https://www.um.edu.mt/library/oar/handle/123456789/129100 2026-11-05T20:39:16Z 2026-11-05T20:39:16Z https://www.um.edu.mt/library/oar/handle/123456789/150599 2026-10-29T08:41:51Z 2025-01-01T00:00:00Z

Title: Logistics simulation of a fabrication facility Abstract: This project aims to improve the logistics processes of Domestica Ltd., a company in Malta that produces custom furniture. The DMAIC methodology is utilised to improve operational efficiency. The project examines two main stages: manufacturing operations in the fabrication facility and installation tasks performed at client locations. Time studies, simulation modelling, and stakeholder interviews provided detailed analysis of both stages to identify inefficiencies while reducing non-value-adding activities and enhancing workflow consistency. During production operations analysis, critical inefficiencies, unnecessary travel, and material storage issues emerged. The improvements aimed at standardising machine setting sheets, reorganising material storage, making workspace adjustments, and suggesting the installation of a gang rip saw to improve batching efficiency. Implementing these changes received validation through discrete event simulations in AnyLogic, which showed a 10–12% average time reduction across all door types. Layout adjustments were considered but eventually dismissed because the existing facility was already optimised, and significant structural modifications proved unnecessary. The process of installing doors outside the facility during the project's second phase was studied. The study identified site adjustment delays during architrave fitting, wasted time from unorganised toolkits, and excessive work being done on-site instead of at the facility. The thesis highlights the necessity of an ongoing improvement approach based on Kaizen principles instead of isolated interventions. The findings recommend developing an organisational culture that continuously empowers employees to identify and resolve inefficiencies instead of viewing the DMAIC cycle as a single event. According to this research study, structured analysis, practical interventions, and a lean oriented mindset improved the productivity and scalability of manufacturing and installation operations for a SME such as Domestica. Description: B.Eng. (Hons)(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150486 2026-10-26T15:02:32Z 2025-01-01T00:00:00Z

Title: Configuration design of a modular and stable ‘above the knee prosthesis’ Abstract: The loss of a lower limb profoundly impacts an individual’s mobility and quality of life, necessitating advanced prosthetic solutions. This final year project at the University of Malta, under the PREMIER (Pioneering Research in Engineering for Mobility, Independence, and Emotional Rehabilitation) initiative, focuses on the redesign and optimization of a modular, stable, low-cost, and aesthetically pleasing above-the-knee prosthesis (AKP). The study employs the DMAIC (Define, Measure, Analyse, Improve, Control) methodology to systematically enhance the existing PREMIER AKP design. Through Failure Modes and Effects Analysis (FMEA) and finite element analysis (FEA) using ANSYS 2024 R2, critical components such as the bevel gears, motor mount, half Y support, pylon, and foot were identified and analysed for instability and structural weaknesses. Key improvements include upgrading to a 54 Nm Docyke S550 servo motor, adopting PA12 helical bevel gears via Multi Jet Fusion (MJF) 3D printing, and using aluminium 2011 for enhanced structural integrity, reducing stresses (e.g., motor mount stress from 8343.8 MPa to 265 MPa) and deformations. The redesigned foot, utilizing carbon fibre composite plates, improves stability and customizability, while a socket-like cover design ensures ingress protection and aesthetic appeal. The updated Product Design Specification (PDS) incorporates new requirements, such as noise levels below 50 dB and adjustable foot compliance, aligning with user needs. Theoretical validations demonstrate significant advancements in stability, mobility, and manufacturability, laying a robust foundation for future physical testing with amputees to further refine this cost-effective, user-centric prosthetic solution. Description: B.Eng. (Hons)(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150485 2026-10-26T14:52:21Z 2025-01-01T00:00:00Z

Title: 5-axis CNC machining process of a vehicle upright Abstract: Computer Numerical Control (CNC) machining is a widely adopted subtractive manufacturing process. It has made traditional machining significantly better due to its efficiency and precision, improving exponentially as the technology advances. However, 3-axis CNC machining still has many limitations with parts having overhangs and blind features requiring manual re-orientation between setups. Hence, 5-axis machining is required for demanding designs to accommodate complex features. This is because 5-axis machining has the ability to continuously alter the workpiece to adapt for the accessibility and design contours of tools. However, the benefits of 5-axis machining come with added complexity and operational challenges. These challenges are secure work holding without excess material usage and keeping features accessible or choosing the appropriate tool to be rigid yet able to access these complex features. In this dissertation these challenges are emphasised due to the limited working volume in the Haas VF2YT fitted with a TRT160 trunnion attachment which enables two additional rotational axes to make it an overall 5-axis capable machine. However, this attachment also tightens the working volume and increases potential collisions between the spindle and this trunnion. This makes machining bigger parts difficult considering the additional work holding devices needed. Hence a strategic approach and well planned out machining was studied to machine the University of Malta Formula Sae race car uprights in the Department of Industrial and Manufacturing Engineering (DIME) labs. This dissertation challenges the Haas VF2YT with the TRT160 restrictions by evaluating different machining toolpaths and discovering different work holding devices and techniques. Using a virtual replica on Fusion360 to plan, create, and visualise toolpaths to detect issues like collisions and adjust accordingly. Experimenting with test parts, to vary parameters and measuring them to compare to the required tolerances. Ensuring that final machining of the upright was done aligning with its specifications. This gives insights into achieving multi-axis machining for complex geometries on compact machines, showcasing adaptable techniques to mitigate spatial and mechanical limitations in small-scale CNC setups. Description: B.Eng. (Hons)(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150481 2026-10-26T14:36:24Z 2025-01-01T00:00:00Z

Title: A novel metered dose inhaler with spacer for effective delivery of drugs to treat COPD Abstract: Chronic Obstructive Pulmonary Disease has a tremendous effect on the quality of life of millions worldwide, especially elderly patients. Being that COPD is a pulmonary disease the main medication intake method is through pressured metered dose inhalers. The main problem with this medication is the lengthy required technique for inhalation, which is often the reason that these patients struggle to receive the optimal amount of medication from these inhalers. This is what motivated this project to carry out the design of a novel spacer solution that aims to optimize the medication intake by patients through inhalation technique correction. A comprehensive problem analysis, incorporating stakeholder feedback and Quality Function Deployment, identified the need for a user-friendly, lightweight, and standards-compliant device. The project employed a structured design methodology following Roozenburg and Eekels’ basic design cycle, progressing through conceptual design, solution synthesis, and simulation phases. Tools such as Function-Means Trees, Morphological Charts, and Analysis of Interconnected Decision Areas (AIDA) were used to generate and evaluate design solutions. The final design features a smart attachment compatible with existing spacer devices, integrating an audible whistle for inhalation feedback, and electronic sensors and controllers for data processing and wireless connectivity. The design prioritizes ease of use, and regulatory compliance, with attention to future scalability for smart features like real-time monitoring and app integration. Prototyping and simulation validated the design’s mechanical fit and functional performance, confirming its ability to maintain effective drug delivery while offering enhanced user feedback. The project successfully meets its objectives by providing an innovative, practical solution that addresses key challenges in COPD management, paving the way for future developments in personalized respiratory care. Description: B.Eng. (Hons)(Melit.)

2025-01-01T00:00:00Z