Design Modeling and Simulation of Block Moulding Machine: Management Approach
Design Modeling and Simulation of Block Moulding Machine: Management Approach
Design Modeling and Simulation of Block Moulding Machine: Management Approach
Abstract: For sometimes now, there has been series of incidence of collapsed building in this Country. The reason
behind this is as a result of the poor quality of material used for the construction. The introduction of block moulding
Machine will help to produce more solid blocks of high quality within a short time which invariably will help reduce this
problem of collapse buildings in our Country, Nigeria. Usually, blocks can be molded by hand but the need for machine
cannot be over emphasized because it will allow for easier, faster and cheaper means of producing blocks. Block
moulding machine comes in different designs, types, shapes and sizes. No other idea or device has impacted
manufacturing as compute. All engineering disciplines routinely use computers for Calculation, Analysis, and Design.
and Simulation. In the Manufacturing phase of the product’s lifecycle, product manufacturers need to consider
manufacturing two products: the physical products that they have always produced and the virtual product that is the
information about the physical product. This virtual product can provide manufacturers with a new of value. The scope
of this project was. to Design,modelling,Simulation and to use gantt chart in scheduling in manufacturing of a more
efficent and versatile block moulding machine. The Block Moulding machine was designed to operate 151.8rad/s which
compacted with the strenght of 0.99n/mm2 the production rate was 500 blocks in 8 hours working day.The machine was
designed to be versatile in operation manually or to be power driven either by an electric,petrol or desel. Provision was
made for mould sliding plates to be introduced into the mould holes so that 6 inches blocks are produced when
required,instead of the regular 9 inches blocks. After thoroughly researching,designing and experimenting with soft
ware’s final machine was developed optimizing the process, the product time was successfully reduced from several
hours to 5 minute. All other engineering and customer design requirement were met,through the success of the design.
I. INTRODUCTION
Property development and building construction have been at the increase in Nigeria as far back as 1970, when
the civil war between Nigeria and Biafra came to an end. It was an era which marked the crude oil boom which
still financed over 90% of Nigeria‘s Capital projects (Olusegun, 2009). The Nigerian cities have experienced
transformation by way of infrastructure in urban and rural areas. The areas of interest for this work was how to
develop machine that is cheaper than the conventional sand crete block making machine so that the cost of block
will be reduced. The semi-automatic sand crete block moulding machines that are found in the Nigerian cities,
produced about 500 standard blocks per day (8 hours working day). It is singular acting with one operator and
two labourers. The designed block moulding machine is one-third the physical size of the conventional semi-
automatic block maker found in the urban areas with a cost of less than a half of the conventional block
machine. It operates with 1/3 the power of the conventional semi-automatic block maker and produces 500
standard blocks per day, using the same number of three workers (one operator and two labourers). The new
machine has the advantage of being smaller and thus moveable to remote interior rural areas. The block
moulding machine has the added advantage that it can be operated manually or driven either electrically or by
petrol engine or diesel engine. Blocks were first known to have been in use at the river basin region of those of
ancient Egypt and Greece. So instead of using stones and marble, clay, mud, silt, and straw were used to make
blocks that were baked before use (Swamy, 1986). However, the durability became possible when blocks were
fired in kilns. Excavations have uncovered perfectly fired blocks as far back as 5000BC. Clay, silt and stave mix
blocks, fired in kilns were used for a very long period up till 3000BC when gypsum and lime mortar were used
in the construction of the pyramids in Egypt. Many other similar materials were used, leading to the discovery
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of Portland cement and Mesopotamia as early as about 10,000BC. The region had no stone or marble as the
production of concrete, (Encarta, 2004).Computer-based design analysis is nowadays a common activity in most
development projects. When new software and manufacturing processes are introduced, traditional empirical
knowledge is unavailable and considerable effort is required to find starting design concepts. The ability to
create something out of nothing makes design one of the most exciting aspects of engineering as well operations
management. Computer technology has touched all areas of today‘s life, impacting how we obtain railway
tickets, shop online and receive medical advice from remote location. CAD began as an electronic drafting
board, a replacement of the traditional paper and pencil drafting method. Over the years it has evolved into a
sophisticated surface and solid modeling tool. Not only can products be represented precisely as solid models,
factory shop floors can also be modeled and simulated in 3D. It is an indispensable tool to modern engineers.
IV. MANAGEMENT
Management is the art, or science, of achieving goals through people. Since managers also supervise,
management can be interpreted to mean literally ―looking over‖ – i.e., making sure people do what they are
supposed to do. Managers are, therefore, expected to ensure greater productivity or, using the current jargon,
‗continuous improvement‘. More broadly, management is the process of designing and maintaining an
environment in which individuals, working together in groups, efficiently accomplish selected aims (Koontz and
Weihrich 1990: 4). In its expanded form, this basic definition means several things. First, as people carry out
the managerial functions of planning, organizing, staffing, leading, and controlling. Second, management
applies to any kind of organization. Third, management applies to managers at all organizational levels. Fourth,
the aim of all managers is the same – to create surplus. Finally, managing is concerned with productivity – this
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implies effectiveness and efficiency. Thus, management refers to the development of bureaucracy that derives
its importance from the need for strategic planning, co-ordination, directing and controlling of large and
complex decision-making processes. Essentially, therefore, management entails the acquisition of managerial
competence, and effectiveness in the following key areas: problem solving, administration, human resource
management, and organizational leadership.
VII. OPERATION
The main features of the vibrator-compactor block making machine (VCM) was the increased vibration of the
die cavity or mould that was achieved through the attachment of an eccentric weight to the compactor drive
shaft (CDS). This caused the rotation of the (CDS) to be irregular, and the mould to vibrate excessively as
required for sand crete compacting. The length of CDS inclusive of pulley is 25cm. The pulley is connected
through a belt drive to a one horse power electric motor which drives the system. The eccentric weight and CDS
are made from mild steel material. . The diameter and length of the CDS are 2.5cm and 25cm respectively. The
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EW and CDS are permanently fastened with a weld. The two flange ends of the CDS are fitted into bearings
housed in a disc 9cm diameter and 2cm wide. The (EW) and (CDS) are encased by the barrel made from mild
steel sheet. The barrel is filled with SAE 40 oil for lubrication and cooling, The EW and CDS thus rotate
eccentrically in an encased environment of lobe oil, sealed by oil gasket which prevent leakage. The vibration
caused by the out-of-balance rotation when the EW and CDS rotate is transmitted to the bottom plate of the
mould of the VCM. The bottom plate rests on two springs on the top of which the lower platform of block
mould rests. Nine rods are used to connect the lower platform to the block mould. Each of the rods are 48cm
long and 1.27cm in diameter. The block mould was fabricated from a mild steel plate of thickness 1.27cm. The
plate of same thickness was used to fabricate a cover for the block mould. A hook is used to lock the block
mould cover when the VCM is being operated. Mild steel frames are used to secure the block mould firmly in
position in all its sides. The lower platform of the block mould is design to move upwards along the inside of the
mould to facilitate the ejection of moulded block. A lever is attached for ejecting the moulded blocks. To
operate the VCM, a wooden palet is placed at the bottom of the mould or die cavity. The wet sand cote mix
which consist of 20% of binders (cement and water) and 80% of fillers (fine aggregates ) are mixed and
shoveled into the mould until it is filled(Asafa ,2006). The top is leveled with a scraper and the cover of the
mould is applied to effect initial compacting. The cover is opened and additional brick mix is applied to refill
the mould. The mould cover is then applied and properly secured with the hook lock
FigMachine
Fig 1; 1; Machine
BaseBase
UnitUnit
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Fig; 7 pulley
Fig;10 spring
Fig 15 shaft
Fig 14.square Shaft Fig 15.belt
Fig 16 shaft
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X. ENGINEERING MANAGEMENT
Engineering managers oversee 4-P‘s – people, projects, products, and processes. Overseeing manufacturing and
production standards, working with creative engineers, and generating technical documentation are just some of
the responsibilities. Specialized knowledge and management practices geared toward the engineering
environment help to enrich an engineering managers‘ toolbox to deal with the 4-P‘s with as much savvy as
technical issues
Project
Every project has people in several different roles. The central person is the project manager. He or she plans the
project, pulls the team together, communicates with everyone, and makes sure that the job gets done right. Part
of the project manager‘s job is to explain to everyone else what his or her role on the project is and how it is
crucial to project success. The project manager must communicate with everyone and persuade each person to
do his or her part
PROJECT MANAGEMENT
Project management Tasks for the project were divided equally among the four team members. Modeling and
Simulation was completed by Engr.Chime and Engr.Ukwuaba while, Engr .Chuka, Prof.Toyi managed the tasks
and deadlines of the project. Many of the experiments were conducted with at least two members present and
each team member was responsible for taking observations and developing design ideas. Online Regular team
meetings were held to discuss shortcomings and progress of the project. A Gantt chart can be found in Appendix
displaying the Individual task assignments and deadlines. This chart was used to guide the team and assure
timely completion of the project. Each experiment provided insight for the project and so Gantt chart was
updated regularly with new tasks to accomplish.
DESIGN PROCESS
Engineers use CAD to create two− and three−dimensional drawings, such as those for automobile and airplane
parts, floor plans, and maps and machine assembly. While it may be faster for an engineer to create an initial
drawing by hand, it is much more efficient to change and adjust drawings by computer. In the design stage,
drafting and computer graphics techniques are combined to produce models of different machines. Using a
computer to perform the six−step‘art−to−part‘ process: The first two steps in this process are the use of
sketching software to capture the initial design ideas and to produce accurate engineering drawings. The third
step is rendering an accurate image of what the part will look like. Next, engineers use analysis software to
ensure that the part is strong enough figure 16 .Step five is the production of a prototype, or model figures 1-3
shown the modeling of machine and sections
XI. MODELLING
Modeling is the process of producing a model; a model is a representation of the construction and of interest .A
model is similar to but simpler then the system it represent. One purpose of a model is to enable the analyst to
predict the effect of change to the system. On the other hand, a model should be a close approximation to the
real system and incorporate most of its salient features Fig;6 -15 shown the process. On the other hand, it should
not be so complex that it is impossible to understand and experiment with it. A good model is a judicious
tradeoff between realism and simplicity. In the final step the CAM software controls that part. During the design
of the machine, the drafting software was used.
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XII. SIMULATION
Simulation technology can provide a highly effective means for evaluating the design of a new manufacturing
system or proposed modifications to existing systems. This technology can be especially useful in supporting
agility, sustainability, supply chain integration, as well as the development of new advanced processes.
Manufacturing simulations are often used as measurement tools that predict the behavior and performance of
systems that have not yet been implemented, or to determine theoretical capabilities of existing systems.
Simulations are essentially experiments. As defined in Jerry Banks Handbook of Simulation, a simulation is:
“…the imitation of the operation of a real-world process or system over time. Simulation involves the
generation of an artificial history of the system and the observation of that artificial history to draw inferences
concerning the operational characteristics of the real system that is represented. Simulation is an indispensable
problem-solving methodology for the solution of many real-world problems. Simulation is used to describe and
analyze the behavior of a system, ask what-if questions about the real system, and aid in the design of real
systems. Both existing and conceptual systems can be modeled with simulation.‖ figure 16.
XIII. PRODUCT
All products start out as virtual products fig1. That is ideas and information about what the physical product
should be . These virtual products are then realized in physical form through the manufacturing process. The
manufacturing of products can be divided into three phases: making the first one, ramp-up, and making the rest.
―Making the first one‖ entailed getting a physical product that embodied the ideas of what the virtual product
was required to accomplish. Ramp-up and production (―making the rest‖) relied on the premise that these
products would be close enough to the first one so as to be functionally and physically equivalent. The accuracy
of that premise varies widely even today, which is why expensive quality audit inspection processes are required
of the actual product instances themselves.
VIRTUAL PRODUCTS
The Value of Virtual Products
There are a myriad number of uses that can be made of the virtual product created through PSM(Product
Specification Management consists).. In the manufacturing or build phase, the ―as-built‖ virtual product is
immediately available and can be transmitted to customers and other parties in the supply chain who need the
information about the product to assure themselves that the product is actually being created to the required
specifications and Customer requirements see Fig1-3.
SUSTAINABILITY –
Simulation technology has been a significant tool for improving manufacturing operations in the past; but its
focus has been on lowering costs, improving productivity and quality, and reducing time to market for new
products. Sustainable manufacturing includes the integration of processes, decision-making and the
environmental concerns of an active industrial system to achieve economic growth, without destroying precious
resources or the environment. Sustainability applies to the entire life cycle of a product fig:5 also detailed
component environment impact. It involves selection of materials, extraction of those materials, of parts,
assembly methods, retailing, product use, recycling, recovery, and disposal will need to occur if simulation is to
be applied successfully to sustainability. Manufacturers will need to focus on issues that they have not been
concerned with before
PRODUCTIVITY
Business Managers, see productivity not only as a measure of efficiency, but also connotes effectiveness and
performance of individual organizations. For them, productivity would incorporate quality of output,
workmanship, adherence to standards, absence of complaints, customer satisfaction, etc (Udo-Aka, 1983). The
administrator is more concerned with organizational effectiveness, while the industrial engineer focuses more on
those factors which are more operational and quantifiable, work measurement and performance standards
(Adekoya, 1989). Productivity can be computed for a firm, industrial group, the entire industrial sector or the
economy as a whole. It measures the level of efficiency at which scarce resources are being utilized. Higher or
increasing productivity will, therefore, mean either getting more output with the same level of input or the same
level of output with less input. Let us look at the sub-concepts.
TOTAL-FACTOR PRODUCTIVITY
This is the ratio of output to the aggregate measure of the inputs of all the factors of production. Theoretically,
this is the true measure of productivity as it incorporates the contribution of all the factor inputs.
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MANUFACTURING
Manufacturing is the means by which the technical and industrial capability of a nation is harnessed to transform
innovative designs into well-made products that meet customer needs. This activity occurs through the action of
an integrated network that links many different participants with the goals of developing, making, and selling
useful things. Manufacturing is the conversion of raw materials into desired end products. The word derives
from two Latin roots meaning hand and make. Manufacturing, in the broad sense, begins during the design
phase when judgments are made concerning part geometry, tolerances, material choices, and so on.
Manufacturing operations start with manufacturing planning activities and with the acquisition of required
resources, such as process equipment and raw materials. The manufacturing function extends throughout a
number of activities of design and production to the distribution of the end product and, as necessary, life cycle
support. Modern manufacturing operations can be viewed as having six principal components: materials being
processed, process equipment (machines), manufacturing methods, equipment calibration and maintenance,
skilled workers and technicians, and enabling resources. There are three distinct categories of manufacturing:
• Discrete item manufacturing, which encompasses the many different processes that bestow physical shape and
structure to materials as they are fashioned into products. These processes can be grouped into families, known
as unit manufacturing processes, which are used throughout manufacturing.
• Continuous materials processing, which is characterized by a continuous production of materials for use in
other manufacturing processes or products. Typical processes include base metals production, chemical
processing, and web handing. Continuous materials processing will not be further discussed in this chapter.
• Micro- and nano-fabrication, which refers to the creation of small physical structures with a characteristic
scale size of microns (millionths of a meter) or less. This category of manufacturing is essential to the
semiconductor and mechatronics industry. It is emerging as very important for the next-generation
manufacturing processes.
Modern Manufacturing
Manufacturing technologies address the capabilities to design and to create products, and to manage that overall
process. Product quality and reliability, responsiveness to customer demands, increased labor productivity, and
efficient use of capital were the primary areas that leading manufacturing companies throughout the world
emphasized during the past decade to respond to the challenge of global competitiveness. As a consequence of
these trends, leading manufacturing organizations are flexible in management and labor practices, develop and
produce virtually defect-free products quickly (supported with global customer service) in response to
opportunities, and employ a smaller work force possessing multidisciplinary skills. These companies have an
optimal balance of automated and manual operations. To meet these challenges, the manufacturing practices
must be continually evaluated and strategically employed. In addition, manufacturing firms must cope with
design processes (e.g., using customers‘ requirements and expectations to develop engineering specifications,
and then designing components
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ENCOURAGE DIRECT AND INDIRECT INVESTMENT: It will help in the expansion of
domestic and international trade. It will equally increase rapid national economic growth and
development.
XV.RECOMMENDATION/CONCLUSION
We recommend that the movable parts of this machine like the lifting arm be oiled properly before usage for
easy movement since they carry heavy load. That the machine must be properly Installed, balanced before usage
to withstand the vibration involved.. The pulley, lifting arm and the viberator should be inspected before usage.
The machine must be properly cleaned after the normal daily work to be free from sand and cement which can
attack the parts and destroy them or the sand also causing friction in the machine. The combination of human
creativity with computer technology provides the design efficiency that has made CAD such as popular design
tool.CAD has allowed the designer to bypass much of the normal drafting and analysis that was previously
required, making the design process flow more smoothly. In fact, software design should be encouraged in our
institution of higher learning base on the following facts, long product development, countless trial and error,
and accountability and limited profitability.
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[15] Olusegun H.D. and Ajiboe T.K. (2006).Design Construction and Testing of Vibrator compactor Block Making machine
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[16] Sanni O.K.(2006) Design and Construction of A Brick Mould Machine University of Ilorin Project Work.
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APPENDIX
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