M.Affan Badar

Indiana State University | ISU · Department of Applied Engineering and Technology Management

Purpose: Reducing wear of undercarriage track propulsion systems used in heavy construction equipment decreases the maintenance costs and increases its life. Therefore, understanding key factors that affect its wear rate is critical. This study is an attempt to predict undercarriage wear. Design/methodology/approach: This research has analyzed a s...

There are numerous techniques and technologies used in the brewing of coffee today. This study is aimed to design an umbrella experiment to examine the impacting key factors consistent across all methods of extraction. These factors were identified as: grind size, roast type, steep time, grind to water as a mass-to-mass ratio and temperature. Sampl...

The growing need for ‘sustainable development’ and the existence of monumental wastes and unsustainable patterns have made scientific movements worldwide towards an emerging paradigm—Sustainable Manufacturing—which is also regarded as an application of the circularity principle to production under the emergent concept of circular economy. To create...

This work aimed to investigate the effect of various factors on cost, customer satisfaction and cycle time with respect to same day delivery (SDD). Using survey and Pareto chart, four factors were identified as the most important: logistics resources ownership, operations management, IT infrastructure, and facility location. Analysis of variance (A...

Allied Health staffing has been a multi-decade challenge for many healthcare organizations and has become a crisis for nearly all healthcare organizations throughout the COVID-19 global pandemic. Mayo Clinic Health System in the Southwest Minnesota Region was not immune to these challenges. Recognition that staffing issues needed to be clearly defi...

The traditional software space (1.0) has seen more than fifty years of creation, testing, and delivery of deterministic software, but this tradition is being disrupted by machine learning (2.0). However, ML and traditional software are considerably different, and the nascent ML industry uses unique workflows and toolsets for both life cycles. This...

Over-coating of the zinc layer in the hot-dip galvanization process is a common issue. The coating thickness of zinc depends on various factors such as zinc bath temperature, dipping time, silicon percentage in steel, alloy composition in zinc bath, etc. In the current work, three factors: dipping time, silicon percentage in steel, and nickel perce...

Purpose The purpose of this paper is to develop a framework that illustrates the role of Lean Six Sigma (LSS) in creating organisational innovation climate by investigating the relationship between LSS’s intangible impacts and organisational innovation climate factors. Design/methodology/approach A self-administrated survey questionnaire was distr...

The hot-dip batch galvanization (HDBG) process is one of the most popular and widely used techniques of galvanization and a prime consumer of 50% of zinc produced annually. An increase in production expenses due to excess zinc and energy consumption is a major problem in the HDBG process of many galvanizing industries. To identify the root cause of...

This study conducted a systematic review of the literature between 2000 and 2021 on the impacts of state budget cuts on public higher education institutions in the US. The inclusion criteria containing search terms 'State Budget cuts', 'Public Higher Education', or 'State Appropriations' in the titles, keywords, or abstracts in three databases, EBS...

COVID-19 pandemic has affected technology, manufacturing, healthcare, education, tourism, and other service industry globally as well as in the US. The pandemic has caused supply chain disruption, chip shortage, worker shortage, etc. Nowadays chips aren't used in computers and smartphones only, but in automotive and various other products. In respo...

The outbreak of COVID-19 had a profound impact on global economic growth. Global trade has transformed drastically and will only continue to do so as countries vote on export and import decisions based on global competition. Many countries would be compelled to reconsider multi-country trade deals as internal interests will push and dictate them. M...

Sustainable supply chain management (SSCM) is an essential strategy to reduce damage to the environment and support organisations in becoming more efficient, which impacts their overall performance. This article provides a framework strategy to help managers apply SSCM to their organisations and partners. The methodology employed in this study is b...

The COVID-19 pandemic in 2020 exposed numerous issues around healthcare availability. Data was collected for 151 rural hospital closures from 2005 to current. From the year of establishment (i.e., open year) until the closure was considered as time to failure (TTF). This research explored if factors like rural-urban commuting area (RUCA), number of...

This work attempts to evaluate the consortium-based Ph.D. program in Technology Management at Indiana State University to offer needed curriculum changes applicable to modern time. Through over two decades of existence, the program has sought to update its curriculum to keep it relevant. Topical coursework concerning Technology Leadership, the Mana...

Student learning experience can be disrupted significantly if the plan of study changes suddenly like it did due to the COVID-19 global pandemic in March 2020. The purpose of this paper is to compare the outcomes of two courses at Indiana State University such as student grades, number of students dropping the course, available resources, etc. befo...

Disruptive technology, especially machine learning (ML), is changing the paradigm in many fields, including quality. Advancements in data science, increasing processing powers of computers, and the availability of massive datasets, have made machine learning a useful tool to solve the problem at scale. In this work, a systematic review of literatur...

The purpose of this study is to compare the similarities and differences between Ph.D. in Engineering Management (EM) programs to Ph.D. in Technology Management (TM) programs. In an earlier study, McKirahan et al. (2020) evaluated Ph.D. in Technology Management programs in the USA. In this study, Ph.D. in Engineering Management programs in the US,...

Since the COVID-19 global pandemic surfaced and soon impacted many lives and industries across the globe, many organizations did not even have time to think about how to respond to such a crisis. This paper explores how the use of one such quality improvement methodology: Lean Six Sigma, helped the healthcare sector to be better prepared during the...

This work proposes a Value Stream Mapping (VSM) to be used in manufacturing industry that combines Lean, Energy and Six-Sigma methodologies. Lean's VSM tool is amended to energy VSM so that the value-added and non-value-added approach can be used to determine the energy use and waste. In order to identify the maximum rejection or rework at a workst...

The respective American Society for Quality (ASQ) Bodies of Knowledge (BoKs) for Certified Quality Engineers (ASQ, 2015a) and Certified Six Sigma Black Belts (ASQ, 2015b) are quite similar; yet anecdotally six sigma black belts are recognized and rewarded more highly than are quality engineers. While quality engineering work is considered preventiv...

The objective of this chapter is to apply risk management framework for risk identification and analysis of steam generating unit (SGU) in sugar plant. Only internal operational risks were considered for analysis. The expert discussion and fish bone diagram were used for identification and presentation of operational risk, and in the second phase r...

In this study, conventional vehicles (CVs) and electric vehicles (EVs) were compared statistically at 95% confidence level in terms of fuel economy (FE), annual fuel cost (AFC), maintenance frequency, and maintenance intensity. Electric Vehicles were hybrid electric vehicles, plug-in electric vehicles, fuel cell electric vehicles, and battery elect...

US healthcare has made huge progress in technological advancements and regulatory standards over the last century. Despite this, healthcare as an industry has many challenges which are experienced by many patients on a daily basis and has also become a hot topic for politicians to debate in recent years. This study aims to identify technological ad...

This paper attempts to evaluate a Consortium-Based Ph.D. in Technology Management program, in general, and to provide a comparison with four other individual degree-granting universities. The consortium program maintains most of the traditional requirement characteristics of advanced graduate study, though it is unique from a resource utilization p...

This paper deals with productivity enhancement of a Caravan Manufacturing company located in United Arab Emirates. A continuous improvement technique: define, measure, analyse, improve, and control (DMAIC) has been implemented in the production department of the case company. A model was developed using Arena software to simulate the caravan manufa...

This work aims to economically evaluate centralized and decentralized Sewage Treatment Plants (STPs) for a metropolitan city. For the same, centralized and decentralized wastewater treatments for a catchment area in Sharjah city (United Arab Emirates) were evaluated by Net Present Value (NPV) method. Three options meeting local government regulatio...

Purpose This research brings together two streams of thought applied to decision-making: lean thinking and stakeholder theory. Both have been identified as ways to improve organizational value. Previous studies disagree regarding whether they can work together. This study investigates if managers balance stakeholders and lean thinking in decision-m...

Numerous factors affect same day delivery (SDD) in E-Commerce. A Delphi survey was designed and sent to industry experts to rate affecting factors based on their respective importance pertaining to SDD in the UAE. The survey findings revealed that the most important factors that affect SDD substantially are: logistics strategy, operations managemen...

Purpose Reciprocating compressors offer an efficient method of compressing almost any gas composition in a wide range of pressures and have numerous applications. Condition monitoring of critical rotating machinery is widely accepted by operators of centrifugal compressors. However, condition monitoring of reciprocating machinery has not received...

Purpose This study investigated the possibility of including the cost consequence of failure in the a priori risk assessment methodology known as Failure Mode and Effect Analysis (FMEA). Design/methodology/approach A model of the standard costs that are incurred when an electronic control module in an automotive application fails in service was...

Active learning differs from traditional instructional pedagogy by emphasizing student activities and engagement in the learning process. The most frequently discussed types of active learning are collaborative learning, co-operative learning, and problem-based learning. Various studies have shown that active learning is gaining attention in the ed...

This work is a case study dealing with the production of examination table covering used in gynecological offices which has been a problem for its manufacturer, Little Rapids Corporation. During production, the rolls of paper break or tear causing production to cease while the machine is reloaded, costing about $10,000 of lost production in a year....

Purpose: The purpose of this study was to develop an optimal model of an integrated quality and safety management system (QSMS). Design: Key words related with these systems were identified from International Standards and subsequently mined from a selection of peer reviewed articles that discuss and propose varying forms of integrated models for b...

While the use of green energy has gained popular support and efforts have been made to market it, few studies have investigated the economic advantages and the savings that could be gained by implementing green solutions for energy challenges. This study aims to measure the financial viability of installing and using a residential grid-connected ph...

Preserving important troubleshooting experience gained in industrial practice, often referred to as “tribal knowledge”, and making it readily available to be re-applied in similar situations represent a serious challenge for many companies in heavy industry. The solution is very often tied to building mental models to capture and express key latent...

An increasing number of both private and municipal landfills throughout the world have met their useful life and are being converted into methane producing power plants. To harness this power, a complex methane gas harvesting system is used that captures and funnels the methane gas to large electric generator sets which send this recycled energy to...

Gregory Poole Equipment Company is the Caterpillar Dealer in eastern North Carolina which sells and services anything that Caterpillar Incorporated manufactures. One value added service provided by this company is fluid analysis. This service consists of 22 separate tests on engine oil, power train lubricants, hydraulic oils, coolants and fuels. On...

“Tribal knowledge” is a terminology commonly used in industry to describe special knowledge procured by only a handful of employees. These employees are usually senior personnel in the quality, maintenance, or control department in the organization, who have acquired expertise on a equipment, system, or process over an extended period, sometimes de...

Purpose – The purpose of this paper is to investigate the impact of costs of quality on the present worth (PW) of a new product launch at a North American automobile manufacturer. Design/methodology/approach – The paper is based on the examination of various cash flows associated with a new product launch within an automobile manufacturer. Standard...

In recent years, formerly depleted domestic oil fields have become producers once again through tertiary oil recovery. In tertiary oil recovery, water and Carbon Dioxide (CO2) are alternatively injected into reservoirs through injection wells. This raises the field pressure and forces oil to producing wells where it is then pumped to a storage tank...

Purpose – The purpose of this paper is to investigate the impact of ISO 9001 certification on US firms’ financial operating performance for a period of five years including one-year prior to certification, year of certification, and three fiscal years after certification. Design/methodology/approach – The paper is based on an examination of a samp...

This main objective of this study is to determine if common platform dishwashing products have similar warranty failure rates when brands and price points are variable. Data for this study are based upon over four years of data involving one million individual sales and over 150,000 warranty failures of a common platform dishwashing appliance. It i...

Engine systems and controls is a core course in automotive engineering (AET) program that teaches students the theory and application of on-board diagnostics and monitoring system. In this paper we report preliminary results of developing customized microcontroller (MCU) boards accompanied with lab modules to engage students in MCU-based, engine-ta...

Kulakova and Kulakov (2012) have presented the generalised net present value (GNPV) method to evaluate non-conventional projects. They have illustrated the method with three examples: a project of 2-year life with multiple internal rate of returns (IRRs), a project of 2-year life without IRR and a project of 3-year life with a unique real-valued IR...

Lean Six Sigma is a hybrid continuous improvement methodology that has various definitions, from those that are Lean dominant to those that are Six Sigma dominant. Text mining and cluster analysis based research has helped to illuminate the degree to which Lean Six Sigma models, as described in articles published in the International Journal of Lea...

The creation of an industrial environment in the classroom helps students to prepare for the real world of work. Manufacturing students must be prepared to apply lean manufacturing (LM) concepts in an industrial environment. Value stream mapping (VSM) is one tool that can be used to implement the LM technique. The aim of this current study was to a...

This study analyses bearing failures that occur in rolling mill applications and determine the associated reliability of the bearings. Specifically, the failures associated with the roller (thrust) bearing portion of a work roll chock and bearing assembly was studied. The relevant data was recorded from 2009-2012. Reliability mathematical computati...

Lean principles focus on elimination of waste by applying tools such as just-in-time, level production, standardized work, quality at the source, and continuous improvement. This chapter discusses the application of lean concepts to design and organize a manufacturing cell. A brief description of system engineering approach as well as a summary of...

Profitability of a company can be affected by the costs associated with backlogs and large inventories due to the bullwhip effect in the supply chain. This work aims to find an ordering strategy that is practical and can minimize the bullwhip effect. Five strategies with different levels of information about inventory and components along the suppl...

This paper presents some of the most important findings of studies of the impact of ISO 9000 and ISO 14000 certifications on organizations, based on a literature review. The article discusses potential synergistic advantages that can be derived from an integrated quality-environment system and qualitative benefits using ISO 9000 and 14000 certifica...

There is a significant resource cost in the development of products. To minimize the resource cost and maximize the return on investment many companies develop several new products from one common platform. Studies have indicated that the assumption of warranty being stable across common platforms is not accurate and branding is a significant varia...

Academic quality measurement through assessing student-learning outcomes targets the crux of teaching and learning activities undertaken by higher education institutions. This pilot study introduced the key elements for conducting direct assessments of student learning via a computer-aided performance-rating process adapted by one engineering colle...

Purpose: The purpose of this paper is to verify if the model method based on estimation of observations of customer complaint levels, when applied to the hinges of a range door, is an acceptable method of estimating future warranty costs. Design/methodology/Approach: Data based reliability was calculated by converting service failures reported in t...

This study investigates the international trade balance to examine the effect of globalization on U.S. manufacturing industries. This work discusses three kinds of manufacturing industries: farm machinery and equipment, motor vehicle and parts manufacturing, and medical equipment manufacturing from 2000 to 2010. To capture globalization effect, tra...

A photovoltaic (PV) two-axis tracking system has been installed on the Technology Center building at Indiana State University located in Terre Haute, Indiana, USA. The PV system supports emergency lighting of the building and provides an opportunity to the students to learn about green energy and its functioning. The present work aims to investigat...

Globalization has often been perceived as the culprit in the decline of employment in several manufacturing industries in the United States. The purpose of this research was to investigate how globalization affected the automotive manufacturing industry in Indiana. Specifically, Indiana’s gas engine manufacturing and parts industry during the perio...

Construction in the 21st century is characterized by a new set of challenges, options and expectations from owners and clients. As we move into a new era of globalization, awareness about sustainability and scarcity of resources have been instrumental in devising and experimenting with newer models of project delivery. Concepts such as Public-Priva...

Purpose The purpose of this study is to examine the effect of individual components' reliability on a system's reliability. The system refers to the Financial Management Information System (FMIS), the US Federal Highway Administration's (FHWA) web‐based project approval and tracking software. Its components are 61 project information fields. Desig...

The quality, productivity and safety of machining can be significantly improved through the optimization of cutting conditions. The first step in achieving such an objective is the development of accurate and reliable models for predicting the critical process parameters. In this paper, an innovative Artificial Neural Network (ANN) model that predi...

This case study involved the implementation of Quality Function Deployment (QFD) into the design process at Reynolds & Co., a small job shop company. The objectives were to find the QFD concepts that were applicable and reduce the average design time or number of design changes in the design process. The study was successful in providing research i...

The safety of oil and gas pipelines has increasingly considered day by day to their vulnerability. Pipelines play a very critical role in the transportation of oil and natural-gas. As they have become the veins of oil industries, the productive design and analysis became more important. This made them more vulnerable to terrorist attacks. Although...

The research was intended to apply lean manufacturing techniques to a healthcare setting, specifically Emergency Department (ED) of a local hospital and improve its performance. The ED process was classified into key subprocesses and data was collected from, the ED computer database and direct observations. The data was statistically analyzed to fi...

This research focuses on the five sampling methods: Hammersley sequence, Halton-Zaremba sequence, Random, Uniform, and Tabu, search-based. The objective of this work is to compare the estimation accuracy of these methods with respect to sample sizes 4, 16, 64, 100, and 256. Two-factor experimental design was carried out to achieve the objective. Ba...

The field of instruction related to engineering economics for technology students has become somewhat static over recent years, and has failed to match the change in technological advances and diversified student constituencies that are altering the educational environment of most universities. This paper is written from the viewpoint of the studen...

In earlier work [Bader et al., ASME J. Manuf Sci. Eng. 125(2), pp. 263-271 (2003); Int. J. Mach. Tools Manuf. 45(1), pp. 63-75 (2005)] the authors have presented an adaptive sampling method utilizing manufacturing error patterns and optimization search techniques for straightness and flatness evaluation. The least squares method was used to compute...

This paper presents an adaptive sampling procedure, which uses manufacturing surface error patterns and optimization search methods for reducing sample size, while maintaining high accuracy. The methodology is demonstrated with straightness and flatness evaluation. Two manufacturing processes, end and face milling are used to fabricate plates used...

This work deals with the application of lean concepts to organize one cell of a local manufacturing industry using 6S program. The 6S stand for Sort, Straighten, Shine, Standardize, Safety, and Sustain. The cell consisted of a H5 Cincinnati (5-axis CNC) and 2 Omni Mills. A point system was designed to account for the 6S (total 155 points). In addit...

Form error estimation with a CMM requires prudent sampling and accurate Zone fitting. This paper proposes use of optimization search methods for reducing sample size, while maintaining high accuracy. The approach is demonstrated with examples of straightness and flatness. For straightness, region-elimination search is used. For flatness, two patter...

Efficient part feature verification through coordinate metrology requires prudent sample point selection as well as accurate zone fitting. Selection of a large sample size typically results in higher accuracy of sampling. This paper suggests search-based methods for reducing the sample size in form verification while maintaining required accuracy....

Fouling of heat transfer surfaces introduces a major uncertainty into the design and operation of heat transfer equipment. After a brief discussion on impact of fouling, we present and discuss a stochastic approach to the analysis of fouling models. In view of the performance indicator (U/U-c) of the heat exchangers, a maintenance strategy for plan...

Aeroplanes are repairable systems consisting of several non-repairable parts; tyres are one of these. Proper record of failure data is valuable in interpreting the failure pattern, for comparative evaluation of the quality of tyres of various manufacturers, and for prediction of the future needs in a specified planning horizon or for specified oper...