https://www.um.edu.mt/library/oar/handle/123456789/9973 2026-10-08T14:36:27Z 2026-10-08T14:36:27Z https://www.um.edu.mt/library/oar/handle/123456789/149749 2026-10-06T13:29:44Z 2025-01-01T00:00:00Z

Title: Human-cobot assembly station for low volume production runs : a cost-effective approach through modularity and scalability Abstract: In today’s increasingly volatile manufacturing environment, companies are under pressure to produce highly customised products in smaller volumes without compromising efficiency, quality, or cost. Traditional dedicated assembly lines (DMS), designed for high-volume production, lack the flexibility needed to adapt to these emerging demands. This research investigates and proposes a solution through the development of a Reconfigurable Human-Cobot Assembly System (RHCAS). This modular, scalable approach combines the strengths of Reconfigurable Assembly Systems (RAS) with Human-Robot Collaboration (HRC) under the guiding principles of Industry 5.0. This thesis outlines the design and evaluation of a generic RHCAS architecture designed to support low-to-medium volume production with high product variety. A comprehensive literature review identifies key design principles from existing HumanCobot Assembly Systems (HCAS), RAS and RHCAS. A modified Modular Function Deployment (MFD) framework is proposed to generate a generic physical RHCAS architecture. The developed architecture is then applied and validated through a case study. Stakeholder evaluations from both industrial and academic backgrounds provided qualitative insights into the practicality of the proposed architecture, while quantitative financial and productivity analyses confirmed its potential feasibility. The results validate the central hypothesis that a well-structured, modular RHCAS can provide manufacturers with a cost-effective and adaptable alternative to traditional assembly systems, particularly in low-volume, high-mix production environments. This research contributes a novel RHCAS design methodology based upon the principles of Integrated Product Development (IPD), promoting concurrent and modular design thinking. Description: M.Sc. IPD(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/149747 2026-10-06T13:27:05Z 2025-01-01T00:00:00Z

Title: An investigation of smart exoskeletons systems for IPD in industry 5.0 Abstract: This study investigates how smart exoskeleton systems can be developed through an Integrated Product Development (IPD) approach to meet the human-centric, sustainable, and resilient objectives of Industry 5.0. While significant progress has been made in industrial automation, numerous tasks remain that require human dexterity, judgement, and adaptability; factors that continue to resist full automation. Smart exoskeletons present a compelling opportunity to support such tasks, particularly when integrated with digital manufacturing systems (DMS) such as ERP, MES, CMMS, and DWIs. Through a combined state-of-the-art review and eight semi-structured interviews with industry professionals, key opportunity areas were identified across two case studies: precision toolroom maintenance and food production. These insights informed the development of the IPDEXO framework, a structured roadmap that guides the adoption of smart exoskeletons across the three IPD pillars: business, engineering design, and production. An economic feasibility study, a generic QFD analysis, and IDEF0 process modelling were conducted to define the physical, cognitive, and system-integration requirements of the proposed system. The study culminates in the conceptual design and digital proof of concept of a modular smart exoskeleton platform, capable of real-time data exchange and ergonomic augmentation. The refined IPDEXO framework demonstrates how exoskeleton adoption can be aligned with strategic business goals, ergonomic design needs, and digitally connected production workflows. In doing so, this research proposes a scalable, IPD-informed framework for embedding human-centric technologies within Industry 5.0 manufacturing environments. Description: M.Sc. IPD(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/149746 2026-10-06T13:16:53Z 2025-01-01T00:00:00Z

Title: Enhancing product development through IPD : innovating with XR collaboration tools Abstract: This research explores the potential of Extended Reality (XR) technologies to enhance collaboration in Integrated Product Development (IPD). As product development (PD) becomes more complex and globally distributed, traditional collaboration methods such as physical meetings and digital collaboration like video conferencing face increasing limitations. These include scheduling difficulties, reduced engagement, and lack of physical interaction with prototypes. XR technologies offer immersive, spatially aware environments that may bridge these gaps. The study began with a comprehensive literature review that assessed collaboration through the lens of two theoretical frameworks, Seven-Factor Model and the FiveDimension Model of Collaboration. These models were used to evaluate traditional, digital, and XR-based methods in terms of communication, process efficiency, trust, and shared understanding. To validate these insights, a survey was conducted targeting industry professionals, gathering data on current collaboration practices, team dynamics, and perceptions of XR technologies. Findings revealed broad awareness but limited adoption of XR, largely due to concerns over cost, complexity, and integration with existing workflows. Based on these results, a Product Design Specification (PDS) was developed to guide the creation of a prototype XR collaboration tool. The tool, built using Unity, was evaluated in a controlled study comparing it with traditional and digital collaboration methods. While XR showed clear potential, the results also revealed practical challenges. These findings suggest that although XR offers new capabilities for design engagement and spatial understanding, its effectiveness is highly dependent on factors such as user training, interface design, and technical stability. Moreover, successful adoption requires more than technical readiness, it must also consider organisational culture, collaboration workflows, and the learning curve associated with immersive technologies. This research demonstrates that XR can serve as a valuable complement to existing collaboration tools in PD. When implemented strategically, XR technologies have the potential to reduce inefficiencies, support distributed teams, and foster deeper collaborative engagement across the IPD lifecycle. More broadly, this study highlights how emerging immersive technologies can reshape collaborative workflows, paving the way for more integrated, responsive, and innovative PD processes. Description: M.Sc. IPD(Melit.)

2025-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/149744 2026-10-06T13:22:53Z 2025-01-01T00:00:00Z

Title: A human-centred design framework for developing smart healthcare products in an IPD context Abstract: The development of smart healthcare products is rapidly transforming patient care, enabled by advances in technology, Internet of Medical Things (IoMT), and artificial intelligence (AI). However, these innovations exist within a highly regulated and multidisciplinary context that demands not only functional and manufacturable products, but also solutions which are safe, usable, and desirable. Although Integrated Product Development (IPD) offers a structured approach focused on cross-functional collaboration ensuring product quality, accelerated time-to-market, and reduced development costs, it often lacks deep engagement with other factors such as user experience (UX). On the other hand, Human-Centred Design (HCD) prioritises function, usability, and empathy for users but does not sufficiently address the crossfunctional dependencies presented in IPD. This dissertation proposes a new theoretical framework that vertically integrates the principles of HCD within the IPD context for the development of smart healthcare products. The framework builds upon the traditional IPD pillars of design, manufacturing, and business by incorporating additional pillars, identified as human factors (HF) and regulatory which are pivotal to the healthcare industry. Using other established design research methodologies, a theoretical framework was iteratively developed and refined through a data gathering survey and two validation surveys. The key findings from the final validation survey indicated strong support for the usability and relevance of the new framework, with the majority of participants agreeing that the model effectively addressed both cross-functional integration and the vertical integration of HCD and IPD as well as addressing the software aspects cybersecurity and data privacy. The developed framework enables a structured, phase-based approach that integrates both the user needs and the technical considerations from the earliest stages of development. While this framework provides a more holistic approach to the development of smart healthcare products, limitations in the study’s survey sample sizes and scope are acknowledge. Future work is recommended to use the developed framework to develop a real-world case study and to expand the framework’s consideration of human interaction at other levels of product development such as at the manufacturing level. Description: M.Sc. IPD(Melit.)

2025-01-01T00:00:00Z