical Sciences, Faculty of Medicine, University of Botswana
Manufacturing of hydroxyapatite components through additive manufacturing (AM) is an
extensively researched field. Lithography-based ceramic (LCM) AM can manufacture
macroporous and microporous structures that mimic human bone. This opens the possibility of
producing biodegradable bone scaffolds in hydroxyapatite that would allow bone regeneration.
This study is aimed at evaluating the biodegradation behaviour of HA480 hydroxyapatite LCM test
specimens. To determine the degradation, LCM HA480 diamond lattice structure specimens
were immersed in simulated body fluid (SBF) for 1, 7, and 28 days under the same conditions.
Surface characterization of the HA480 lattice structures after immersion in the SBF for 28 days
provided evidence of surface flake-like appetite, which confirmed that HA480 possesses good
bioactivity. HA480 samples were subjected to compression tests until failure for samples
submerged in SBF for 1 day, samples immersed in SBF after 28 days, and dry samples. Samples
were further characterized by X-ray diffraction analysis (XRD). The XRD results for HA480 after
SBF treatment confirmed the presence of appetite. The grain size and structural changes to the
grain boundaries indicated degradation of the HA480 structures after 28 days. After 28 days of
biodegradation, the diamond lattice structure still had good structural integrity. HA480 can
potentially be used for bone regeneration as it indicates slow degradation properties and
bioactivity.
94
Session 10C: Additive Manufacturing
Investigating the mechanical properties of additively manufactured Al-
Ti-Zr-Nb-V-Cr high entropy alloys for Multifunctional Application
Adebayo. O. Ogunyinka1, API Popoola1, Sisa. L. Pityana2, Emmanuel. Sadiku1, and Olawale.
Popoola3
1Department of Chemical, Metallurgical and Materials Engineering, Tshwane University of
Technology, Pretoria, South Africa
2Council for Scientific and Industrial Research (CSIR) Pretoria, South Africa.
3Centre for Energy and Electric Power, Tshwane University of Technology, Pretoria, South Africa
a Corresponding author: adebayo2602@gmail.com
In the area of materials science, Al-Ti-Zr-Nb-V-Cr high-entropy alloys (HEAs) were developed for
engineering applications to address mechanical and structural failures. These alloys exhibit a
unique dual-phase structure that can be optimized to meet a wide range of engineering
demands. Among the many benefits of these materials are its multifunctional properties,
including its capacity to store hydrogen, its resistance to corrosion, wear and abrasion. These
attributes make it highly suitable for demanding industrial applications where traditional
materials may fall short. Here in, the alloy was fabricated using direct-energy deposition. The
structure-property correlations with the alloys' microhardness, wear, and corrosion resistance
were investigated. It was found that the tuning of this alloy resulted in the formation of multiphase
structures that include BCC and Lave phases. The alloy was then characterized and found to
exhibit excellent microhardness of 760HV, a corrosion rate of 0.45076 mm/year, a wear rate of
0.0002457 mm2/N/m, and good high-temperature oxidation resistance. Hence, this material can
be applied in various industries where such properties are critical, such as cutting tools, nuclear
reactors, turbine blades, and armour plating
95
Session 10C: Additive Manufacturing
Post-processing heat treatment analysis for additively manufactured
AlSi12
Alliance Bibili
The evolving landscape of fluctuating customer demands with requirements for high-
quality products, delivered within shorter lead times has influenced the manufacturing
dynamics. These dynamics have spurred the rapid adoption of metal additive manufacturing
(AM) technologies to address the issues of delivery time. However, addressing high-quality
outputs also depends on the finishing post-processing operations conducted after the
fabrication of the part using the layer-by-layer approach. The metal AM approach is
characterised by a high rate of heating and solidification that creates residual stresses which
might be due to the various parameters inherent in processes like selective laser melting
(SLM). Certain alloys such as AlSi10Mg have been extensively studied. Their post-processing
methods and data have been published for adoption. AlSi12 is one of the alloys that has
recently gained interest due to its high weight-to-ratio and corrosion resistance. Yet scant
research data exist for post-processing treatment to ensure the quality of the fabricated
part integrity and density. This study contributes to recommending the post-processing
heat treatment methods for AlSi12 fabricated by SLM. The effects of the heat treatment are
studied on density and tensile strength. The results revealed that the heat treatment at a
higher temperature of 350 ºC for 4 h drastically decreased the strength. In contrast, at a
lower temperature of 100ºC for 8h, the treatment provided a good compromise of the tensile
strength and ductility of the material. Moreover, the density increased for all samples during
the Archimedes testing. This study is conducted to ascertain the post-processing treatment
of the additively manufactured AlSi12 for different applications.
96
Session 11A: Technological Applications in Sustainabilitys
Aptasensor platform based on CDQ-TiO2 for the detection of
Cryptosporidium in water
Indiphile Nompetsheni*, Xolile Fuku1, Ntuthuko Wonderboy Hlongwa1, Nithyadharsen
Palaniyandy2
1Institute for Nanotechnology and Water Sustainability (iNanoWS), College of Science,
Engineering, and Technology, University of South Africa, Roodepoort, Florida, 1710, South
Africa.
2Institute for catalyst and Energy Sustainability (ICES), College of Science, Engineering, and
Technology, University of South Africa, Roodepoort, Florida, 1710, South Africa.
*Corresponding author: 21068046@mylife.unisa.ac.za
Recently, water contamination has emerged as one of the critical global conundrums.
Cryptosporidium is among the numerous parasites that deteriorate water quality, potentially
leading to outbreaks of waterborne diseases. Concerns over environmental pollution and its
impact on public health have spurred research in the development of sustainable environmental
technologies. Electrochemical biosensors for ecological monitoring denote the utilization of
electrochemical sensing technology to assess various environmental parameters. These
biosensors, comprising receptors immobilized on electrodes, oer sensitive and selective
detection capabilities for multiple analytes, including heavy metals, pesticides, organic
pollutants, and microbial contaminants.
This study focuses on the development of an Aptasensor based on carbon quantum dots (CQDs)
supported on titanium oxide (TiO2) nanocomposite for early detection of Cryptosporidium in
water bodies, addressing both pollution and scarcity concerns. The nanomaterials used for the
development of the aptasensor were produced using the hydrothermal method and then
characterized via various chemical and physical approaches including X-ray diraction (XRD),
high-resolution transmission electron microscopy (HRTEM), and Fourier transform Infrared
spectroscopy (FTIR). For the application of the biosensor , cyclic voltammetry (CV) was used to
check the electrochemical properties of the materials.
Figure 1 shows the characterization of the composite using FTIR technique. The FTIR spectra of
the synthesized materials were observed in the range of 400 – 4000 cm-1. As shown in Figure 1,
the broad absorption peak at 3478 cm -1 is attributed to the hydroxyl group's O-H stretching
vibration, indicating the presence of moisture in the sample. The characteristic peak at 1629 cm-
1 is associated with the bending of Ti-O and the stretching of Ti-OH, respectively. For CQD, the
peak at 1629 cm-1 may be attributed to water adsorbed on the TiO2 surface . These results agree
well with the earlier reports. A broad peak at ∼3412 cm−1 is assigned to the –OH groups, and the
absorption peak at 2922 cm-1 is related to C-H stretching vibrations. Additionally, a sharp peak
at 1610 cm-1 is attributed to C=N bending vibration, while other peaks observed at 1393 cm-1
and 990 cm-1 are related to O-H bending and C=C vibrations. These observations confirm the
presence of carbonyl and hydroxyl functional groups on the surface of CQDs, imparting excellent
water solubility. However, it's worth noting that the typical vibrational peaks of Ti-O at 1855 cm−1
in the composite material were weakened, at 1698 cm−1 compared to the other produced
nanoparticles. This indicates the successful creation of the nanocomposite. Additionally, no new
functional groups were found in the produced nanocomposite.
Keywords: Monitoring technologies, Cryptosporidium, Aptasensor, water quality, sustainability.
97
Session 11A: Technological Applications in Sustainabilitys
References:
1. S.Gavrilaș, C.S.Ursachi, S.Perta-Crisan, F.D.Munteanu, recent trends in biosensors for
environmental quality monitoring. sensrs . 4, 1513 (2022).
2. J. Xiong, Z. Sun J.H. Yu, H. Liu, X.D. Wang, thermal self-regulatory smart biosensor based on
horseradish peroxidase-immobilized phase-change microcapsules for enhancing detection
of hazardous substances. Chem. Engin. J. 430, 132982 (2022).
3. M.S Islam, K. Sazawa, K. Sugawara, H. Kuramitz, electrochemical biosensor for evaluation
of environmental pollutants toxicity. Environments 10, 63 (2023).
4. T. Beiki, G. Najafpour-Darzi, M. Mohammadi, M. Shakeri, R. Boukherroub, fabrication of a
novel electrochemical biosensor based on a molecular imprinted polymer-aptamer hybrid
receptor for lysozyme determination. Anal. and Bioanal. Chem. 5, 899-911 (2023).
98
Session 11A: Technological Applications in Sustainabilitys
Optimizing Automotive Injection Molding Processes through Predictive
Modeling Techniques
Fikile Poswa 1, Olukorede Tijani Adenuga2, Khumbulani Mpofu 3, and Boitumelo Ramatsetse4
Department of Industrial Engineering: Tshwane University of Technology Staatsartillerie Rd,
Pretoria West, 5 Pretoria, 0183;
fposwa44@gmail.com; AdenugaOT@tut.ac.za; MpofuK@tut.ac.za; Ramatsetse@sun.ac.za
Corresponding author: fposwa44@gmail.com
The automotive industry is characterized by its competitiveness and fast-paced evolution that
requires constant improvement to remain competitive. Mass production and product
customization are the key elements in the automotive industry that requires high precision.
Material sustainability in production process is still a challenge by not having parameters set to
ideal setting for optimal production. This paper aims to optimise automotive injection molding
process using Moldex3D injection molding predictive techniques that combine parameters such
as temperature, pressure, and cooling time that determine the quality of the final product.
Emphasis how machine learning, statistical and analytical methods, and computational
simulations can enhance production process optimisation are expounded in the study.
Moldex3D injection molding simulation shown the effectiveness of predictive techniques with an
improvement of 0.255% of the shrinkage percentage. These results emphasize the potential of
predictive modeling in process improvement to promote quality, efficiency, cost reduction, and
provide sustainability to injection molding and automotive industry at large.
Keywords: Predictive Modeling, Injection Molding Optimisation, Automotive Industry, Machine
Learning, Process Paramet
99
Session 11A: Technological Applications in Sustainabilitys
Establishing Resilience for Manufacturing Systems Through Smart
Technology Strategies
Ngaka Mosia1, a)
1University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding author: mosian@unisa.ac.za
The impact of the pandemic has resulted in a lack of robust and resilient manufacturing
systems. Leadership in the manufacturing sector has discovered that inefficiencies and
bottlenecks in the current traditional manufacturing process render manufacturing
systems ineffective. Due to the pandemic's exposure to flaws in conventional production
techniques, the sector is currently looking for methods to increase sustainability,
efficiency, and productivity. The rise of intelligent technologies such as robotics, AI, and
IoT offers a chance to improve resilience and revolutionize manufacturing. The teaching
and learning process in relation to manufacturing resilience is the main topic of this study
report. An in-depth discussion of resilient manufacturing is provided, and the research
results generated are methods for integrating smart technologies into manufacturing
systems to achieve resilience. The study offers a thorough understanding of how these
technologies might enhance the resilience of manufacturing systems. The research
adopts a qualitative approach to explore and explain the impact of smart technologies on
manufacturing, contributing to the enhancement of future work in the field of
manufacturing education and learning.
Keywords: Technology, Manufacturing, IoT, Robotics, AI
100
Session 11A: Technological Applications in Sustainabilitys
A bibliometric analysis of Industry 4.0 technologies in sustainable
manufacturing
Charles Mothobiso
Tshwane University of Technology
The integration of Industry 4.0 technologies in manufacturing is indicating a new era of enhanced
eiciency, precision, and environmental stewardship. This bibliometric analysis systematically
examines the literature on the convergence of Industry 4.0 and sustainable manufacturing,
identifying key trends, inuential studies, and emerging research themes. Through an extensive
review of publications from major databases like Web of Science, Scopus, and Google Scholar,
this study maps the evolution of research over the past decade. Using bibliometric tools such as
citation analysis, co-authorship network analysis, and research cluster identication with
VOSviewer, the analysis reveals prolic authors, leading institutions, and pivotal studies shaping
the discourse on sustainable manufacturing enabled by smart technologies. Key themes include
IoT for real-time energy monitoring, AI-driven predictive maintenance, big data analytics for
resource optimization, and advanced robotics for precision manufacturing. The study also
examines collaboration patterns, uncovering signicant international partnerships driving
innovation. The discussion interprets these ndings in the context of Industry 4.0 and
sustainability, addressing gaps in the literature and suggesting future research directions. This
work guides academics, industry professionals, and policymakers in leveraging these
technologies to foster sustainable development.
Keywords: Industry 4.0, Environmental stewardship, Smart technologies, Sustainable
manufacturing.
101
Session 11A: Technological Applications in Sustainabilitys
Cyber defence mechanisms and digital customer experience for
sustainable manufacturing companies in South Africa
Genevieve Bakam
Tshwane University of Technology
Customer knowledge has changed the digitalised manufacturing landscape leading to the
adoption of Manufacturing as a Service (MaaS) for customer satisfaction and operational
efficiency. However, local legislation does not always highlight digital regulatory perspectives
and limited studies mention the longitudinally between digital customer experience, cyber
defence mechanisms and sustainable initiatives in the manufacturing field. This study
investigates the association of cyber defence mechanisms and digital customer experience
(DCX) to enable sustainable manufacturing companies in South Africa. A content analysis was
conducted using secondary data to establish cybersecurity and digital customer experience
requirements and identify digital expectations and policy integration factors. A comparative
analysis of cybersecurity techniques is carried out between manufacturing and other industries
like accounting and information technology (IT) firms to optimise cyber defence solutions for
sustainable manufacturing in South Africa. Results revealed that upgraded digital innovations
including Artificial Intelligence (AI) and machine learning, blockchain applications, threat
intelligence platforms, and multifactor authentication are required for stakeholders’
management and customer loyalty. Manufacturing companies should develop multimodal
security solutions while investing in cyber security, education, cyber governance, and data
capital. Furthermore, specific digital policies such as the integrated compliance (IC) and
cybersecurity alliance (CA) policies should be established by the government for effective
integration between digital defence, customer experience and sustainable best practices in
manufacturing companies. The South African government and industry policymakers should
consider local requirements and global representation to upgrade laws and regulations
promoting the digital resilience and prosperity of manufacturing companies.
Keywords Cyber defence, digital customer experience, sustainability, cybersecurity solutions,
manufacturing companies and South Africa.
102
Session 11B: Renewable Energy Research and Waste Heat Recycling
The current state of South Africa's transition to hydrogen-powered
energy transition
Emmanuel Olusegun Ogundimu and Coneth Graham Richards
Department of Electrical Engineering
University Tshwane University of Technology
South Africa
South Africa faces a complex transition to a hydrogen-powered energy system, marked by
the need to address energy security, economic sustainability, and environmental goals.
Despite having significant renewable energy resources, such as solar and wind, the country
struggles with infrastructural limitations, insufficient investment, and regulatory hurdles that
hinder the development of a robust hydrogen economy. South Africa, a country endowed with a
significant array of natural resources, has developed a strategic plan, known as Hydrogen
South Africa (HSA), to facilitate the development, transportation, and use of hydrogen.
This plan was introduced in 2007 as a key component of the nation's energy
transformation agenda. The Republic of South Africa has identified many key goals in
its development of hydrogen technology. These objectives include the promotion of
economic growth and exports, as well as the need to achieve de-carbonization. Hydrogen as
a source of energy is seen as a promising avenue for improving both residential and
industrial sectors. This approach aligns with the emissions reduction targets outlined in the
Paris Accord of 2015, specifically about the reduction of CO2 emissions. Additionally, the
adoption of hydrogen-powered energy has the potential to mitigate socioeconomic
disparities. This study investigated the existing techniques used in the production of
ecologically sustainable hydrogen, along with the advantages associated with the availability
of platinum, the principal catalyst utilized in the synthesis of fuel cells and other natural
resources. The evaluation of South Africa's readiness for the transition towards a
hydrogen-based energy economy is conducted in conjunction with areas situated in both
the Eastern and Western parts of the world. If South Africa effectively adheres to her
roadmaps, policies, and strategies concerning green hydrogen, there is a significant possibility
for the nation to emerge as a global frontrunner in the production and exportation of
green hydrogen. Additionally, South Africa could also establish herself as a prominent hub for
the manufacturing and assembling of hydrogen electrolysers and fuel cells soon.
103
Session 11B: Renewable Energy Research and Waste Heat Recycling
Modelling and analyis of bidirectional converters and supercapacitors
in wind turbines to manage short-term voltage output variations
Banele Mbendane 1, Bolanle Abe1, Coneth Richards1 and Adeniyi Onaolapo1
1 Tshwane University of Technology, Department of Electrical Engineering, Pretoria 0001,
South Africa
a) Corresponding author: bcmbendane@gmail.com
Green energy generation shows the potential to reduce emissions and achieve net carbon
neutrality by 2050. However, they are weather-dependent, which leads to voltage output
fluctuations. During the first phase of wind cut-in speed for wind turbines, voltage output
fluctuates, and the wind turbine-rated output power is not achieved. This research focuses on a
control strategy to maintain voltage output when wind speed fluctuates. The study uses
supercapacitors and bidirectional converters integrated with wind turbines to correct and
maintain the voltage output. The integrated system is designed, modelled, and validated in
MATLAB Simulink software. An input stair generator is set at different wind speeds from the
GLOBAL wind atlas at different intervals to emulate real-life operations. The research’s validation
encompasses a comparison study of the simulations where output trends are reviewed to
measure the output voltage with and without supercapacitors and bidirectional converters. The
simulated outcomes support the control strategy of using a bidirectional converter with a
supercapacitor. This is seen in the energy output improvement of the wind turbine, which is
increased by 50% when cut-in speeds are still in the initial phases. The outcomes further show a
reduced ripple current output when wind variation occurs.
Keywords: Supercapacitors; Wind energy; bidirectional converter; fluctuations; controlling
strategy.
104
Session 11B: Renewable Energy Research and Waste Heat Recycling
Status of Centralized and Decentralized Solar Photovoltaics and Wind
Technologies and their Performance Potential in the African sub-
Saharan Region – A Review
Hulisani T. Matsila
Department of Electrical Engineering, Tshwane University of Technology, South Africa
Corresponding author: matsilaht@tut.ac.za
The electricity generation sector is experiencing exponential growth of grid-integrated solar
photovoltaic (PV) and wind technologies, including distributed generations. Continents like Asia,
Europe, North America, South America, and Oceania have seen rapid growth in the connection
of solar and wind plants to the grid for the last decade. This growth is inspired by the need to
achieve the Sustainable Development Goal 7 (SDG-7) and global zero net emissions by 2050.
Africa is also partaking in the transition towards clean energy but as of 2023, the continent has
only tapped into a fraction of its renewable energy potential, especially in the sub-Saharan
region. This study uses a systematic review method approach to address the status of grid-tied
and distributed generation solar PV and wind technologies in sub-Saharan Africa. Also included
in this study are current renewable projects, challenges, and renewable energy performance
potential. The focus is on solar PV and wind technologies as they are currently the fastest-
growing clean energy sources around the world. Different literature sources have been reviewed
extensively to collect recent data on the status of solar PV and technology adoption in all 51
countries of the sub-Saharan region. Only data on grid-tied and decentralized renewable energy
sources have been covered in this study. Findings show that as of 2023 and 2024, most countries
in the sub-Saharan region are still with very little or no access to clean and sustainable energy
from solar PV and wind technologies despite targeting SDG-7. Although there are various
political, economic, and other social factors affecting access to renewable energy sources in
many sub-Saharan African countries, solutions are required to ensure social development in this
region. There is a lack of literature that addresses the status of renewable energy for all the sub-
Saharan continents, including its small island members.
105
Session 11B: Renewable Energy Research and Waste Heat Recycling
The impacts of environmental conditions on the output power
efficiency of photovoltaic (PV) solar modules
Emmanuel Olusegun Ogundimu and Coneth Graham Richards
Department of Electrical Engineering
University Tshwane University of Technology
South Africa
Solar photovoltaics (PV) provide the potential to serve as a sustainable and enduring substitute
for fossil fuels; yet their efficiency remains a significant challenge. The deterioration
of photovoltaic (PV) panel efficiency is influenced by various internal and external
elements, involving ambient conditions, framework aspects, instatement procedures, and
maintenance practices. This work investigates the impact of environmental situations on
the efficiency of photovoltaic (PV) solar modules. The result denotes that temperature
has a destructive correlation with the maximum power output, resulting in a reduction of
-8.31% to -10.87%. Additionally, relative humidity is found to be inversely proportional
to the efficiency of photovoltaic solar panels, with an increase in relative humidity leading to
a decrease in output power efficiency. Furthermore, when the humidity level exceeds 50%, it
may lead to a decrease in efficiency ranging from 15% to 30%. Consequently, this has a
detrimental impact on the operational effectiveness of the system. An augmentation in
solar radiation results in a corresponding elevation in the output current, so bolstering
the overall efficiency of the photovoltaic solar panel in terms of output power. Conditions
characterized by low temperature, low relative humidity, and high sun radiation levels are
deemed more suitable for attaining optimal power values.
106
Session 11B: Renewable Energy Research and Waste Heat Recycling
Indigenous Innovation way of turning waste from coal and cow dung to
manufacture bricks for sustainable use for bioresource
Hluphi Constance Mafuwane1*, Anna Moloto2, Gift Nenzhelele2, Jan Swanepoel2,
Mammo Muchie2
1Tshwane University of Technology Industrial Engineering, South Africa
Correspondence: Moganec50@gmail.com
Due to population increase, climate change, poverty, unemployment, load shedding, and other
factors that aect society and economy, Renewable Energy Sources, used to produce energy
from natural processes, are nowadays used to meet the ever-increasing energy requirements
worldwide, replacing conventional energy sources. A signicant portion of the energy market is
devoted to renewable sources because of the threat posed by climate change, which is brought
on by emissions from fossil fuels. Cow dung and coal waste are being undermined and regarded
as waste in other parts of the world. Traditional energy sources are nite and under depletion. On
the contrary, renewable energy sources are constantly appearing in the natural environment.
Load shedding has aected the urban and rural communities of South Africa. High electricity
taris have aected low-income earners and left them with no choice but to use electricity
illegally which causes risk to human beings. The primary objective of this research was to
evaluate the feasibility of using coal waste and cow dung as alternative raw materials in brick
production, assess their impact on the quality and sustainability of the bricks, and identify the
benets and challenges associated with this innovative approach. The study demonstrated that
coal waste and cow dung could manufacture sustainable bricks. The bricks produced met the
required construction standards and oered improved thermal insulation. The environmental
benets, including reduced waste and lower emissions, along with Reduce cost savings,
highlight the potential of this innovative approach. Community acceptance and positive
feedback further support the feasibility of adopting this method on a larger scale. Future research
should focus on long-term durability testing and exploring the scalability of this process for
widespread implementation.
Keywords: renewable, energy, cow dung, bricks, sustainable
107
Session 13B: Innovative Engineering Management
How to Train Tomorrow's Engineers
[Empowering Education with Digital Twins]
Ngaka Mosia1, a) and Kemlall Ramdass2, b)
1,2University of South Africa, Science Campus, Florida, Johannesburg, Gauteng, South Africa
1709
a) Corresponding author: mosian@unisa.ac.za, b)ramdakr@unisa.ac.za
Engineering education stands at the forefront of transformation, in the digital age. The
changing environment is influenced by emerging technologies that impact production,
manufacturing, and service industries. Thus, graduates must acquire skills that will enable
a successful transition into jobs, which only occurs when graduates leverage their
acquired skills in their new occupations. By incorporating digital twins, students gain
hands-on experience in design, analysis, and problem-solving, preparing them for the
complexities of modern engineering practices. With advancements in technology, there is
a growing emphasis on experiential learning and practical applications. Virtual replicas of
physical assets offer a unique opportunity to bridge the gap between theoretical
knowledge and real-world practice. Students can explore complex engineering concepts
in a simulated environment, gaining valuable insight and skills for their future careers.
Integrating digital twins into engineering curricula enhances student engagement and
learning outcomes. The research delves into pedagogical implications, challenges, and
future perspectives of integrating digital twins into engineering curricula. Highlighting their
role in fostering creativity, critical thinking, and technological innovation. This research
adopts a qualitative approach to explore and explain the integration of digital twins into
engineering education. The research result is a guideline for training engineers in a digital
era.
Keywords: Education, Training, Digital Twins, Technology, Engineering.
108
Session 13B: Innovative Engineering Management
Assessment of a Model for Carbon Emissions at the Logistics and
Transportation Stage of Conveyor Belt Procurement Processes in a
Manufacturing Industry
Ozuzor Onyisi 12, Adefemi Adeodu 1, Ilesanmi Daniyan23, Grace Kanakana-Katumba24, and
Rajesh Ransing25
1Department of Project Management, Bells University of Technology, Ota, Nigeria
2Department of Mechanical Engineering, Covenant University, Ota, Nigeria
3Department of Mechanical Engineering, Achievers University, Owo, Nigeria
4Department of Industrial Engineering, Tshwane University of Technology, Pretoria, South Africa
5Department of Mechanical Engineering, Swansea University, Swansea, United Kingdom
Corresponding author:aoadeodu@bellsuniversity.edu.ng
Massive greenhouse gas emissions have led to global warming, resulting in extreme climate
disasters such as glacier retreat, melting permafrost, droughts, and torrential rains. These
emissions, measured as CO2 equivalents, are primarily due to human activities, especially
during the project procurement phase of a product's life cycle. This study aimed to assess carbon
emissions at the logistics and transportation stage of conveyor belt procurement processes in
the manufacturing industry using an existing carbon emission model based on the carbon
emission factor method. The model estimated carbon emission levels during the transportation
stage of conveyor belt procurement. Additionally, the study evaluated the effect of full-load rates
on carbon emission levels of the procured components. The results demonstrated that the full-
load rate significantly impacts carbon emissions during transportation, with a 54.32% reduction
in emissions at 100% full load. Therefore, increasing the full-load rate can effectively reduce
carbon emissions from transportation, provided the loading requirements are met.
Key words: Eco-friendly procurement, conveyor belt project, procurement management, net-
zero carbon emissions, procurement process activity
109
Session 13B: Innovative Engineering Management
Agent-based corrosion under insulation model detection for insulated
pipeline
Sipho Mokoena 1, a) Khumbulani Mpofu1, b) and Boitumelo Ramatsetsebi 2, a )
1Tshwane University of Technology, Staatsartillerie Road, Pretoria 0001, SA
2Stellenbosch University, Joubert Street, Stellenbosch, SA
a)sipho.mokoena@sasol.com. a)MpofuK@tut.ac.za
b)ramatsetse@sun.ac.za
Corrosion under insulation is a signicant issue in the South African Petroleum Industry, because
of increasing failure rates on the condensate pipes. Corrosion remains undetected due to
limitations on the traditional non-destructive testing methods used by local renery. Insulation
corrosion under insulation, rstly cladding and insulation material should be partially removed
on the pipeline. A framework has been developed with the Pulsed-Eddy Current tool as a
preventative maintenance approach to scan emerging corrosion without the removal of
insulation materials. This paper use collected data from theories, at rening X and integrates
them into Anylogic software by employing Agent-Based Model. They serve as input parameters
to calculate the corrosion rate, condition-based monitoring (planned) and operate-to-failure
(emergency) job cards. The results from a model were interpreted periodically starting from, 2
months, CBM (Condition Based Maintenance) (0.34); OTF (Operate to failure) (0.65), idle timer
(0.97); at 24 Months, CBM (0.33), OTF (0.67), idle timer (0.11); and nally, 36 Months, CBM (0.32),
OTF (0.64), idle timer. (0.09). The benet is the quickest way to determine corrosion without
removal of insulation, adjusting inspection frequencies, and improve use of resources in the
South African petrochemical industry.
110
Session 13B: Innovative Engineering Management
Dynamic Smart Service Design for Twin Transformation in the
Packaging Industry
Maren Kobusch1,2, a), Josef Gochermann1,2, b) and Khumbulani Mpofu1, c)
1Department of Industrial Engineering, Faculty of Engineering and the Built Environment,
Tshwane University of Technology, Pretoria 0001, South Africa.
2Institute for Dual Study Programmes, Faculty of Management, Culture and Technology,
University of Applied Sciences Osnabrueck, 49809 Lingen, Germany.
a) Corresponding author: maren.kobusch@hs-osnabrueck.de
b) J.Gochermann@hs-osnabrueck.de
c) Mpofuk@solusi.ac.zw
The packaging industry is evolving towards a stronger integration of smart services and Internet
of Things (IoT) technologies, driven by the concept of Twin Transformation - a sustainable growth
paradigm within ecological limits. Challenged by regulations such as the European Green Deal,
the Packaging and Packaging Waste Directive (94/62/EC), or changing customer demands, the
industry faces increasing pressure for innovation and competitiveness. To fulfil constantly
changing customer requirements, smart service systems must also adapt dynamically. This
paper presents a design model for smart service systems, focusing on the transition from static
to dynamic configurations in a time-dependent manner. Key factors here are transparency,
availability, efficiency, cost-effectiveness and compliance with Industrial Control System
requirements. Using the example of energy control, a dynamic approach to adapting to changing
requirements in a specific area of application is presented. This approach is transferable to other
aspects of production and manufacturing processes, such as automation. The model highlights
the importance of smart service design for the Twin Transformation in the packaging industry and
provides insights into how to overcome complexity and drive innovation amid regulatory and
environmental challenges, immediately following the heading.
111
Session 13B: Innovative Engineering Management
Implementation Guidelines for Total Productive Maintenance and
Reliability Centered Maintenance
1Mesuli Percival Mhlungu, 2Festus Fameso, 3Julius Ndambuki, 4Ilesanmi Daniyan*, 5Boitumelo
Ramatsetse
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, South
Africa.
2,3Centre for Climate Change, Water Security and Disaster Management, Department of Civil
Engineering, Tshwane University of Technology, Pretoria, 0183, South Africa.
4Department of Mechatronics Engineering, Bells University of Technology, Ota, Nigeria.
5Department of Mechanical & Mechatronics Engineering, Stellenbosch University,
Stellenbosch, 7602, South Africa.
*Corresponding author: Ilesanmi Daniyan (afolabiilesanmi@yahoo.com)
The dynamics of production, increasing production and market requirements necessitate the
availability of reliable production systems. To achieve this, maintenance of the production
systems must be rightly decided and implemented. To avoid, cost implications in the form of
unplanned failure and maintenance of production systems, this study presents implementation
guidelines for Total Productive Maintenance (TPM) and Reliability Centered Maintenance (RCM).
The study draws relevant findings from the literature using the systematic literature review and
thereafter, implementation guidelines were proposed for TPM and RCM. Existing studies indicate
that the TPM can be deployed to engage people from all levels within the organization to reduce
defects and self or unplanned maintenance, while achieving zero breakdown, defects and
accidents in all functional areas within the entity. The outcome of the literature review also
indicate that the RCM can reduce the frequency of failures by implementing maintenance
procedures that reduce the likelihood of component failure; thus, enhancing its dependability.
Thus, this study provides a guideline that can assist organisations to make effective decision
about maintenance practices and also to deploy appropriate resources and implement
maintenance operations in a cost and time effective manner.
Keywords: Production systems, Maintenance practices, RCM, TPM
112
Session 14
Industry 5.0 – A systematic and holistic approach to establish the
current trends and guidance for future research
Nampuraja Enose Kamalabai
Industrial Engineering and Management, Lappeenranta-Lahti University of Technology LUT,
Lappeenranta, Finland
Industry 5.0 represents a transformative shift towards a more sustainable, resilient and human-
centric economy (Breque et al., 2021) moving beyond the purely technological focus of Industry
4.0. It prioritizes incorporating societal and environmental objectives (Ferreira & Serpa, 2018)
alongside advanced technologies, seeking to balance between economic growth, social equity,
and environmental performance (Yazan et al., n.d.). Future research agenda must therefore be
adopted to a systematic, holistic approach, bridging the gap between technological
advancements and sustainable development. This encompasses a range of critical pathways
aimed to create an inclusive, comprehensive and collaborative approach across multiple
dimensions (Danvers et al., 2023). At its core of this shift are industry themes such as Industrial
Sustainability, Circular Economy, and Human Centric Manufacturing. These themes emphasize
the need to not only advance industrial processes but also to integrate societal well-being and
environmental considerations (Mengistu & Panizzolo, n.d.) into the design and operation of
industrial systems. Furthermore, the research agenda intersects with vital technology topics
including, Cloud and Edge computing, Automation, Industrial IoT, Digital Twin, and Cyber-
Physical Systems (Aslanpour et al., 2020, Fraga-Lamas et al., 2021) These technologies are
pivotal in enabling a sustainable industrial ecosystem envisioned by Industry 5.0. As digital
technologies continue to evolve, they provide the foundation for intelligent systems that optimize
production processes while reducing environmental impacts. In parallel, industry themes such
as Design for Sustainability (DfS), Closed-loop Manufacturing, Triple Bottom Line (TBL) and Life
Cycle Management (LCM) will be crucial in guiding future research (Khan et al., 2021,. Kara et al.,
2022)This involves embedding sustainability into the entire product lifecycle, from design
through to end-of-life, ensuring that resource utilization is optimized, waste is minimized, and
environmental impacts are reduced. In addition to environmental considerations, there is a
growing focus on developing metrics (Mengistu & Panizzolo, 2023) for carbon footprint reduction,
renewable material use, and the overall sustainability of production systems. The coevolution of
sustainable production and process efficiency through lifecycle management offers another
area of deep exploration. This approach requires continuous advancements in process
efficiency, facilitated by technologies that enable real-time monitoring and control over
production processes. The emphasis will be on developing new strategies that move beyond
compliance to create business models that are sustainable by design. A critical area of
exploration will be the role of human-centric design in ensuring workplace safety and improving
human-machine collaboration, facilitated by innovations such as Operator 5.0 and Human-in-
the-Loop systems (Pacaux-Lemoine et al., 2017). In addition, future research must account for
policy aspects (Tagliapietra, 2020) that influence industrial sustainability, including net-zero
strategies, regulations, governance, compliance, and greenhouse gas emissions management.
This comprehensive analysis offers an extended research agenda and a comprehensive
roadmap for researchers and practitioners navigating the complexities of Industry 5.0.
References
Aslanpour, M. S., Gill, S. S., & Toosi, A. N. (2020). Performance evaluation metrics for cloud, fog
and edge computing: A review, taxonomy, benchmarks and standards for future research. In
Internet of Things (Netherlands) (Vol. 12). Elsevier B.V.
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Session 14
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Danvers, S., Robertson, J., & Zutshi, A. (2023). Conceptualizing How Collaboration Advances
Circularity. In Sustainability (Switzerland) (Vol. 15, Issue 6). Multidisciplinary Digital Publishing
Institute (MDPI).
Ferreira, C. M., & Serpa, S. (2018). Society 5.0 and Social Development: Contributions to a
Discussion. Management and Organizational Studies, 5(4), 26.
Fraga-Lamas, P., Lopes, S. I., & Fernández-Caramés, T. M. (2021). Green iot and edge AI as key
technological enablers for a sustainable digital transition towards a smart circular economy: An
industry 5.0 use case. Sensors, 21(17).
Kara, S., Hauschild, M., Sutherland, J., & McAloone, T. (2022). Closed-loop systems to circular
economy: A pathway to environmental sustainability? CIRP Annals, 71(2), 505–528.
Khan, I. S., Ahmad, M. O., & Majava, J. (2021). Industry 4.0 and sustainable development: A
systematic mapping of triple bottom line, Circular Economy and Sustainable Business Models
perspectives. In Journal of Cleaner Production (Vol. 297). Elsevier Ltd.
Mengistu, A. T., & Panizzolo, R. (n.d.). A Systematic Review of Indicators Used to Measure
Industrial Sustainability.
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sustainability: a systematic review. In Environment, Development and Sustainability (Vol. 25,
Issue 3, pp. 1979–2005). Springer Science and Business Media B.V.
Pacaux-Lemoine, M. P., Trentesaux, D., Zambrano Rey, G., & Millot, P. (2017). Designing
intelligent manufacturing systems through Human-Machine Cooperation principles: A human-
centered approach. Computers and Industrial Engineering, 111, 581–595.
Tagliapietra, S. V. Veugelers. (2020). GREEN INDUSTRIAL POLICY FOR EUROPE. BRUEGEL.
Yazan, D. D. M., Abhishta, D. A., & Daneva, D. M. (n.d.). Business Information Technology An
Enterprise Architecture Approach Towards Sustainability and Environmental Performance.
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Session 15
An industry perspective on deploying real-world AI and data systems in
the manufacturing sector
Peter Brookstein
DataProphet
Deploying real world machine learning and AI systems in the manufacturing sector has
the practical potential to help achieve manufacturing excellence.
This talk focuses on the realities and complexities of building and deploying reliable
data systems needed to power advanced analytics & AI, through the lens of an
experienced team working closely with the manufacturing sector
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Session 16A: Computing and Analytics
Adaptive Control of Machining Parameters in Machine Tools for
Enhanced Product Accuracy Using DDPG Approach
Olugbenga Adegbemisola Aderoba 1,2,a) and Khumbulani Mpofu1
1Department of Industrial Engineering, Tshwane University of Technology, Pretoria, SOUTH
AFRICA
2Department of Mechanical Engineering, Landmark University, Omu-Aran, NIGERIA
a) Corresponding author: olugbenga.aderoba@gmail.com
Conventional machining operations using pre-determined machining parameters neglect the
dynamic nature of manufacturing operations leading to increased scrap rates and suboptimal
accuracy levels of manufactured components. This study leverages the Deep Deterministic
Policy Gradient (DDPG) algorithm, a deep reinforcement learning technique for adaptive control
of cutting speed, feed rate, and depth of cut parameters based on varying machining conditions
and material properties. The algorithm uses the actor-critic approach to autonomously learn
from and adjust machining parameters dynamically using environmental feedback for improved
product accuracy. The test results obtained from the experiment conducted on a Computer
Numerical Controlled (CNC) lathe machine at Company "A" Engineering workshop indicate that
the proposed method works better in achieving superior accuracy, surface finish quality and
machining efficiency than old static settings. This study gives practical solutions to
manufacturing plants to make high-quality
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Session 16A: Computing and Analytics
Optimising FMEA processes for enhanced risk management and
continuous improvement – A case study
Meghana Ransing1,2, Adefemi Adeodu3, Philip Pe1, Grace Kanakana-Katumba4
and Rajesh S. Ransing
1Department of Mechanical Engineering, Swansea University, Swansea, UK.
2p-matrix Ltd, Swansea, UK.
3University of South Africa, Florida, South Africa.
4Tshwane University of Technology, South Africa
This paper examines how Failure Mode and Effects Analysis (FMEA) can be optimised to improve
risk management and foster continuous improvement. The key phases of FMEA, including
Planning & Preparation, Structure Analysis, Function Analysis, Failure Analysis, Risk Analysis,
and Optimisation are explored to highlight their importance in guiding effective risk assessment
and decision-making. Through real-world examples, it is illustrated how organisations can utilise
FMEA to identify potential failures and take proactive measures to enhance product reliability
and safety. The significance of using process step and process work element functions and their
failures is emphasised to ensure that valuable actionable insights from FMEA are preserved for
future use. By adopting a systematic approach to FMEA implementation, organisations can
transform analysis findings into actionable strategies for sustained success in today's
competitive landscape.
Future work in this area involves further integration of FMEA with advanced technologies such as
digital twin AI to enhance risk management capabilities. Exploring the application of digital twin
AI in FMEA processes could revolutionise the way organisations predict and mitigate potential
failures, leading to more efficient and proactive risk management strategies.
Keywords: Failure Mode and Effects Analysis (FMEA), Risk Management, Knowledge
Management, Continuous Improvement, Digital Twin AI, 7Epsilon.
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Session 16B: Additive Manufacturing
Influence of laser cladding process parameters on the hardness and
wear resistance of titanium alloys
Shyline Chingowo1*, Mukuna Patrick Mubiayi 2 and Ndivhuwo Ndou3
1Department of Mechanical, Bioresources, and Biomedical Engineering, College of Science,
Engineering and Technology, University of South Africa, Florida, Johannesburg 1709, South
Africa.
2 Department of Industrial Engineering and Engineering Management, University of South
Africa, South Africa
3 Institute for Nanotechnology and Water Sustainability, College of Science, Engineering and
Technology, University of South Africa, Florida, Johannesburg 1709, South Africa
Laser Cladding is a surface modification technique that uses a high-power laser to melt the
powder into a surface layer of the substrate. Laser cladding of titanium alloys has grown in
popularity because of better bonding and reduced deformation owing to its lower heat input. This
review examines certain laser-cladded titanium alloys using data and results from previously
published work. This study aims to systematically identify the link between laser cladding
process parameters and mechanical properties of titanium alloys to propose optimum process
parameters and improve titanium alloys' surface performance. Existing challenges in laser
cladding titanium alloys are forecasted along with the prospectus of laser cladding with
improved technology. A conclusion is drawn that the hardness and wear properties of titanium
alloys are greatly influenced by process parameters such as laser power, scanning speed, and
powder feed rate. Hardness which is influenced by a finer grain size is promoted by a high laser
power and lower scan speeds. An adverse increase in scanning speed deteriorates the wear
resistance noticeable by the flaking of debris during the wear test of samples laser cladded at
high scan speeds. Power feed rate influences the microstructural evolution, dilution, and
bonding strength, a higher feed rate reduces the dilution in titanium alloys.
Keywords: Laser cladding, titanium alloys, microstructure, hardness, and wear resistance
118
Session 16B: Additive Manufacturing
Addressing Polypropylene (PP) Warping in Fused Deposition Modelling
(FDM)
Magadi Katuma1, a) Khumbulani Mpofu2, Washington Mhike1 and Rumbidzai Muvunzi3
1Department of Chemical, Metallurgical and Materials Engineering, Tshwane University of
Technology, South Africa
2Department of Industrial Engineering, Tshwane University of Technology, South Africa
3Department of Industrial and Systems Engineering, Cape Peninsula University of Technology,
South Africa
a) Corresponding author: Corresponding author: magadikatuma@gmail.com
sThe field of additive manufacturing is continuously developing, moving from prototyping to
actual part creation over a wide range of applications. This is because the technology has the
excellent advantage of being able to produce complicated parts quickly without requiring
expensive tooling, which makes it a less expensive option for prototyping. Fused deposition
modelling (FDM) technique makes use of thermoplastic extrusion and inexpensive. This study
delves into the most consumed semicrystalline polymer, PP. One challenge encountered is
warping, a contraction of internal thermal stresses that occurs during part fabrication due to PP’s
high coefficient of thermal expansion and high degree of crystallinity. This paper seeks to address
polypropylene warping by optimization of process parameters. Taguchi method was employed
for optimization of fan speed, printing speed and the profile (layer thickness). Optimum
parameters obseved for PP were printing speed 30 mm/s, build plate 90 °C, two slow initial
layers, layer thickness 0.25 mm and fan speed 0 mm/s. Warping was effectively corrected and
successful printing was achieved. Tensile properties for printed samples measured are 10 MPa
tensile strength, 233,41 MPa modulus and 557,39% at 40 mm/s printing speed, and 8,38 MPa
tensile strength, 253,5 MPa modulus and 553,38% elongation at 30 mm/s.
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Reverse Engineering and Rapid Prototyping in Product Development
Steadyman Chikumba
University of South Africa
A model creation is an essential in product development in engineering, product restoration and
biomedical applications. In many cases an engineering drawing is not available or difficult to
obtain but a physical sample may be available. Reverse engineering is applied to create an
engineering drawing using scanning technology which can be manufactured using a number of
traditional manufacturing methods or to STL file formats for 3D printing. However, there are
several cases where a visual physical model is required. In this paper the technology required,
way in which a model can be developed by reverse engineering and rapid prototyping is
discussed. Practical applications and opportunities for use in cost effective product
development of this method are discussed.
120
Understanding intrapreneurship: Definition, Characteristics and
Importance
Tlotlo Ramasu
Tshwane University of Technology
In a world marked by globalisation and increased competition, organisations are in need of
continuous innovation. Intrapreneurship plays a role in spurring innovation within organisations.
However, despite its increasing importance, intrapreneurship remains an ambiguous concept,
with no universally accepted definition. The lack of definitional clarity hinders the effective
adoption and implementation of intrapreneurship within organisations. It also lead to
inconsistent approaches towards the subject among researchers. This paper to advance the
understanding of the concept of intrapreneurship through critically reviewing some key
definitions of intrapreneurship provided in literature.
The critical review focused on 12 key articles published between 1984 and 2024, selected from
a pool of 78 identified studies using rigorous inclusion and exclusion criteria. The critical review
involved a thorough search across academic databases, including Scopus, EBSCOHost, Google
Scholar, and ProQuest.
Analysis of the definitions reveals a significant lack of consensus regarding the definition of
intrapreneurship, although common themes such as creativity, risk-taking, and innovation
emerged as essential characteristics.
The paper recommends further study of intrapreneurship focused on identifying the
characteristics that lead to fruitful intrapreneurial activities. The paper suggests that a universal
set of criteria be designed for use in defining intrapreneurship.
121
Internet of Things (IoT) Sensor Development for Real-Time Monitoring
of Water Quality and Distribution
Rendani Maladzhi
Durban University of Technology
Quality water is vital to sustain life and guaranteeing good public health. However, challenges
such as contamination, ageing facilities, pipe leaks, and unstable distribution disrupt the quality
of water delivery. Therefore, there is an urgent need to solve these problems. The deployment of
the Industry 4.0 technological approach will help to monitor in real time the availability of quality
water distribution, and pipe surveillance to ensure the availability of potable water supply. This
study seeks to use IoT (Internet of Things) sensors to monitor water quality and supply in real
time. To develop IoT sensors that accurately measure water quality, and detect pipe leakage in
the distribution network is necessary. This can be achieved by developing algorithms and
systems for quality water (H2O) treatment and monitoring the pipe distribution network to help
detect leaks and surveillance. Installation of sensors at strategy locations helps to constantly
monitor the water key quality parameters to detect any difference from regulatory standards and
transmit the same in real time to provide decision support for water management authorities.
The system would ensure regular potable water supply to the citizenry at a low cost.
Keywords: Quality water, Internet of Things, Sensors, real-time monitoring, pipe leaks
122
Synthesis and characterization of silica-supported cobalt catalyst with
different pore sizes using the Stber process for use in Fischer Tropsch
synthesis
Nicholas Jim
ICES, University of South Africa
The catalyst pore diameter and surface morphology carries a very significant impact on the
catalyst performance in the Fischer Tropsch reaction [1]. Mesoporous silica nanoparticles that
serve as a cobalt catalyst support for Fischer Tropsch Synthesis (FTS) reaction were synthesized
by the Stober process [2], using Tetraethyl Orthosilicate (TEOS) as the silica precursor. The
synthesis reaction involved the Hydrolysis of TEOS in the presence Ethanol, using Ammonium
Hydroxide as the catalyst. Different ratios of Water : TEOS : NH4OH : Ethanol were used to form
different pore sizes of the mesoporous silica by varying the water and NH4OH amounts
while keeping the others constant. The effects of the concentration of water and Amonnium
Hydroxide in the mixture was discussed. Thermogravimetric Analysis (TGA) was done on the
synthesized samples to determine the calcination temperature from which a suitable
temperature of 620⸰C was chosen from the differential thermogravimetry analysis.10% Cobalt
loading was used on all the prepared silica supports and BET analysis was done for each catalyst
sample to determine the pore sizes, surface areas and pore volumes of the catalysts, the pore
type and structures were determined from the Nitrogen adsorption-desorption isotherms from
the BET analysis. Scanning Electron Microscopy (SEM) was used to determine the catalyst
morphology. The effects of the Water/Ethanol ratios and Water/NH4OH ratios, on the resultant
catalyst morphology and pore structure were also deduced.
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