THESIS ANDY ANAK BUJA - UTHM Institutional Repository

38 Pages·2014·1.79 MB·English

DECISION MAKING WITH ANALYTICAL HIERARCHY PROCESS (AHP)
FOR VIABLE MANUFACTURING OF SCREW

ANDY ANAK BUJA

A project report submitted in partial fulfillment of the requirement for the award of the
Degree of Master of Mechanical Engineering

Faculty of Mechanical and Manufacturing Engineering
Universiti Tun Hussein Onn Malaysia

JUNE 2013
v

ABSTRACT

This study is an approach to investigate the viable impacts of screw manufacturing and
to choose the suitable material for selected manufacturing process of screw by putting
environmental aspects as important as economic aspect. The parameters involved were
types of material and manufacturing process of screw that using the available data of
environmental and production volume. The two different manufacturing approaches
being evaluated were machining and forging process. The types of material concerned
for forging process encompassed low carbon steel, alloy steel stainless steel, and
aluminium alloy. On the other hand, for machining process, the material being
considered in screw manufacturing were cast iron, low carbon steel, alloy steel, stainless
steel and aluminium alloy. The information of environmental impacts that generated
from SolidWorks Sustainability tool and screw production cost were calculate using
Manufacturing cost model, both information was used in Analytic Hierarchy Process
(AHP) analysis to obtain local priority of economic and environmental impacts. Then,
the ranking of global priorities with combination of local priority from economic impact
and environmental impacts had enabled the determination of appropriate material used
for those selected screw manufacturing process. As result, low carbon steel was chosen
for forging process whereas cast iron was excelled in machining process, at the same
time, stainless steel was not suggested to be used in all two processes.
vi

ABSTRAK

Kajian ini merupakan satu pendekatan untuk mengkaji gabungan kesan alam sekitar dan
kesan economi bagi pembuatan skru dan memilih bahan yang sesuai untuk proses
pembuatan skru yang terpilih, aspek alam sekitar diletakkan sama pentingnya dengan
aspek ekonomi. Parameter yang terlibat adalah jenis bahan skru dan jenis proses
pembuatan skru. Jenis proses pembuatan skru yang dikaji adalah proses pemesinan dan
proses penempaan. Jenis bahan skru yang dikaji dalam proses penempaan merangkumi
keluli karbon rendah, keluli aloi, keluli tahan karat, dan aloi aluminium. Sebaliknya,
untuk proses pemesinan, bahan yang dikaji dalam proses pembuatan skru ialah besi
tuangan, keluli karbon rendah, keluli aloi, keluli tahan karat dan aloi aluminium.
Maklumat impak alam sekitar yang dijana daripada perisian SolidWorks Sustainability
tool dan maklumat kos pula diperolehi melalui modul kos pembuatan, kedua-dua
maklumat telah digunakan dalam Analytical Hierarchic Process (AHP ) untuk
mendapatkan pemberatan untuk impak ekonomi dan impak alam sekitar. Kemudiannya,
daripada pemberatan gabungan daripada kesan ekonomi dan impak alam sekitar telah
membolehkan penentuan bahan yang sesuai dipilih. Hasilnya, keluli karbon rendah telah
dipilih untuk proses penempaan manakala besi tuang telah cemerlang dalam proses
pemesinan, pada masa yang sama, keluli tahan karat tidak dicadangkan untuk digunakan
untuk kedua-dua proses yang dikaji.
vii
CONTENTS

TITLE i
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
CONTENT vii
LIST OF TABLE x
LIST OF FIGURE xi
LIST OF SYMBOLS xiii

CHAPTER 1 INTRODUCTION

1.1 Background of study 2

1.1.1 Screw types 3

1.1.2 Screw materials 4

1.1.3 Sustainability 4

1.2 Objectives 5

1.3 Scopes 5

1.4 Limitations of study 6

1.5 Statement of problem 7

1.6 Expected result 8

1.7 Thesis outline 8
viii

CHAPTER 2 LITERATURE REVIEW

2.1 Manufacturing industry and impact on
environment 9

2.1.1 Impact of recycling 10
2.1.2 Eco-design 11
2.2 Screw manufacturing 11
2.2.1 Forging 12
2.2.2 Hot forging 13
2.2.3 Cold forging 13
2.2.4 Comparison between hot forging and cold
Forging 15
2.2.5 Screw machining 15
2.2.6 Screw threading 16
2.2.7 Screw manufacturing process flow chart 18
2.3 Material selection 19
2.3.1 Green materials 19
2.3.2 Recyclable materials 20
2.4 Sustainability and sustainable development 20
2.4.1 Economic aspect in sustainability 23
2.4.2 Environmental aspect in sustainability 23
2.4.3 Social aspect in sustainability 24
2.4.4 Sustainability analysis 25
2.5 Decision making method 26
2.5.1 Multi-criteria analysis 27
2.5.2 Analytical Hierarchy Process 27
2.6 Previous study 30
ix
CHAPTER 3 METHODOLOGY

3.1 Overview 31
3.2 Methodology flow chart 32
3.3 Screw determination 33
3.4 3D CAD drawing 33
3.5 Parameter selection 34
3.6 Environmental impact analysis 35
3.7 Decision Making 36
3.7.1 AHP methodology 36
3.8 Screw Manufacturing Cost Model 40

CHAPTER 4 RESULTS AND DISCUSSION

4.1 Data of environmental impact 46
4.2 Data of economic impact 46
4.3 Analytic hierarchy process (AHP) Analysis 47
4.3.1 Global priority for environmental impact 49
4.3.2 Global priority for economic impact 50
4.3.3 Global priority for viable impact 50

CHAPTER 5 CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion 53
5.2 Recommendations 54

REFERENCES 55

APPENDICES 58
x

LIST OF TABLE

TABLE NO. TITLE PAGE

2.1 Herman Daly proposal 24
2.2 Environmental indicator 25
2.3 Example of goal, criteria and alternatives 28
2.4 The fundamental scale of absolute numbers 29
3.1 Data of environment impacts of screw production 35
3.2 Pair-wise comparison matrix for Secondary Criteria 38
3.3 Summation of the values in each column 38
3.4 Division of each value in matrix to the column total
and then summation of each row 38
3.5 Division of each row summation with total row
summation. 39
3.6 RI values of different value of n 39
4.1 Data of environment impacts for M5 hex screw
under forging and machining operation 46
4.2 Production cost with different production volume 47
4.3 Priority weight (environmental) 50
4.4 Priority weight (economic) 50
4.5 Results of global priority 51
4.6 Global priority with different production volume 52
4.7 Table for viable impact 52
xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Screw parts 2
1.2 Fastener categories 3
1.3 Screw head style 4
1.4 Venn diagram of sustainable development 5
1.5 Interlocking circle model 6
1.6 Sustainable company criteria 8
2.1 Shares of Global Final Energy
Consumption and CO2 Emissions 10
2.2 Types of metal forming 12
2.3 Hot forging processes for a screw 13
2.4 Cold heading 14
2.5 Grain structure 16
2.6 (a) solid die (b) split die
(c) spring die (d) pipe die 17
2.7 External threading 17
2.8 (a) single point (b) multi point
(c) self-opening die 18
2.9 Flow chart of screw manufacturing 19
2.10 The hierarchical structure 21
2.11 Theme indicator framework 22
2.12 Sustainable development triangle 22
2.13 Summary of AHP method 29
3.1 Full thread hexagon head screws 33
3.2 Hexagonal machine screw 34
3.3 Sustainability toolbar 35
3.4 Flow chart of AHP methodology 37
xii

FIGURE NO. TITLE PAGE

3.5 Hierarchical structure 38
3.6 How to get λ 39
max
3.7 P (basic processing cost) for
c
forming process 41
3.8 Relative cost data for material
processing suitability 41
3.9 Three basic shape categories 42
3.10 Subcategory of category A 42
3.11 Shape complexity coefficient
against sub category classification 43
3.12 Section coefficient against
maximum dimension graph. 44
3.13 (a)Tolerance coefficient,
(b) Surface finish coefficient 44
3.14 Sample material cost values per
unit volume 45
3.15 Waste coefficient (W ) 45
c
4.1 The hierarchical structure used in
a. forging, b. machining process 48
4.2 AHP analysis (Front page) 48
4.3 AHP analysis (Main frame) 48
xiii
LIST OF SYMBOLS

M = VC + R P
i mt c c
V = volume of material required in order to produce the component
C = the cost of the material per unit volume
mt
P = Basic processing cost for an ideal design of component by a specific
c
process
R = relative cost coefficient assigned to a component design.
c
R = C C C C
c mp c s ft
C = suitability of using various materials with different processes
mp
C = Shape complexity
c
C s Section coefficient
=
C = Tolerance coefficients
t
C surface finish coefficients
f =