Innovative Product Design for Industrial Application Series 2

Innovative Product Design for Industrial Application – Series 2

Innovative Product Design for Industrial Application – Series 2 Editor MAHMOD ABD HAKIM MOHAMAD KHAIRULNIZAM BIN OTHMAN 2019 ©Penerbit UTHM First Published 2019 Copyright reserved. Reproduction of any articles, illustrations and content of this book in any form be it electronic, mechanical photocopy, recording or any other form without anypriorwrittenpermissionfromThePublisher’sOfficeofUniversitiTun HusseinOnn Malaysia, Parit Raja, Batu Pahat, Johor is prohibited. Any negotiations are subjected to calculations of royalty and honorarium.

Published by: Penerbit UTHM Universiti Tun Hussein Onn Malaysia 86400 Parit Raja, Batu Pahat, Johor Tel: 07-453 7051 Fax: 07-453 6145 Website: http://penerbit.uthm.edu.my E-mail: [email protected] http://e-bookstore.uthm.edu.my Penerbit UTHM is a member of Majlis Penerbitan Ilmiah Malaysia (MAPIM) Perpustakaan Negara Malaysia Cataloguing-in-Publication Data Innovative Product Designfor Industrial Application. Series2 / Editors: MAHMOD ABD HAKIM MOHAMAD, KHAIRULNIZAM BIN OTHMAN. ISBN 978-967-2306-93-1 1. Product design. 2. Industrial design. 3. Government publications--Malaysia. I. Mahmod Abd. Hakim Mohamad. II. Khairulnizam Othman. 658.5752

KANDUNGAN Senarai Penyumbang vii Prakata viii Bab 1 Design and Development of Trash Compacting Bin Mohd Najib Janon, Mahmod Abd Hakim Mohamad, Tuan Mohd Hafeez Tuan Ibrahim, Rosdi Ab. Rahman, Muhamad Badrul Amin Abu Bakar, Fikri Hakim Zainuzzamree, Mohamad Azizan Salleh, Norrizal Mustaffa 1 Bab 2 Hand Plough Tool Khairulnizam Othman, Mohd Shahir Yahya, Noraniah Kassim, Ahmad Faiz Bin Mat Zian @ Mat Zin, Faiz Safwan Jusoh, Hafizul Qairan Ismai, Wan Muhammad Izzuddin Wan Shuib 13 Bab 3 Mekanisme Pemegang Bahan Kerja Kimpalan Berbentuk Silinder Automatik Mahmod Abd Hakim Mohamad, Noraniah Kassim, Siti Mariam Basharie, Mohd Shahir Yahya, Muhammad Haris Azizan, Muhammad Havid Noor Azlan, Mohd Amirul Haziq Md Zali 23 Bab 4 Oil Palm Loose Fruits Collector Khairulnizam Othman, Rosdi Ab. Rahman, Hafsa Mohammad Noor, Mohd Najib Janon, Nur Maisarah Md Tarmuzi, Nur Husna Izyan Hamla, Rahimi Arif Abdul Razak 34 Bab 5 Foldable Multipurpose Trolley Siti Mariam Basharie, Hafsa Mohammad Noor, Muhammad Hanafi Asril Rajo Mantari, Muhammad Qusyairi Abdul Rahman, Nur Addin Kusyairi Rosmadi, Muhammad Syam Naqiuddin Sahari, Muhammad Zuhair Mohd Rizal 50

Bab 6 Alat Pengumpul Habuk Besi Amin Shah Omar, Ahmad Faiz Mat Zian @ Mat Zin, Tuan Mohd Hafeez Tuan Ibrahim, Hairul Mubarak Hassim, Muaz Jaapar, Muhamad Amirul Haziq Arman, Nurul Fitrah Kamarolzaman 61 Bab 7 Mesin Pemotong Rumput Mudah Alih Syamsul Azrin Kamaruddin, Muhammad Hanafi Asril Rajo Mantari, Mahmod Abd Hakim Mohamad, Suhairi Ismail, Mohammad Saifuddin Sukito, Muhammad Fikri Aiman Rosli, Muhammad Hanif Sarwi 73 Bab 8 Mesin Pengering Minyak Kerepek Muhammad Qusyairi Abdul Rahman, Hairul Mubarak Hassim, Suhairi Ismail, Syamsul Azrin Kamaruddin, Izzat Khair Mahmud, Izzul Faris Abdul Aziz, Wan Sharizat Wan Salleh 85 Biografi Penulis 95 Indeks 97

vii Senarai Penyumbang Ahmad Faiz Bin Mat Zian @ Mat Zin Hafsa Binti Mohammad Noor Hairul Mubarak Bin Hassim Khairulnizam Bin Othman Mahmod Abd. Hakim Bin Mohamad Mohd Najib Bin Janon Mohd Shahir Bin Yahya Muhammad Hanafi Bin Asril Rajo Mantari Muhammad Qusyairi Abdul Rahman Noraniah Binti Kassim Rosdi Bin Ab. Rahman Siti Mariam Bin Basharie Suhairi Bin Ismail Syamsul Azrin Bin Kamaruddin Tuan Mohd Hafeez Bin Tuan Ibrahim Universiti Tun Hussein Onn Malaysia

viii PRAKATA Buku ini merupakan perkongsian inovasi, reka bentuk dan pembangunan mesin sebagai usaha berterusan yang menyumbang dalam peningkatan produktiviti. Tajuk bab yang dipilih dapat memberi maklumat dan membantu masyarakat yang selama ini bergantung kepada cara manual untuk melaksanakan kerja. Penggunaan mesin yang telah dibangunkan terbukti berkesan untuk mengurangkan kos operasi serta meningkatkan margin keuntungan. Semua tajuk yang digarap dalam penulisan ini merangkumi proses pemantapan idea, reka bentuk, analisis kejuruteraan, pembangunan produk dan penilaian keberkesanannya. Buku ini juga sangat sesuai dijadikan rujukan pelajar yang berhasrat untuk mendalami kaedah pembangunan produk. Mahmod Abd Hakim Mohamad Khairulnizam bin Othman Pusat Pengajian Diploma Universiti Tun Hussein Onn Malaysia 2019

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 1 BAB 1 DESIGN AND DEVELOPMENT OF TRASH COMPACTING BIN Mohd Najib Janon1 , Mahmod Abd Hakim Mohamad1 , Tuan Mohd Hafeez Tuan Ibrahim1 , Rosdi Ab. Rahman1 Muhamad Badrul Amin Abu Bakar1 , Fikri Hakim Zainuzzamree1 , Mohamad Azizan Salleh1 , Norrizal Mustaffa2 1Department of Mechanical Engineering, Centre for Diploma Studies, 2Department of Mechanical Engineering, Faculty of Engineering Technology, Universiti Tun Hussein Onn Malaysia (UTHM), 84600 Pagoh, Muar Johor 1.0 Introduction In the current era, the excessive usage of plastic bag is one of the most concerned issue in terms of the environment especially as the population of earth rises (Adane & Muleta, 2011). Plastic is not something that is easily traded out for the usage of something else especially with the advantage that plastic provides. Some of the advantages of using plastic is due to its cheap price and accessibility, which makes it a very popular choice for the domestic daily usage. However, plastic is not something that is easily disposable and its mass usage funds to many environmental issues that is concerning to the public due to improper disposing method (Subramanian, 2000). Some of the common plastic usage is garbage bag. It is being used almost by every household on a daily basis. The reason as to why garbage bag is the most used in every domestic household is because of the absence of alternatives that are as reliable as plastic garbage bags are. However, the absence of alternatives does not mean that there is no other way to help reduce the usage of plastic. The problem is however; the excessive usage of plastic trash bags contributes to the alarming rise of plastic usage. This is due to the plastic trash bags not being used to its maximum capacity potential and are being disposed of more frequently. There is however a method to prevent this from happening, and that is by compacting the trash to allow more space to be filled in with trash before being disposed of. This step in its own is also a problem as it takes more effort, compacting your trash is not something that can be done seamlessly, and

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 2 effortlessly, in which consumers would not be bothered to take the extra step required. The change towards the problem can only be solved by the involvement of many people (Zen et al., 2013). 1.1 Importance of Study From the study conducted by Geyer et al. (2017) it shows that throughout the year 1980 to 2015, it can be observed that the amount of plastic being recycled has increased which is a positive feedback. However, it can still be observed that the amount of plastic recycled is the minority compared to trash disposed by incineration or plainly discarded at the composition of 19.5% recycled, 25.5% incinerated and 55% discarded at the year 2015 (Geyer et al., 2017). With the increasing amount of population and developing countries, the proportions of trash being recycled is not enough to put plastic wastage problem under control. Seeing that there are currently no alternatives that can be reliably used to replace plastic, there will be no boycott of plastic happening anytime sooner. However, consumers could still contribute to solve plastic wastage problem while still using plastic trash bags by reducing the usage of plastic trash bags. 1.2 Aims of Project The aims of this project are to develop an alternative to domestic trash compacting bin at an affordable design and manufacturing cost to ensure affordability to be implemented on a domestic scale. It also need to be a reliable trash compactor that is able to reduce the usage of plastic bags and wastes on a domestic scale. 1.3 Objective The objective of this project are to identify current design of trash can that is actively in product and other alternatives currently in market. The study also aims to design and develop an alternative to current trash cans in market which can potentially solve the current problem. Analyzation of the performance and achievements of current alternatives in the market is also one of the study objective. The last objective is to compare and verify the performance result of produced product with current alternatives in market. 1.4 Scope The scopes of this project are to create a domestic trash compacting bin prototype that is able to compact trash in an approximate displacement area of 16 litres, to create a

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 3 domestic trash compacting bin prototype in a rectangular design, to reach performance level of trash compactness that can fill in approximately 3 times the load of normal trash cans, to be able to reduce the usage of plastic trash bag approximately 3 times the usage of normal trash cans and to develop a prototype that uses affordable material and cheap manufacturing cost to promote affordable product for consumers. 2.0 Literature Review Up to this day, several devices and methods has already been created in pursuit for a solution towards waste and plastic management by means of compacting. Some of the alternatives presented are simple and requires manual labour and some of them are mechanized internally and highly complex in build. Trash compacting does not necessarily always require cutting edge technology to achieve its objective. Trash can be compacted by any means as long as it has enough force to compress it down. That also include compressing by using the hand. This method is the most inexpensive to trash compacting as it costs nothing. However, this method is also the one with the most drawbacks and disadvantage. By using hand, it is highly inefficient as it lacks the reach of depth to compress effectively. The compression is also not effective as the surface of the palm is not big enough for effective compression. Aside from performance inefficiency, hygiene issue is also a concern as direct contact with waste product is prone to be affected by hygiene related diseases. Figure 1: Manual Hand Compressing

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 4 A trash compacting stick is a direct improvisation of using hand for compressing trash. It solves the issue of depth reach and also has bigger surface area to fix performance issue. However, this method is also unreliable enough to be implemented on a domestic household as it is unreliable and requires manual effort. Figure 2: Trash Compacting Stick Several inventions are addressed to solve the problem regarding trash disposal related issues. However, these inventions are not suitable to be implemented on a regular household. Some of the weakness of the inventions are size restriction and also cost related issues. Some of the inventions are very big in size causing it to be unsuitable to be implemented in the common household. Other inventions are very expensive due to advanced build and mechanics implemented on the product. This makes it unsuitable to be implemented in households due to affordability issues. Some of the products that were invented are Stationary Compactor. A stationary compactor is used to dispose of dry waste such as cardboard, paper and similar items. The stationary compactor however is very large and is normally used on industrial scale and application. The compactor is made out of structural steel. The mechanisms used for compacting trash are motor powered hydraulics connected to a control panel to control its mechanisms. For the stationary compactor, specifically the Marathon model RJ-450, the size capacity is 3 cubic meters with the box opening of 1.7 meters x 1.5 meters (Stationary Compactors, n.d.). For this model in particular, the motor used to power up the hydraulic mechanism is around 15 horsepower.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 5 Figure 3: Marathon model RJ-450 (Stationary Compactors, n.d.) The next invention is the invention that resembles the closest to this project, but with various variations on design and mechanisms. The product is categorized as a modular electrical pump trash compactor. The Gladiator GACP15XXMG is a trash compactor powered by a 1/3 horsepower electrical motor with a compression force of about 2200 lbs per square inch. The product has a load capacity of 1.4 cubic-foot. The performance of the device is commendable as it is able to achieve a compressing ratio of 4 to 1 (Gladiator Garage Works, n.d.). The device is highly effective and reliable in achieving its objective. However, a product of this calibre costs roughly around RM 4000, which is very expensive and most household, cannot afford luxurious items however practical it might be. The electrical motor to compress the trash within its capacity powers the working principle for the gladiator. The interface allows the device to control the locking mechanism as well as the compression cycle. Figure 4: Gladiator GACP15XXMG (Gladiator Garage Works, n.d.) 2.1 Research highlight and design concept of Trash Compacting Bin The working principle for the prototype resembles closely to a stripped down version of The Gladiator GACP15XXMG. The application of this device is similar to the prototype compared to large sized stationary compactor. The prototype has grooves on both sides of the bin that acts as a guide for the compressing mechanisms to slide

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 6 in and out during compacting cycle. It also prevents the mechanisms from derailing during the compressing process. Since there are no power source or motorized component on the prototype, manual handling is required to initiate the compressing cycle. 3.0 Methodology 3.1 Design Process The prototype undergoes a formulation stage in which the design must meet the objectives and criterias for the prototype. The operating environment of the prototype is inside a household, therefore the application of the prototype must be suitable to be used in a domestic household and dimensional properties of the design should also complement the operating environment. For the purpose of implementing the prototype in a household, the dimensional properties of the prototype are set around the size of an average domestic trash can to make it suitable to be used in majority of the household. On the concept design phase, possible design ideas of the prototype is being projected in a form of sketches. The possible design ideas and concepts are sketched with the articulations of the different concepts and method to implement on the mechanisms and overall design to best suit the objective. On configuration design phase, the arrangment of features and arrangments of the product and components are finalized to be implemented on the final design of the prototype. Paramatric design is the stage where all the details of the prototype concerning dimensions are listed out for designing process. Details such as specific sizes, lengths material types and others are being listed out for the designing process. The selection of material for the prototype however must be limited to the prototype scope. 3.2 Product Fabrication and Integration The prototype undergoes fabrication and modification of various parts and component to be assembled into a working singular unit. Since the product scope is to create an affordable product, the materials used are limited to plastic only. The materials used to build the compacting mechanisms are 3 mm acrylic plastic plate and 4 mm perspex. The raw plastic plates are fabricated into individual parts by cutting them into specific dimensions according to the drawing specifications. To cut and shape the materials, an angle grinder is used with a metal cutting wheel attachment. The compressing mechanism are made out of various parts using a combination of both acrylic and perspex plate. However, the trash bin is not fabricated but is modified to suit the prototype objective instead. The trash bin is fitted with grooves that is fabricated by using PVC trunking casing to compliment the compressing mechanism of the bin.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 7 After the fabricating process for individual parts, the assembly and joining process will take place. For the joining method, the project uses a mixture of both permanent and mechanical fasteners. Example of permanent fasteners used are rivets and adhesive while mechanical fasteners are bolt and nuts. Some of the fastening process requires material removal to properly fasten the product; therefore, drills are used to create holes of various size depending on the fastening method. For the compressing plate, the material thickness is doubled to allow more force to be exerted on the compressing cycle. Two 4 mm perspex plate of similar dimension will be joined together with adhesive and rivets to secure the plate. The moving joints on the compressing mechanism such as the arms and connecters are fastened to one another by using bolt and nuts. Figure 5: Configuration design of Domestic Trash Compacting Bin 4.0 Result and Recommendation The results obtained and analyses had made based on the results of the laboratory tests conducted. The experiment that has been carried out is Push and Pull test. This research prove that this prototype is able to reduce the usage of plastic bag by reaching the performance level of trash compactness that can fill in approximately 3 times the load of normal trash cans. Summary of the calculation: (a) Ratio of the weight of trash (kg) To obtain result for the compressing ratio performance, a test has been carried out

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 8 to compare the mass of uncompressed trash within a volume compared to compressed trash. To carry out this study, fill in trash into the prototype until its maximum capacity. Record the mass of the trash accumulated without compressing. Repeat the same procedure but compact the trash and fill it to its maximum capacity. Compare the mass of the two accumulated trashes. The study revealed a compressing result ratio as listed below. Mass of compressed trash (kg): Mass of uncompressed trash (kg) 0.508 kg: 0.169 kg 3:1 (b) Pressure required to push the compactor mechanism for this prototype To obtain the compressing pressure required to compress trash of varying parameter, the prototype undergoes a test to measure the amount of pressure applied. For the experiment parameter, the mass of trash need to be compressed is 0.2 kg, 0.4 kg and 0.6 kg. The obtain the force exerted, a balance scale is placed on top of the compressing plates and record the amount of mass being exerted on the plate. By using the formula force divided by area, the amount of force exerted can be obtain. Proceed to calculate the pressure by using the formula below. The table shows the result obtained for this study. Pressure (N−2 ) = Force Applied (N) Area (m2) (Frantziskonis, 2013) Force = Weight (N) = Mass (kg)x Gravity (ms −2 ) (Kurtus, 2011) Table 1: Calculation of pressure required to push the compactor mechanism Mass (kg) Pressure Applied (Pa) 0.2 = = 3.218(9.81) 210(10−4) = 1503.27 /2 0.4 = = 7.008(9.81) 210(10−4) = 3273.74 /2 0.6 = = 9.721(9.81) 210(10−4) = 4541.09 /2

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 9 Figure 6: Pressure applied, Nm-2 against Mass of trash, kg 4.1 Final Design From the design process of the prototype and development, a final design has been obtained in a form of a working prototype. (a) (b) Figure 7: (a) Final design of Domestic Trash Compacting Bin from top view (b) Final design of Domestic Trash Compacting Bin from front view 1503.27 3273.74 4541.09 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 0.2 0.4 0.6 Pressure applied (Nm-2 ) Mass of trash (kg) pressure applied (Nm-2 ) against mass of trash (kg) pressure applied (Nm^2)

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 10 4.2 Operating Procedure 1. Attach the plastic trash bag to the compressing plate by using a bulldog clip. 2. Allow the trash bin to be filled in with trash. 3. Initiate compressing cycle by joining the left and right compressing handle to join the compressing plate. 4. Push the compressing plate downwards to compress the trash to maximum range. 5. Reset the compressing mechanism by retracting the plate to its initial position. 5.0 Conclusion From the development of prototype and evaluation of data analyzation, the following conclusions can be made: 1. This project has successfully created a prototype that implemented the mechanisms and working principle of a trash compactor through adaptation 2. The result obtained through testing shows that the prototype is able to achieve a compressing ratio of approximately 1:3. 3. Prototype efficiency able to save the usage of plastic trash bags of approximately 3 times compared to a normal trashcan. 4. Obtain minimum compressing pressure of 1503.27 /2 and maximum of 4541.09 /2 5.1 Recommendation From the development and fabrication of the prototype, several recommendations can be mad to improve the efficiency and quality of the product such as: 1. Revising selection of material to allow easiness in fabricating process as plastic fabrication is very limited and hard to execute. 2. Develop the product by using injection moulding or 3D printing method to improve dimensional accuracy and efficiency of the product. 3. Use a trash bin without loft to make dimensional decision for the template easier and would not cause any clearance issue. 4. Include secondary compacting mechanism that is placed perpendicular to the current compacting mechanism to increase compacting performance. 5. Increase the displacement size of the trash bin to allow more plastic saving per gram of trash.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 11 References Adane, L., & Muleta, D. (2011). Survey on the usage of plastic bags, their disposal and adverse impacts on environment: A case study in Jimma City, Southwestern Ethiopia. Journal of Toxicology and Environmental Health Sciences, 3(8), 234-248. Frantziskonis, G. N. (2013). Essentials of the Mechanics of Material. Lancaster: DEStech Publications Inc. Geyer, R., Jambeck, J. R., & Law, K. L. (2017). Production, use, and fate of all plastics ever made. Science advances, 3(7), e1700782. Gladiator Garage Works. (n.d.). (Whirlpool Corporation) [Online] https://www.gladiatorgarageworks.com/-[GACP15XXMG]- 1700113/GACP15XXMG/. [Accessed 14 December 2018]. Kurtus, R. (2011). Gravity and gravitation: derivations, equations and applications. SfC Publishing. Subramanian, P. M. (2000). Plastics recycling and waste management in the US. Resources, Conservation and Recycling, 28(3-4), 253-263. Stationary Compactors. (n.d.). (Marathon Equipment Company) [Online] https://www.marathonequipment.com/products/compaction-products/stationarycompactors/rj450. [Accessed 14 December 2018]. Zen, I. S., Ahamad, R., & Omar, W. (2013). No plastic bag campaign day in Malaysia and the policy implication. Environment, development and sustainability, 15(5), 1259-1269.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 13 BAB 2 HAND PLOUGH TOOL Khairulnizam Othman, Mohd Shahir Yahya, Noraniah Kassim, Ahmad Faiz Mat Zian @ Mat Zin, Faiz Safwan Jusoh, Hafizul Qairan Ismai, Wan Muhammad Izzuddin Wan Shuib Department of Mechanical Engineering, Centre for Diploma Studies, Universiti Tun Hussein Onn Malaysia, Educational Hub Pagoh, Muar, Johor, Malaysia. Corresponding E-mail: [email protected] 1.0 Introduction A plough (UK) or plow (US) is a tool of field used for agriculture for early planting of land as a provision to sow the seed or plant to loosen or change the soil. In early stage, people traditionally used the ploughing tool that is drawn by animals such as cattle and horses, but in modern times are mostly drawn by tractors. The plough can be made of wood, iron, or steel frame with a knife or stick used to cut the soil and loosen it. The primary purpose of ploughing is to turn over the upper layer of the soil, bringing fresh nutrients to the surface, while burying weeds and the remains of previous crops and allowing them to break down. As the plough is drawn through the soil, it creates long trenches of fertile soil called furrows. In modern use, a ploughed field is typically left to dry out, and is then harrowed before planting. Ploughing and cultivating a soil homogenises and modifies the upper 12 to 25 centimetres of the soil to form a plough layer. In many soils, the majority of fine plant feeder roots can be found in the topsoil or plough layer. Ploughs were initially human-powered, but the process became considerably more efficient once animals were pressed into service.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 14 1.1 Problem Statement Based on the observations we have made the channel creation to create the most suitable soil conditions for plant growth can be minimized as possible. We try to apply the best way to develop the method of soil treatment and improve the existing ploughing equipment. In addition, we have identified the history of the various types of land piracy system. In our research we also found that there are several ways to fertile and one of them is the 'beneath and crouch' method. 1.2 Objective Create the design for the type of plough that use the concept beneath and chopped for agro source in small-scale farms. 1.3 Project Scope The scope of our research is only focus to produce a plough tool that can help farmers in agriculture economy. It is because plough is one of the important medium to plant the seeds. Apart from that, this hand plough tool can give the farmers to reduce the time to plough and backache (Kar et al., 2003). 1.4 Project Significant With the Hand Plough Tool, a people that used this tool do not have to worry about the time taken and the backache. This research had their own importance which is to produce a design for the type of plough that use the concept ‘beneath and chopped’ that are rarely used in this country. This innovation can improve the time taken to plough and reduce the backache (Kar et al., 2003). 1.5 Project Background Malaysia is known as one of the developing country in the world. The consistent development can be seen with the increases of the rate of the ‘Keluaran Dalam Negara Kasar’ (KDNK) as recorded as much five to six percent per year since 2002. The rate of the KDNK is used to see the progress of the development in a country. The rate of

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 15 the KDNK will increase directly proportional with the rate of the agriculture sector. The increase of the agriculture sector rate in the KDNK right now is about 8.1%. It is being predicted that the rate will increase for about 5% until year 2025. We need to know that the main source of the agriculture sector comes from the government estate property, non-government estate property and private land. 2.0 Literature Review 2.1 Introduction A plough is a tool of field used for agriculture for early planting of land as a provision to sow the seed or plant to loosen or change the soil. The way to use the ploughing tool is depending on the size of field work. So, our group had make a tool that is low cost build that used the different way of ploughing method. 2.2 Human Factors Figure 1: Backache problem Human factors is the application of psychological and physiological principles to the engineering, design of products, processes, and systems. The goal of human factors is to reduce human error, increase productivity, and enhance safety and comfort with a specific focus on the interaction between the human and the thing of interest. It is this sudden activity of digging or racking or sweeping, or even repainting the sorry looking decking after a reasonably prolonged period without exercise, that can trigger acute lower backache. Usually, these activities entail us adopting poor posture for relatively extended periods of time, with motions involving repetitive twisting, moving our rake or hoe towards us, and lifting way from ourselves such as digging that cause our backache. Generally, it is not necessarily the weights involved, that end up causing us backache, it is often the fact that our backs are not designed for these repetitive, un-ergonomic movements, certainly not for extended period of time. Backache can occur as a result of those inter-vertebral nerves positioned very close to the swollen joints or tissue

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 16 becoming irritated or pinched. This can manifest itself in sciatica symptoms and pain down our legs or buttocks, or indeed backache as a result of muscle spasm. The most effective backache treatment for this condition is to encourage normal movement of the area and keep it that way long enough for it to heal, and try to keep reasonable mobile. By having good mobility in the swollen and sore joints, the inflamed tissues can be flushed out as the circulation inside the joint is improved, helping the joints heal much faster. Finally, the conclusion for the human factors for the hand plough tool is the result of the backache can be reduced. The reason for this statement can be said because this product uses less to crouch when ploughing the soil. 2.3 Literature Review The things that we used to build this model are mild steels, nuts, bolts and wooden stick handle. The ploughing technique is very important to study for those who want to sow the seed for farming activity. Normally, people in Malaysia plough their soil by using the garden fork, rake and other garden tools. After that, they make hilling the soil and then plant the seed on top of it. It is very important to plough the soil because the seeds can grow faster than usual (Jafry & O'Neill, 2000). The garden tool also can plough the soil but the technique will be different. As we know, the soil need garden tools to plough it. There are many types of ploughing tool that had been designed before. One of the plough tool types is hand trowel. It is a small hand tool used for digging, applying, smoothing, or moving small amounts of viscous or particulate material. This type of tool almost used the same concept as the hoe or spade (Kosch & Zach, 2005). Usually this type of tool is easier to carry it than the hoe or spade. The second type of the plough tool is garden fork. This type of tool also called as spading fork, digging fork or grip. It is used for loosening, lifting and turning over soil in gardening and farming (Krafka, 1997). It is used similarly to a spade, but in many circumstances, it is more appropriate than a spade.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 17 Table 1: Advantages and disadvantages of tools Types of tool Advantages of tool Disadvantages of tool Human factors Hoe It can be used for many functions such as shape soil, remove weeds, plough, clear soil, and harvest root crops. Less cost used to buy than other innovative tools. Take more time other than innovative tools. This item may be exchange or purchase new when the timber is broken. - Hand Plough Tool Take less time than hoe to finish the work scale area. Item more durable because it is made from steel Item will cost more than hoe. Tool can only be used for ploughing. Reduce backache by used less crouch. 2.4 Summary The research of the literature review have resulted the idea to create the Hand Plough tool. This simple and easy to build tool is a need for people who want to plough their land or soil in a small scale farming activity. The materials to build Hand Plough Tool are: i. Mild Steel ii. Nuts iii. Bolts iv. Wooden stick (Handle) With only this 4 materials and some welding, drilling and designing skill, Hand Plough Tool can be built easily. This tool is recommended for farmers that plough their soil in small-scale area. By using this tool people also did not have to worry about having backaches.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 18 3.0 Methodology 3.1 Prototype Production Process Figure 1: Process involved in producing the prototype A few materials are needed to build a hand plough tool. The materials used refer to the product produced and the correct specification is required in producing a product that is used for heavy work. Table 1 shows the materials required and their function. Table 2: Materials needed and their function. Material Function 1. Mild steel Acts as the end of the product that is used to cut into soil 2. Wooden stick Used as the handle and body of the prototype 3. Nuts Nuts are used in conjunction with a mating bolt to fasten multiple parts together 4. Bolts Nuts are used in conjunction with a mating bolt to fasten multiple parts together

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 19 3.2 Working Process Diagram 2: Flow chart of the functionality of product 3.3 Analysis Approach The methodology used in building this project consists of four aspects namely study, design, fabrication and analysis. For the study process, the idea for this project was because smallest farmers use much traditional method to plough soil that is using a hoe. This method requires more energy to be used by farmer and takes long time to

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 20 finish (Kosch & Zach, 2005). From the observation, this project can help to solve or reduce the problem. For the design process, the sketching process is done using AutoCAD software to get the correct dimensions for the product and to visualize it. The fabrication process is done by various metal fabrication techniques including welding, drilling, and grinding. Finally, project analysis in done by testing the product and its efficiency. 4.0 Result and Discussion 4.1 Result Table 3: Result of tested tools Length of land tested with hand plough tool, (m) Time take to finish with hand plough tool, (s) Length of land tested with hoe, (m) Time take to finish with hoe, (s) 1 28 1 57 2 56 2 122 4.2 Discussion Two methods are used to plough the soil, one is using a hoe and another one using our product. These two tools can be used to plough soil with different time taken to finish. The tools are tested to plough soil with length of 1 meter and 2 meter. Each tools are recorded its time taken to finish ploughing soil with length of 1 meter and 2 meter. From the data, the time taken using a hoe takes almost twice the time taken for the hand plough tool. From the data, it can be deduced that by using the hand plough tool is far better than by using a traditional method that is by using a hoe. One also uses less energy while using the hand plough tool rather than using a hoe (Rusu et al., 2009). Finally, this product can be used by various parties and ages. For some other product there are limit for the suitable age used. This product can be used for people more than 60 years old because it reduced the time to crouch when ploughing. For example, hoeing used to much time to crouch for digging or ploughing. This reason may cause people to easily obtain the backache. By using the hand plough tool, it will reduce the backache by reducing the time to crouch.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 21 5.0 Conclusion For the conclusion, the Hand Plough Tool is a great innovative for ploughing tool and it is surely recommended to use by farmers that plough their soil in small farming area. The skill that is being used in this product is beneath and chopped. It provides a disparity by using techniques that are rarely used in Malaysia agriculture activities. By using this, it can improve the time take to finish their work and reduce the backache. References Jafry, T., & O'Neill, D. H. (2000). The application of ergonomics in rural development: a review. Applied ergonomics, 31(3), 263-268. Kar, S. K., Ghosh, S., Manna, I., Banerjee, S., & Dhara, P. (2003). An investigation of hand anthropometry of agricultural workers. Journal of Human Ecology, 14(1), 57- 62. Krafka, E. G. (1997). Garden hand tool. U.S. Patent No. 5,615,744. Washington, DC: U.S. Patent and Trademark Office. Krafka, L. J., & Kosch, A. J. (2005). Powered soil tillage device. U.S. Patent No. 6,904,976. Washington, DC: U.S. Patent and Trademark Office. Rusu, T., Gus, P., Bogdan, I., Moraru, P. I., Pop, A. I., Clapa, D., ... & Pop, L. I. (2009). Implications of minimum tillage systems on sustainability of agricultural production and soil conservation. Journal of Food, Agriculture & Environment, 7(2), 335-338.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 23 BAB 3 MEKANISME PEMEGANG BAHAN KERJA KIMPALAN BERBENTUK SILINDER AUTOMATIK Mahmod Abd Hakim Mohamad, Noraniah Kassim, Siti Mariam Basharie, Mohd Shahir Yahya Muhammad Haris Azizan, Muhammad Havid Noor Azlan, Mohd Amirul Haziq Md Zali Jabatan Kejuruteraan Mekanikal, Pusat Pengajian Diploma, Universiti Tun Hussein Onn Malaysia, Hub Pendidikan Pagoh, Pagoh, 84600, Johor, Malaysia. 1.1 Pengenalan Kimpalan adalah proses untuk mencantumkan dua bahagian yang berlainan melalui tindakan haba. Teknik kimpalan boleh dibezakan melalui jenis haba yang dibekalkan semasa proses tersebut. Haba semasa proses kimpalan boleh dibekalkan oleh reaksi kimia, gas, rintangan elektrik atau arka elektrik. Kimpalan sesuai untuk kebanyakan logam, sendi kekal dan juga bahan kerja yang berbentuk silinder (Mattar, 2013). Untuk mendapatkan sambungan kimpalan yang baik, banyak parameter atau syarat harus dipertimbangkan. Salah satu pertimbangan yang boleh memudahkan proses kimpalan ialah penggunaan pemegang kimpalan. Oleh itu, kajian ini dilakukan untuk mereka bentuk dan membangunkan mekanisme pemegang bahan kerja kimpalan berbentuk silinder automatik khusus untuk silinder dengan kadar saiz diameter 5 cm sehingga 8 cm dan panjang 20 cm sehingga 50 cm. Jenis mesin kimpalan yang sesuai digunakan untuk kajian ini adalah mesin kimpalan MIG dan arka.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 24 1.2 Latar Belakang Kajian Kajian ini berdasarkan permasalahan yang dihadapi oleh para pelajar UTHM yang menjalankan kerja kimpalan di bengkel kimpalan UTHM Pagoh. Fungsi mekanisme pemegang bahan kerja kimpalan berbentuk silinder automatik adalah untuk memegang, memutarkan dan menyokong bahan kerja semasa proses mengimpal. Dengan menggunakan mekanisme ini, ia dapat memberi kemudahan bagi pelajar yang baru menceburi bidang kimpalan. Mekanisme pemegang bahan kerja kimpalan berbentuk silinder automatik ini berfungsi sebagai alat untuk melancarkan pergerakan dan mengurangkan kesilapan teknikal semasa proses kimpalan. Selain itu, ia juga dapat menjimatkan penggunaan masa semasa proses mengimpal. 1.2.1 Jig Dan Fixture Jig adalah sebuah alat yang berfungsi untuk mengarahkan sebuah atau lebih alat potong pada posisi yang sesuai dengan proses pengerjaan suatu produk. Alat bantu ini merupakan peralatan yang terikat secara tetap pada mesin utama. Alat bantu ini banyak digunakan pada pertukangan kayu, pembentukan logam, dan beberapa kerajinan lainnya yang membantu untuk mengawal lokasi atau gerakan Fixture adalah suatu alat bantu yang berfungsi untuk mengarahkan dan mencengkam benda kerja dengan posisi yang tepat dan kuat. Fixture adalah elemen penting dari proses produksi massal seperti yang diperlukan dalam sebagian besar pembuatan automatik untuk inspeksi dan operasi perakitan dengan tujuan menempatkan benda kerja ke posisi yang tepat yang diinginkan (Okpala & Okechukwu, 2015). Menurut Meduettaxila (2012), jig dan fixture menghapuskan keperluan penyediaan khusus untuk setiap bahagian individu. Mechnol (2015), menyatakan yang kelebihan utama jig dan fixtures adalah ketahanan, pengurangan masa penyediaan dan penambahbaikan produktiviti. Beza utama jig dan lekapan adalah jig menjadi panduan mata alat untuk bergerak pada posisi yang tepat dan juga menyokong bahan kerja ketika operasi. 1.2.2 Portable Tacking Table (Projek Tahun Akhir Kolej Vokasional Alor Setar) Rajah 1 menunjukkan sebuah jig sedia ada yang dinamakan Portable Tacking Table (PTT). PTT adalah projek pelajar tahun akhir Kolej Vokasional Alor Setar,

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 25 Muhamad Firdaus Mat Isa (2015). Objektif penciptaan PTT adalah untuk digunakan untuk melakukan kimpalan paku pada paip. PTT mampu untuk membantu melakukan kimpalan paku pada paip dalam masa yang lebih singkat. PTT merupakan inspirasi utama penghasilan projek ini dan sedikit konsep daripada PTT telah diaplikasikan terhadap projek ini iaitu bahagian roller untuk memusingkan bahan kerja. Konsep tersebut telah diaplikasikan kerana konsep tersebut dapat mengurangkan kos dalam pembuatan projek ini kerana konsep tersebut adalah mudah dan ringkas. Rajah 1: Portable Tacking Table. Jadual 1: Perbezaan PTT dan Pemegang Bahan Kerja Kimpalan Berbentuk Silinder. Portable Tacking Table (PTT) Mekanisme Pemegang Bahan Kerja Kimpalan Berbentuk Silinder Automatik Digunakan untuk paip bersaiz 3 x 2 kaki Digunakan khas untuk silinder bersaiz 5 cm – 8 cm diameter dan 20 cm – 50 cm panjang Kedudukan roller mendatar dan menegak Kedudukan roller secara hanya mendatar Berkuasakan motor wiper kereta 70 watt 150 RPM Berkuasakan DC Worm Gear Motor 0.5 watt A58SW-555 Zumo Robot 27 RPM 1.2.3 Pengapit Kimpalan Pengapit kimpalan digunakan untuk memegang dua keping bahan bersama sebelum proses mengimpal dimulakan. Terdapat pelbagai variasi pengapit telah dicipta untuk memudahkan bahan kerja yang pelbagai bentuk dipegang rapat sebelum dikimpal. Antara variasi pengapit yang telah dikomersialkan ialah pengapit untuk kerja logam, kerja kayu, mengangkat, dan majlis-majlis

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 26 khas. Setiap variasi pengapit harus digunakan mengikut peraturan yang telah disediakan agar dapat mengurangkan kerosakan pada pengapit dan bahan kerja. Antara peraturan yang harus dipatuhi semasa menggunakkan pengapit ialah sentiasa gunakan sekeping kayu bekas di antara rahang pengapit dan bahan kerja untuk mengelakkan kerosakan bahan kerja. Selain itu, beban pengapit hendaklah ditujukan berserenjang ke arah bahan kerja untuk mengelakkannya daripada tergelincir. Rajah 2 di bawah menunjukkan beberapa variasi pengapit kimpalan yang telah dikormesialkan di dalam pasaran masa kini. Rajah 2: Pelbagai variasi pengapit kimpalan di pasaran. 1.3 Kaedah Kajian Proses pembangunan mekanisme bermula dengan mengenal pasti masalah yang dihadapi oleh pelajar kimpalan UTHM bagi tujuan mendapatkan fungsi mekanisme yang sesuai untuk penyelesaian masalah ini. Proses seterusnya adalah perincian reka bentuk mekanisme dan proses pembangunan mekanisme. 1.3.1 Carta Alir

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 27 Rajah 3: Carta Alir Projek. 1.3.2 Mengenalpasti Masalah Di Universiti Tun Hussein Onn Malaysia, kebanyakan pelajar yang mengambil kursus kimpalan tidak mempunyai pengetahuan asas dalam proses kimpalan. Ini menyebabkan proses pembelajaran menjadi sukar bagi tenaga pengajar dan juga pelajar terutamanya ketika mengimpal bahan kerja berbentuk silinder. Hal ini juga menyebabkan banyak masa terbuang akibat kesukaran yang mereka hadapi. Untuk menyelesaikan masalah ini, kami bercadang untuk membangunkan mekanisme pemegang bahan kerja kimpalan berbentuk silinder automatik supaya ia dapat memudahkan proses pengimpalan dan dapat menjimatkan masa yang diambil untuk mengimpal. 1.3.3 Perincian Reka Bentuk Reka bentuk merupakan suatu pelan atau cadangan sesuatu mekanisme atau prototaip yang diterjemahkan secara visual. Proses pembangunan atau disebut sebagai fabrikasi yang baik tidak dapat dijalankan tanpa mereka bentuk sesuatu prototaip terlebih dahulu melalui spesifikasi prototaip yang dikehendaki. Proses reka bentuk ini menggunakan perisian SolidWork versi 2017. Rajah 4 menunjukkan hasil akhir bagi reka bentuk mekanisme yang akan dibangunkan untuk kajian ini.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 28 Rajah 4: Reka bentuk mekanisme. 1.3.4 Pemilihan Bahan Jadual 2 menunjukkan senarai bahan yang telah dipilih mengikut spesifikasi yang dikehendaki untuk membangunkan mekanisme pemegang bahan kerja kimpalan berbentuk silinder automatik. Namun terdapat beberapa bahan atau peralatan telah terdapat di bengkel antaranya keluli lembut, plat keluli lembut, keluli lembut berongga, silinder keluli lembut bentuk berongga dan pejal yang pelbagai saiz. Jadual 2: Senarai spesifikasi dan kos bahan No. Senarai Bahan Spesifikasi Bahan Kuantiti (Unit) Kos (RM) 1. Bearing Diameter luar: 25 mm Diameter dalam: 10 mm 8 48.00 2. DC Worm Gear Motor A58SW-555 Zumo Robot Kelajuan: 27 rpm Kuasa: 0.5 A , 12 V 1 84.00 3. Rantai motosikal Panjang: 150 cm 1 15.00 4. Gegancu Saiz: 13 3 18.00 5. Bolt & nat Diameter: 10 mm 2 4.00 6. CCM6N Forward Reverse Speed Controller Kuasa: 6A 1 23.00 7. Wayar Panjang: 1m 1 1.50

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 29 8. Cat sembur Warna: hitam 1 7.00 9. Bateri motor Voltan: 12 1 30.00 Jumlah kos 230.5 0 1.3.5 Pengukuran Bahan Proses ini dilakukan bagi untuk mendapatkan ukuran yang diperlukan pada bahan kerja. Ukuran yang tepat diperlukan agar tiada kecacatan yang akan berlaku pada mekanisme ini. Proses pengukuran bahan ini telah dilakukan dengan menggunakan pita pengukur. 1.3.6 Proses Pembuatan Bahagian ini menerangkan beberapa proses yang terlibat semasa proses pembuatan mekanisme dijalankan. 1.3.6.1 Pemotongan Bahan Proses pemotongan dilakukan sejurus selesai proses pengukuran bahan. Proses ini telah dijalankan dengan berhati-hati dan cermat agar pemotongan yang tepat dapat dilakukan. Proses pemotongan ini dilakukan dengan bantuan mesin pemotong besi. 1.3.6.2 Pengimpalan Proses pengimpalan menggunakan mesin kimpalan MIG telah dijalankan untuk mencantumkan besi-besi yang telah dipotong untuk membangunkan mekanisme ini. 1.3.6.3 Pemasangan motor dan litar elektrik Pemasangan motor DC Worm dan litar penyelaras kelajuan telah dilakukan setelah segala proses pencantuman mekanisme tersebut selesai. 1.3.6.4 Proses Pengemasan

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 30 Proses pengemasan merangkumi proses membuang sisa-sisa besi yang tidak diperlukan dengan menggunakan grinder. Setelah itu, proses mengecat menggunakan cat sembur juga telah dilakukan pada mekanisme sebagai langkah untuk mengelakkan daripada bahan besi pada mekanisme menjadi karat. 1.3.7 Hasil Pembangunan Produk Rajah 5 menunjukkan hasil akhir pembangunan mekanisme dan disertakan juga lakaran reka bentuk mekanisme dalam perisian SolidWork 2017. Rajah 5: Hasil akhir mekanisme dan lakaran mekanisme dalam SolidWork 2017. 1.3.8 Proses Menguji Mekanisme Proses ini dilakukan mengikut prosedur operasi standard (SOP). Langkah pertama, bahan kerja diletakkan di atas roller dan kerangka badan diselaraskan mengikut ukuran panjang bahan kerja. Langkah kedua, suis dihidupkan dan kelajuan bahan kerja dikawal oleh penyelaras kelajuan. Langkah ketiga, proses kimpalan dimulakan. Pemegang rod elektrik haruslah berserenjang dengan bahan kerja semasa mengimpal. Setelah selesai proses mengimpal, tutup sius dan tunggu sehingga bahan kerja menyejuk. 1.4 Keputusan dan Perbincangan Untuk analisis projek ini, satu ujian telah dilakukan untuk melihat potensi produktiviti mekanisme ini. Silinder yang dijadikan bahan ujikaji bagi ujian ini

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 31 berdiameter 4 cm dan panjangnya 20 cm dengan menggunakan mesin kimpalan MIG. 1.4.1 Analisis Masa Analisis masa melibatkan perbandingan masa yang diambil untuk dua kaedah pengimpalan yang berbeza, iaitu kaedah pertama adalah situasi ketika tidak menggunakan mekanisme ketika mengimpal silinder dan kaedah kedua pula adalah situasi ketika menggunakan mekanisme ketika mengimpal silinder. Data yang telah direkod dan dikaji bagi ujian ini adalah perbezaan masa yang diambil untuk melakukan pengimpalan penuh pada bahan kerja silinder terbabit. Jadual 3 dan rajah 6 menunjukkan hasil ujian yang telah dilakukan pada bahan kerja silinder berdiameter 8 cm sebanyak tiga kali dan purata masa akhir bagi setiap kaedah telah diambil. Jadual 3: Analisis masa. Kaedah Masa 1 (s) Masa 2 (s) Masa 3 (s) Purata Masa (s) A Tanpa menggunakan mekanisme 89 91 93 91 B Menggunakan mekanisme 53 50 56 53

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 32 Rajah 6: Graf perbandingan purata masa kimpalan. Hasil analisis kajian telah mendapati bahawa tempoh purata masa yang diambil untuk melakukan satu kimpalan penuh pada silinder dengan menggunakan kaedah B adalah lebih singkat daripada kaedah A iaitu kaedah B mengambil masa selama 53 saat berbanding kaedah A yang mengambil masa selama 91 saat. 1.4.2 Analisis Kadar Produktiviti Berdasarkan hasil analisis masa seperti yang dijelaskan pada subtopik sebelum ini, terdapat jurang perbezaan masa yang ketara antara dua kaedah pengimpalan tersebut. Kadar produktiviti ketika mengimpal mengimpal menggunakan mekanisme lebih tinggi daripada mengimpal silinder secara manual iaitu mengimpal tanpa menggunakan mekanisme. Nilai kadar produktiviti pengimpalan ketika menggunakan mekanisme dapat ditingkatkan sebanyak 41.8%. Nilai kadar produktiviti boleh didapati mengikut parameter seperti berikut: = ℎ − ℎ ℎ 100% 1.5 Kesimpulan Kesimpulannya, objektif projek ini untuk mereka bentuk dan membangunkan sebuah mekanisme pemegang bahan kerja berbentuk silinder automatik yang memudahkan aktiviti kimpalan pada bahan kerja yang berbentuk silinder telah tercapai. Beberapa ujian telah dijalankan ke atas mekanisme ini dan keputusan ujian telah mendapati bahawa masa yang diambil untuk membuat kimpalan dengan menggunakan mekanisme ini adalah lebih singkat iaitu selama 53 saat berbanding masa yang diambil untuk membuat kimpalan secara manual selama 91 saat. Oleh itu, kadar produktiviti kimpalan ketika menggunakan mekanisme ini terbukti lebih tinggi berbanding kaedah manual iaitu sebanyak 41.8%. Hasil dapatan ini jelas menunjukkan bahawa mekanisme ini mampu untuk memudahkan dan menjimatkan masa yang diambil untuk aktiviti

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 33 pengimpalan pada bahan kerja berbentuk silinder. Rujukan Mattar, Z. A. S. (2013). Welding Parameter Optimization Using Taguchi Method and Grey Relational Analysis for Gas Metal Arc Welding A1008 Butt-Joint (Doctoral dissertation, Universiti Putra Malaysia). Mechnol (2015). “Applications of Jigs and Fixtures” [Online] http://www.mechnol.com/applications-of-jigs-andfixtures.htm [Accessed 12 December 2018]. Meduettaxila (2012). “Jigs and Fixtures Module” [Online] https://2k9meduettaxila.files.wordpress.com/2012/04/scanjigs-and-fixtures.pdf. [Accessed 12 December 2018]. Muhamad Firdaus Mat Isa (2017), “Portable Tracking Table” Projek Tahun Akhir Kolej Vokasional Alor Setar 2017. Okpala, C. C., & Okechukwu, E. (2015). The design and need for jigs and fixtures in manufacturing. Science Research, 3(4), 213-219.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 34 BAB 4 OIL PALM LOOSE FRUITS COLLECTOR Khairulnizam Othman, Rosdi Ab. Rahman, Hafsa Mohammad Noor, Mohd Najib Janon, Nur Maisarah Md Tarmuzi, Nur Husna Izyan Hamla, Rahimi Arif Abdul Razak Department of Mechanical Engineering, Centre of Diploma Studies (CeDS), Universiti Tun Hussein Onn Malaysia, 86400, Parit Raja, Batu Pahat, Malaysia. 4.1 Introduction According to the Malaysia Palm Oil Board (MPOB, n.d.), Malaysia is one of the world’s largest palm oil exporter with around 39% of world palm oil production and 44% of the world export. In the year 2011, the oil palm industries had contributed, RM53 billion to the national income and the total labours involved in the industry were more than 600 000 people. In the oil palm industry, the oil palm loose fruit are the fruits that detached from the fruits bunches during the harvesting process. They usually contain more palm oil than the fruits on the fruits bunches as they are riper. If the loose fruit are not collected, it is estimated that there would be potential loss of RM10 million annually. Currently the collection of the loose fruits is still depending on human labour and is usually done by picking up the loose fruits manually. This collection method is very time consuming and also inefficient. Furthermore, this method can also cause health issue such as back pain to the workers as it requires the workers to squat down over an extended period of time. It has been assessed that the limit for manual collecting of loose fruits is ½ kg in 2 minutes. Then the fruits will be transferred to the wheelbarrow and carried to the collection point before it transported to oil palm processing mill by the trailer or lorry.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 35 1.1 Literature Review There are few prototypes of loose fruits collector have been invented, though the acknowledgment by the industry is as yet restricted because of a few reasons, for example technical limitations as well as high expenses. Abd Rahim et al. (2012) developed a loose fruits collecting machine that operates using vacuum suction concept. A mobile type machine that apply a layer of rotating drums has been invented by Ahmad Zamri & Mohd Zulfahmi (2017) with variable speed to remove debris from loose fruits with zero damage. Even though it promised high production of oil palm, still the machine is not commercially available. Thus, regardless of high content of debris manual raking is used. Referring to Table 1, the advantage of raking is in the speed of loose fruits recovery, particularly during periods extended harvesting rounds due to labour shortage (Amirshah & Hoong, 2003). This method not only required many workers and longer time but tiring and uninteresting. Besides, the debris content while raking can be as high as 60% by weight (Ahmad et al., 1995). The loose fruits must be in clean condition before sending it to the mill to produce higher oil extraction because loose fruits with debris will absorb the oil hence resulting in the reduction of oil extraction rate (OER). The estate will be penalised by the certain mill if they keep sending the loose fruits with a large quantity of debris. Therefore, with the new oil palm loose fruits collector, the amount of debris can be reduced to a lower level and zero damage to the loose fruits. The collector was designed to be a cost-effective device and useful for loose fruits collection. Other than that, this tool was invented to help reduces work related health issues among the workers. The workers need to squat down and stand up throughout the day during the collecting process and this collector can reduces likelihood of backaches because of it ergonomic design.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 36 Table 1: Productivity of workers with different loose fruits collection systems. Figure 1: Conventional method of collecting loose fruits by hand. Table 2: Method that was invented. No. Methods Advantages Disadvantages 1. Handpicking Debris-free Fit for small plantation Cause back pain problem Need longer time to pick the loose fruits Need more workers.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 37 2. Raking Quicker Easy and convenient Fit for small plantation. Does not separate loose fruit from debris. Need more workers. Cause back pain problem. 3. Oil Palm Loose Fruit Collector (MKIII) Using vacuum suction concept Faster Can collect large amount of loose fruits in one time. Less time consume. Less back pain problem Less burden to workers as they do not need to carry loose fruits bag. Does not separate loose fruit from debris. High cost 4. Roller-type Oil Palm Loose Fruit Picker Easy and convenient Light Debris-free Fit for small Need more workers. Consume longer

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 38 plantation. time 5. Nakula Palm Oil Loose Fruit Collection Device Minimises operation risks. Ideal for small plantations. Debris-free Damaged the loose fruits Require more workers Need longer time 1.3 Methodology 1.3.1 Materials Preparation Material selection is one of the crucial steps in design process. In this project, a few factors that were considered during material selection are strength of the material, cost, easy to machine, resistance to corrosion and lightweight. Table 3: Material used for every parts of the collector. Parts Materials Functions Framework Angle iron steel To tow the collector Handle Steel bar Enable the user to move the tool by hand Framework cover Aluminium plate Blocking the loose fruits from drop out Cyclone Steel plate Turn over the loose fruits

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 39 before entering the exit Wheel Bicycle rim Wheel Bearing and wheel connector Basket’s holder Steel rod Connect the bearing and wheel Hold the plastic basket Basket Plastic Basket Gather the fall loose fruits Trapper Spring Split open and trap the loose fruits inside the case Most of the parts used material that are made of steel. As stated by American Iron and Steel Institute (n.d.) carbon steel has no more than 2% carbon and no other appreciable alloying element. Steel has high tensile strength, easy to shape and inexpensive. Steel also has high resistance to corrosion so it does not rust easily. As steel has low density, it can be considered as a lightweight material hence the tool are easy to handle and do not require much energy for the worker. 1.3.2 Methods The design approach of the loose fruits collector as shown in Figure 1.

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 40 Figure 1: Flow chart of the project. The flowchart is generally drawn in early stages to guides until the finishing works. In early stage, the data are collected by an observation made in oil palm plantation. It can be seen the workers are still using conventional method as raking and handpicking are still used to collect the loose fruit. The existing tool are not efficient as it trapper are made from rods hence, ideas come out whether to use spring or flexible rods. After finalized, the material are choose to meet the criteria that required. In making this product, there are few fabrication processes involved: Start

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 41 Marking and measuring Grinding Cutting Shaping Welding The product was fabricated based on the final design by following the detail dimension that has been determined. Then, the analysis process is conducted to find out the effectiveness of the tool, the cost and the materials. The tool is considered successful when it does its function to collect the oil palm loose fruit with debrisfree. Figure 2: Drilling process Figure 3: Grinding process

Innovative Product Design for Industrial Application - Series 2 2019 ISBN 978-967-2306-93-1 42 Figure 4: Welding the rods 1.3.3 Calculation Height one, ℎ1 tan 30 = 1.95 ℎ1 ℎ1 = 1.95 tan 30 ℎ1 = 1.95 0.577 ℎ1 = 3.38 ℎ2 = ℎ1 + 16.5 ℎ2 = 3.38 + 16.5 ℎ2 = 19.88 Volume for whole cyclone Volume of cylinder – (Volume of cone 1 – Volume of cone 2) 2ℎ − ( 1 3 2ℎ1 − 1 3 2ℎ2) =[(14.45) 2 (16.5)] − [( 1 3 (14.45) 2 (19.88) − 1 3 (1.95) 2 (3.38)] =10823.54 − (4346.91 − 13.46) =10823.54 − 4333.45 =64903 Volume for 1 4 of the cyclone h1 h2 16.5c m 28.9cm