Essam Shehab

Essam Shehab
Nazarbayev University | NU · Department of Mechanical and Aerospace Engineering

PhD CEng FIET FACostE FHEA

About

197
Publications
222,371
Reads
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5,805
Citations
Additional affiliations
October 2018 - present
Nazarbayev University
Position
  • Head of Department
October 2017 - July 2021
Cranfield University
Position
  • Professor
October 2004 - September 2017
Cranfield University
Position
  • Professor (Full)
Description
  • Research Interests: • Aerospace Design and Manufacturing • Cost Modelling for Innovative Product/Service Development • Knowledge Engineering for Product/Service Development • System Design • Enterprise Resource Planning

Publications

Publications (197)
Article
Full-text available
Digital transformation is of crucial importance in the manufacturing industry, especially after the COVID-19 pandemic because of the increasing need for remote working and socially distanced workplaces. However, there is a lack of a clear and well-defined process to implement digital transformation in manufacturing. This paper aims to identify the...
Article
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Purpose In recent years, 3D printing technologies have been widely used in the construction industry. 3D printing in construction is very attractive because of its capability of process automation and the possibility of saving labor, waste materials, construction time and hazardous procedures for humans. Significant researches were conducted to ide...
Article
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Carbon Fibre Reinforced Polymers (CFRPs) are commonly used materials in manufacturing components and products in the automotive, aerospace, and wind energy industries generating thousands of tons of waste, thus creating a threat to the environment if not recycled. Therefore, it is important for both academia and industry to investigate various ways...
Article
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Cost-effective and environmentally responsible ways of carbon fiber-reinforced composite (CFRP) recycling are increasingly important, owing to the rapidly increasing use of these materials in many industries such as the aerospace, automotive and energy sectors. Product designers need to consider the costs associated with manufacturing and the end-o...
Conference Paper
Full-text available
The use of carbon fiber reinforced polymers (CFRPs) has expanded in many industries due to superior properties compared to traditional materials. Nevertheless, their recycling is challenged by immature recycling market and poor legislative support. This study evaluates the application and disposal of CFRPs within the different industries in Kazakhs...
Chapter
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Globally the manufacturing industry is undergoing a shift in the way product specifications are defined, used, and re-used from conventional drawing-based systems to a comprehensive 3D digital product model. This transformation is at the heart of the digitization processes. The true benefits lie in the adoption of this technology throughout the pro...
Chapter
The successful operation of Electric-Vehicle Batteries (EVB) is paramount for the ever-continuing goal of approaching a low carbon emission future. The Lithium-ion battery (LIB) is currently the best wager to implement on Electric Vehicles (EV). Nonetheless, it comes with its fair trade of challenges. The complexity involved in the design, manufact...
Chapter
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Over the years, there has been an advancement in how manufacturing companies conduct maintenance. They have begun transitioning from Preventive Maintenance (PM) to Predictive Maintenance (PdM). With the introduction of technologies such as Digital Twin (DT), Internet of Things (IoT), and Intelligent Manufacturing (IM), the world is rapidly changing...
Chapter
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The world is adopting digital technologies at a rapid pace which are the key enablers to improve every walk of life in the modern era. This quest for digitization has equal rigor within the manufacturing industry. 2D drawings have been used historically to define the specifications of a product for manufacturing. The evolution in digital technologi...
Conference Paper
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Recycling of carbon fiber reinforced polymer composites (CFRPs) is a trending topic in the context of the current levels of CFRPs application in different industries and evolving environmental legislation and regulations. However, the recycling processes tend to be accompanied by various uncertainties leading to an increase of difficulties in evalu...
Conference Paper
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Although digital transformation has been extensively researched in recent years, there is no clear definition, especially in the manufacturing industry. In addition, there is no oblivious model for the current manufacturing firms to be digitally transformed. As a part of a current research project, this paper proposes a framework for the digital tr...
Conference Paper
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Digital Transformation becomes an essential strategy for organisations in this new digital arena, specifically after the COVID-19 pandemic and its unprecedented effects on the whole world and the manufacturing sector. In this new digital era, consumers became more expert and more engaging in the products using new technologies. At the same time, co...
Chapter
Unique properties such as high strength, wear and fatigue resistance at high temperatures have made superalloys best candidate materials for the aerospace industry. On the other hand, the development of composite materials particularly metal matrix composites (MMCs) have comparable properties to superalloys and have an advantage of being lightweigh...
Article
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The concept of Industry 4.0 is becoming more and more popular all over the world. The implementation of its assumptions in business practice changes the way companies operate. The enormous innovative potential of the Industry 4.0 concept and the intensive use of processes based on the implementation of advanced technologies in its assumptions have...
Conference Paper
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The implementation of digital transformation features is highly required to provide sustainable growth and a high level of competitiveness. One of the essential components of the ensuring of SMEs readiness for digital transformation is a digital maturity model that can assess the maturity level based on the features of SMEs in Kazakhstan. This stud...
Conference Paper
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With the evolving of Industry 4.0 in the 21st century, digitalization gains popularity in companies, because it is a need that makes the company competitive and optimizes the work. Many factors influence the company and its transformation, especially in large companies, for example, financial situation, organizational culture, employees and their s...
Conference Paper
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The digitalization has become a leading trend for developing a stable economy through industry and firm digital transformation. However, there is no unified recipe for the successful implementation of these technologies. This work aims to define Critical Success Factors of digitalization for the manufacturing industry and compare them with Kazakhst...
Article
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This study aimed to conduct a systems engineering investigation for the integration of reverse vending machines (RVM) into the waste management system of Kazakhstan. By conducting a wide-scale survey among the general public, the study was able to identify the underlining reasons for low recycling rate, the awareness and willingness of the public t...
Article
Purpose Numerous leanness assessment models were developed for both manufacturing and service sectors. However, little research effort was made to provide an instrument that can be used to measure the leanness level of the product-service system (PSS). This paper aims to propose an index to assess the leanness of PSS in a UK manufacturing company....
Article
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The research in wearable lower limb exoskeletons is showing an increasing interest in the last few years. An exoskeleton is a structure that helps paralyzed patients stand and walk. Nowadays, wearable exoskeletons have a growing interest in healthcare, as they help make patient's rehabilitation process more comfortable and more natural. External ex...
Article
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Industry 4.0 concept is one of the growing concepts worldwide for the last five years. It combines the physical and digital world, thus creating new capabilities which affect not only the manufacturing industry but to all other sectors and organizations. Furthermore, many experts worldwide declare that Industry 4.0 will have a substantially positiv...
Article
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In order to support accelerating the diffusion of innovations in high value manufacturing related to enabling flexible mass customization, this paper presents a research-based maturity model for forecasting the speed of innovation diffusion from ideation to market saturation. The model provides an early stage applied research view of (groups of) “g...
Article
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Aircraft manufacturing industries often evolve in the ecosystem of complex designs and manufacturing processes associated with large volume of information generated along the lifecycle. Digital Twin (DT) technology has the potential of leveraging such information to provide useful insights benefiting the overall business in many ways. Information M...
Article
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Digital transformation is one of the most evolving areas both in the research literature and in industrial applications. No doubt that this process will be crucial in the survival of any manufacturing organisation in the future, especially during the current COVID-19 crisis. This paper aims to present a review of the concept in the manufacturing in...
Chapter
The use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost...
Article
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Digital Twin (DT) is the imitation of the real world product, process or system. Digital Twin is the ideal solution for data-driven optimisations in different phases of the product lifecycle. With the rapid growth in DT research, data management for digital twin is a challenging field for both industries and academia. The challenges for DT data man...
Conference Paper
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3D modeling is in use for the last many decades at various stages of the product lifecycle i.e., design, analysis, manufacturing, and inspection. In the modern era of Industry 4.0 where the high-value manufacturing industry is aiming at the digital thread, Model-Based Definition (MBD) has been considered as the heart of this transformation. However...
Article
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Model-Based Definition (MBD) is being adopted by the manufacturing industry as a single source for all product information in place of conventional 2D drawings. This paper aims to review the current literature on Model-Based Definition (MBD) and Model-Based Enterprise (MBE) to recognize the main contributions towards the development and implementat...
Article
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Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to dr...
Conference Paper
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The use of carbon fiber composites (CFCs) has become broad in many industries due to its superior properties compared to conventional materials. However, the increased demand coupled with environmental regulations has led to the development of different recycling methods for CFCs such as mechanical, thermal and chemical processes. Each recycling me...
Article
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Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are consid...
Article
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Laser drilling is a high-speed process that is used to produce high aspect ratio holes of various sizes for critical applications, such as cooling holes in aero-engine and gas turbine components. Hole quality is always a major concern during the laser drilling process. Apart from hole quality, cost and productivity are also the key considerations f...
Conference Paper
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Manufacturing Industry is moving towards adoption of 3D models as the ultimate authoritative source for complete product definition replacing 2D drawings, which is called “Model-Based Definition”. Starting its journey from geometric information on design, manufacturing, and inspection, the targets are to achieve the ultimate goal of lifecycle model...
Conference Paper
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In the context of aerospace digital transformation, gaining and maintaining competitive advantage has led aerospace manufacturers to change how product definition is communicated. Model-Based Definition (MBD) and Enterprise (MBE) are the next generations of product definition that aim to move from 2D drawings to a full 3D digital model. Even though...
Conference Paper
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To achieve an excellent workpiece surface quality and long tool life in machining of hardened steel is an inordinate challenge. Recently, conventional flood cooling assisted machining processes are used to address this problem. However, such proposed processes have adverse effects on the environment as well as on the machine shop worker's health. H...
Conference Paper
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Cutting fluids have frequent use in industrial sector to improve the machinability. Due to the negative impact on our ecology, recent focus has shifted to explore some environment-friendly cooling techniques such as cryogenic cooling. Cryogenic cooling involving liquid nitrogen is one of the alternative techniques which improves the efficiency of t...
Conference Paper
With the rapid digitalisation in the aerospace industry, the emergence of Digital Twin (DT) is significant as it can facilitate the urgent need of data-driven optimisations in existing products, operations and services. Data management for a novel concept like DT is new for both academia and industry. In this paper, an efficient data management app...
Conference Paper
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Laser drilling is used to produce micro holes in various components which have widespread applications in the automotive, aerospace and medical sectors. Many researchers have examined several ways to enhance the performance of this process by investigating different process parameters that seek to improve drilled hole quality. The productivity and...
Conference Paper
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Environmental legislation puts more pressure on solving carbon fibre composites (CFC) waste management through recycling and reuse. Despite their superior properties, CFC creates environmental issue when it reaches its end of life. The aim of this paper is to to provide a framework that represents the first step towards the development of a cost mo...
Article
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Assembly Lines (ALs) are used for mass production as they offer lots of advantages over other production systems in terms of lead time and cost. The advent of mass customization has forced the manufacturing industries to update to Mixed-Model Assembly Lines (MMALs) but at the cost of increased complexity. In the real world, industries need to deter...
Article
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Electrical discharge machining is a non-traditional machining method broadly employed in industries for machining of parts that have typical profiles and require great accuracy. This paper investigates the effects of electrical parameters: pulse-on-time and current on three performance measures (material removal rate, microstructures and electrode...
Article
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Parametric modelling and optimisation play an important role in choosing the best or optimal cutting conditions and parameters during machining to achieve the desirable results. However, analysis of optimisation of minimum quantity lubrication–assisted milling process has not been addressed in detail. Minimum quantity lubrication method is very eff...
Article
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In practice cost estimators typically assume that cost risk and uncertainty continuously decrease across the whole product life cycle. Industry case studies and semi-structured interviews indicate that while cost risk and uncertainty decreases between technology readiness levels / stage gates, it increases when technology readiness levels / stage g...
Article
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In practice the forecasting of cost uncertainty for high value manufacturing products is typically a statistical exercise focused on predicting a static cost range at a future point in time. This only leads to robust forecasts if sufficient historical data is available, robust knowledge of cost estimating relationships exists and these relationship...
Conference Paper
Full-text available
Digital Twin (DT) is a dynamic digital representation of a real-world asset, process or system. Industry 4.0 has recognised DT as the game changer for manufacturing industries in their digital transformation journey. DT will play a significant role in improving consistency, seamless process development and the possibility of reuse in subsequent sta...
Conference Paper
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Scheduling of jobs in Flow Shop (FS) is NP-hard problem which is usually solved by using heuristic and metaheuristic algorithms. In this paper modified Genetic Algorithm (GA) was used to solve FS scheduling problem to minimize the makespan. The proposed algorithm involved two improvements in GA. First is the modification in Roulette Wheel Selection...
Conference Paper
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The efficiency of an organizational supply chain system depends upon several factors. One of the major factors is inventory management. Efficient inventory management can generate more profit. To have an efficient control of a huge amount of inventory items, the traditional approach is to classify the inventory into different groups. Inventory clas...
Conference Paper
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Quality of any manufactured product is closely associated with to maintenance of manufacturing systems of any organization. To achieve a world class manufacturing system, two new manufacturing paradigm Total Productive Maintenance (TPM) and Total Quality Management (TQM) have emerged over the period along with other widely used concepts. In this pa...
Conference Paper
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Laser drilling is a non-conventional machining process which is widely used in automotive, electronics and aerospace sectors to produce holes in diverse range of materials. Different types of lasers and methods are available to produce various hole geometries. Big number of researchers have examined several ways to enhance the performance of this p...
Article
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Industrial Product-Service Systems (IPS²) can provide insights to enhance the environmental sustainability and lower environmental impact. However, its successful realisation for preventing the production of waste, while increasing efficiencies in the uses of energy and human capital remains a highly convoluted problem. This research article aims t...
Conference Paper
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Laser drilling is a widely used non-traditional machining process, in power generation and high-value manufacturing industries, to produce components such as nozzle guide vanes, combustion chambers, fuel injection nozzles and turbine blades. The operating cost of the drilling process is one of the critical factors for companies to consider to survi...
Conference Paper
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In the past few years, Additive Layer Manufacturing (ALM) utilisation has increased significantly. The high cost of manufactured products is the main barrier for the implementation of this technology in mass production. This implies that companies need to search the cost-efficient way to remain competitive. The aim of this study is to develop a cos...
Conference Paper
Full-text available
Laser drilling, an unconventional machining process, is widely used for the machining of high strength and high-temperature resistant metals and alloys. This process has widespread applications in aerospace industries to produce cooling holes in nozzle guide vanes, combustion chambers and turbine blades. The quality of hole is an important factor a...
Article
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Link to open access article: https://authors.elsevier.com/sd/article/S0968090X18302055 National railways are typically large and complex systems. Their network infrastructure usually includes extended track sections, bridges, stations and other supporting assets. In recent years, railways have also become a data-rich environment. Railway infrastr...
Article
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Nowadays austerity policy and reduced funding promote the Defence Sector (DS) interested in improving interactions across the supply network to achieve more outcomes with less expense. The quality of the information link plays a key role in the supply chain. The information is often lost causing costs increase. Information Asymmetry (IA) exists whe...