https://www.um.edu.mt/library/oar/handle/123456789/117776 Wed, 28 Oct 2026 17:50:38 GMT 2026-10-28T17:50:38Z https://www.um.edu.mt/library/oar/handle/123456789/150440 Title: Sustainability assessment of a pneumatic monitoring and control system Abstract: Sustainability has emerged as the central focus of many manufacturing and automation industries, particularly in compressed air systems (CAS). This is because these systems are very inefficient, as they typically have an average output energy of 10-12%. This inefficiency often results due to compressed air leakages and other pneumatic faults. In Malta, such leakages can result in a waste of 16,000 MWh/year, €2 million in costs, and 6,000 tonnes of carbon dioxide (CO2) annually. To address this, project AIR SAVE developed a Pneumatic Monitoring and Control System (PMCS) which saves 30% of the compressed air consumption during a lifetime of 10 years. Despite its benefits, such a system has its own environmental and financial impact. Therefore, a sustainability assessment was carried out through a Life Cycle Assessment (LCA) and a Life Cycle Costing (LCC) to evaluate the system’s feasibility. An LCA was conducted using SimaPro, employing a cradle-to-grave approach to analyse the environmental impact of the PMCS with a focus on the Global Warming Potential (GWP). The Life Cycle Environmental Impact Assessment (LCEIA) concluded that the PMCS had a total environmental impact of 536.42 kgCO2eq. Additionally, the use phase was determined to have the highest environmental impact with 60%, followed by the raw material production and manufacturing and disposal phase, with 39% and 1%, respectively. Moreover, through an LCC analysis, the total life cycle cost of the PMCS was determined to be €4710.25 + €8.63/year. The Environmental Payback Period (EPP) and Financial Payback Period (FPP) were calculated for the PMCS implemented in a pick and place system at the University of Malta (10 end uses) with an average flow rate of 188 NL/min. The results showed that the EPP was less than 3 months for all scenarios, signifying immediate environmental payback. Conversely, the FPP was determined to be 24 years, which is not viable given the 10-year lifespan of the electronic components. Consequently, a sensitivity analysis was conducted to vary key parameters to achieve the desired financial payback period and hence understand whether the analyses are sensitive to the assumptions taken into consideration. In summary, this dissertation concluded that PMCS is environmentally feasible, however it is not financially feasible. Description: B.Eng. (Hons)(Melit.) Mon, 01 Jan 2024 00:00:00 GMT https://www.um.edu.mt/library/oar/handle/123456789/150440 2024-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150439 Title: Development of an augmented reality system to assist operators in the assembly of a mechanical product Abstract: The industrial manufacturing environment is undergoing constant evolution, resulting in a transition from mass production to mass customization in response to evolving consumer preferences. To meet the demands of this shift, manufacturers are increasingly turning to innovative technologies, among which Augmented Reality (AR) stands out as a transformative tool. AR technology offers unique capabilities that enhance assembly tasks by providing real-time guidance and facilitating knowledge transfer and retention. In this dissertation, an investigation into the potential of AR to assist operators in the assembly of mechanical products is performed. Specifically, the project scope involves developing an AR system that provides real-time, interactive instructions and guidance to technicians and operators during the assembly process. Utilizing the Plan-Do-Check-Act (PDCA) methodology, an AR application was designed and developed, aimed at improving assembly operations. Through comparative testing against traditional paper-based manuals, this study demonstrates the significant benefits of the AR prototype, particularly in terms of completion time and component visualization. These findings underscore the potential of AR technology to revolutionise assembly processes, offering manufacturers a powerful tool to enhance productivity and efficiency. Notably, future iterations of the AR system hold promise for even greater advancements, paving the way for a new era of manufacturing excellence. Description: B.Eng. (Hons)(Melit.) Mon, 01 Jan 2024 00:00:00 GMT https://www.um.edu.mt/library/oar/handle/123456789/150439 2024-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150438 Title: Design of a human-machine-interface for integration with an automated robotic vehicle Abstract: Automated Guided Vehicles (AGVs) and Automated Robotic Vehicles (ARVs) are increasingly being integrated into manufacturing factories. However, a prevalent challenge that arises in areas where both these vehicles and human workers operate is the frequent interruption of vehicle movement due to individuals inadvertently obstructing their path. The aim of this dissertation was to come up with a system that prevents such interactions at STMicroelectronics. Following a visit to STMicroelectronics and consultations with the engineering team, it was determined that a floor projection system would offer the most effective solution. Concurrently, research was conducted on AGV/ARVs, collaborative robots, and analogous solutions to inform the development process. Customer requirements were analysed and a house of quality exercise to identify the optimal solution was conducted. This concluded that the AGV-mounted projector system was best, with a Roof-mounted system developed for comparison. Through evaluation of various sensory technologies, a machine vision human detection algorithm was chosen for its ability to distinguish humans from other objects. This algorithm was integrated with a basic Human Machine Interface, projecting a warning, and emitting a sound. The control system chosen for this project was the Raspberry Pi 4 Model B. Three code iterations were developed which monitor people from Face Distance measurement, Face or Pose detection and Pose only detection. Both prototype systems underwent testing, with the AGV-mounted system tested on a trolley at STMicroelectronics and the Roof-mounted system tested at the University of Malta. Despite marginal performance from both systems, the AGV-mounted system showed slight improvement over the Roof-mounted one in both iteration time and catching people attention. The limited performance is mainly attributed to projector limitations and human adaptation. The Roof-mounted system's performance was also affected by projector constraints and testing environment factors. The analysis favours the AGV-mounted system over the Roof-mounted system for further development. Improvements are needed in both hardware and software. Description: B.Eng. (Hons)(Melit.) Mon, 01 Jan 2024 00:00:00 GMT https://www.um.edu.mt/library/oar/handle/123456789/150438 2024-01-01T00:00:00Z https://www.um.edu.mt/library/oar/handle/123456789/150437 Title: Logistics simulation of an automated guided vehicle for material handling Abstract: As customer demands become more complex and urgent, automating manufacturing processes is crucial for manufacturers to quickly develop and deliver new products, maximising profits by capitalising on demand fluctuations. Automated Guided Vehicles (AGVs) are popular for streamlining manufacturing lines, but traditional AGVs can't move between floors, challenging multi-level facilities. Advances in the Internet of Things (IoT) now allow AGVs to communicate with elevators, enabling seamless movement between floors and overcoming this limitation. The collaboration between STMicroelectronics Malta's key engineers and the University of Malta aimed to modernise processes through automation, expanding operational space for enhanced efficiency, productivity, and safety. The facility’s layout spans multiple floors, each crucial for the creation of microelectronic components. Cutting-edge technologies such as AGVs and ARVs streamline material flow, minimising manual intervention and enhancing workplace safety. Logistic simulations were developed to optimise material handling, guiding strategic decision-making for cost-effectiveness and efficiency. By identifying and eliminating bottlenecks, the project maximises throughput and operational efficiency. It was found that adding another laser-marking machine for the production of microchips increases the number of delayed trolleys at the first process in the basement but increases the utilisation of all basement processes. Furthermore, in the current set-up with only one laser marking machine, it was noted that there are no delayed trolleys in the basement but the process has a lower utilisation. Additionally, it was also found that utilising two AGVs one on the ground floor and the other on the first floor to perform 3 and 5 missions respectively was the most effective method for material handling. The reason is that this system had the highest useful AGV utilisation, the lowest amount of lift delays and a low AGV collection time. In summary, this project validates the efficacy of automation systems, displaying STMicroelectronics Malta's commitment to innovation. Insights gained will drive further advancements, fostering continuous improvement in microelectronics manufacturing. Description: B.Eng. (Hons)(Melit.) Mon, 01 Jan 2024 00:00:00 GMT https://www.um.edu.mt/library/oar/handle/123456789/150437 2024-01-01T00:00:00Z