Dr Paul T Mativenga

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Implementing technical and experimental
projects/case studies
Dr Paul T Mativenga Manufacturing and Laser
Processing School of Mechanical, Aerospace and
Civil Engineering
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What is a case study (common view)
An in-depth study of an individual unit where
that unit is approached as an example of some
larger phenomenon.
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???

• Who is doing a technical/experimental PhD?
• Whose technical/experimental PhD has a case study
  component?
• Whose technical/Experimental PhD is a case study?

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When do we need a technical case study

• Introducing new technology Step change needed,
  new legislation
• Process improvement Increased demand, tighter
  output requirements, better products
• Reclaiming of systems in decline - e.g. company
  observes quality issues, bridge is about to
  collapse

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Getting into the organisation

• Understand the overlap between immediate
  organisational goals and your expertise
• The academic solution may not have value to a
  commercial problem.
• Industry may not necessarily be interested in
  your ideas but in how you think and approach
  problems

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Constraints on engagement

• Technical processes are covered by
• Patents
• Non disclosure agreements
• Collaboration agreements
• Censorship
• There is limited scope for dissemination that can
  be obtained by undertaking technical case studies
  or case implementation in a commercial company.

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Winning an industrial collaboration case
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Disjointed or Invisible Circles-Goals
Academia (academic expertise)
Industry (needs)
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Establishing the intersection

• Industry does not broadcast institutional
  challenges/problems/focus areas.
• Personal relations are a vital part in gaining
  access into a company and successfully taking
  through a case implementation or technology
  transfer project
• Networking
• Conferences
• SME are more accessible than large companies
  (most large companies have strategic University
  partnerships)
• Visit institutional functions or seminars IMechE,
  IET
• Publicise your capability, expertise, facilities
  etc.

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Why would a company agree to a case
implementation/study

• Process not in control
• Process lead time too long
• Need to increase plant capacity
• New processing route required
• New materials to be processed

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Implementing a technical project (case study) in
a PhD

• You have a new idea and want to try it out NOT
  ENOUGH
• You have a tried idea but want to take it to a
  different application - YES
• You have a proven idea but what to develop
  operating envelop and process repeatability - YES
• You have a working prototype but want to scale it
  up for pre-production (on actual machines, actual
  components) - NO

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Technology Readiness Levels
When a new technology is first proposed/invented/c
onceptualized, it is not suitable for immediate
application. New technologies should normally be
subjected to experimentation refinement and more
representative/realistic testing. Once the
technology is sufficiently proven, it can be
incorporated into a system/subsystem. Technology
Readiness Level (TRL) is a measure used to assess
the maturity of evolving technologies prior to
incorporating that technology into an industrial
process or system/subsystem.
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TRL and MCRL

• While Technology Readiness Levels (TRL)s are
  generic to all technologies, Manufacturing
  Capability Readiness Levels (MCRL) are more
  focussed on implementation of manufacturing
  technologies

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Manufacturing Capability Readiness
Level(Technology assessment and proving)

• MCRL1 Process concept proposed with scientific
  foundation.
• MCRL2 Applicability and validity of concept
  described demonstrated and vetted
• MCRL3 Analytical and experimental critical
  function and/or characteristic proof-of-concept
  completed.
• MCRL4 Technology component and/or basic
  technology subsystem validated in laboratory
  environment using representative development
  equipment.

MCR1 to 4 Relevant to a PhD could be a PhD
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Implementing a technical project
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Manufacturing Capability Readiness
Level(Pre-production)

• MCRL5 Basic capability demonstrated using
  production equipment (validation in relevant
  environment).
• MCRL6 Process optimized for capability and rate
  using production equipment.

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Manufacturing Capability Readiness
Level(Production Implementation)

• MCRL7 Technology system prototype demonstration
  in an operational environment (capability and
  rate confirmed via economic run lengths on
  production parts).
• MCRL8 Actual technology system completed and
  qualified through test and demonstration. Fully
  production capable process qualified on full
  range parts over significant run lengths.
• MCRL9 Fully production capable process on full
  range of parts over extended period. Actual
  technology system qualified through successful
  mission operations.

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TRL Pros and Cons
Advantages include Provides a common
understanding of technology status Enables the
making of decisions concerning transition of
technology Enables risk management to be used to
make decisions concerning technology funding
Disadvantages include More reporting,
paperwork, reviews and meetings Systems
engineering not addressed in early TRLs
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Who Pays
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A dream

• A man had a recurring dream. He dreamt he was
  being shown the secrets of the universe.
• Each morning he woke up but would not remember
  what the secret was.
• He went to a wise man and asked for advice on how
  he could capture the secrete in the dream
• Take a piece of paper and pen to bed

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• Think in other terms

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Criteria for industry engagement

• THE WORK PACKAGE HAS TO BE
• Realistic Manage risk
• Achievable Demonstrate capability of delivery
• Quantifiable Goal money/cost reduction/lead
  time reduction/process capability
• Time bound industry wants results fast and in
  the promised delivery time.

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Investigation Techniques

• Analytical modelling Enables inferred
  understudying of process)
• Computer Modelling (e.g. Finite Element
  Modelling)
• Experimental and analytical/computer modelling
  (closes the loop)
• Experimental Design Techniques Factorial
  design/Taguchi experiments
• Serial Testing and Mechanism studies (answers the
  why and how. Can effect a step change)

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Concluding Remarks - 1

• Manufacturing technology is an applied science
• The true value of manufacturing technology
  innovation has to be realised through
  implementation in industry or as company spin
  offs
• New and original ideas may not be ready for
  implementation in an industrial environment
• Technology readiness levels can be applied in the
  transfer of research expertise from academia to
  industry
• Academic expertise has to be matched to
  industrial commercial needs.
• Implementing manufacturing technology within a
  commercial company needs a project that is
  REALISTIC, ACHIEVABLE, QUANTIFIABLE AND TIME
  BOUND

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Concluding Remarks - 2

• A fact is a simple statement that everyone
  believes. A hypothesis is a novel suggestion that
  no one wants to believe. It is guilty until found
  effective
• Edward Teller (1908-2003)
• Think beyond the possible and then back off to
  reality
• Sir Robin Saxby, 2008

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The value of technical ideas

• Okay we have set-up manufacturing facilities,
  organised the distribution network, hired the
  marketing expertise, and allocated the
  advertising budget.
• Any ideas for a product?

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Thank You We can open the discussion