Browsing by Author "Gamage, JR"

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item: Article-Full-text
Additive manufacturing of recycled plastics
(Springer, 2023-05) Jayawardane, H; Davies, IJ; Gamage, JR; John, M; Biswas, WK
Plastic materials have been widely used to replace metals in functional parts due to their lower cost and comparable technical properties. However, the increasing use of virgin plastic material in consumer and industrial applications has placed a significant burden on waste management due to the volume of waste created and the potential negative effects of its end-of-life processing. There is a need to adopt circular economy strategies such as plastic recycling within industrial applications in order to reduce this significant waste management pressure. The present study used recycled polylactic acid (PLA) material as a feedstock for the 3D printing of a centrifugal semi-open pump impeller. The technical performance of 3D printed recycled PLA material and virgin PLA material was compared in this study. The environmental impacts for technically feasible impellers were assessed through the environmental life cycle assessment, while costs were evaluated by life cycle costing. The results were incorporated into a techno-eco-efficiency framework to compare the technical properties, environmental impacts, and costs. The social impacts of additive manufacturing and recycled feedstock material were also explored. The technical assessment results indicated that tensile strength, fatigue strength, density, and hardness decreased with recycled material content compared to virgin material. Microscopy of the fracture surfaces revealed the presence of slightly higher porosity and defects in recycled specimens, which could result in slightly lower technical properties. However, the recycled material was accepted for further ecological analysis as it offered higher pumping performance when compared to the original component and could reduce the burden on virgin material-based production and waste material disposal. Importantly, the results showed that 3D printed recycled PLA impellers are more eco-efficient when compared to 3D printed virgin PLA impellers.
item: Conference-Extended-Abstract
A Coconut deshelling machine for improved safety and productivity
(Engineering Research Unit, 2023-12) Bandara, A; Jayawickrama, D; Kuladasa, B; Dinuka, A; Subasinghe, LU; Gamage, JR
Coconut is the third largest cash crop grown in Sri Lanka. There are a variety of coconut-based products available, and deshelling is an essential step in the manufacturing processes of all those products. However, the deshelling process faces several safety concerns which are yet to be addressed. It was found through field visits that on average, 4 accidents per month are reported by the laborers who work in deshelling machines. These injuries are caused by slippage of coconut when it is held onto the cross cutter of the deshelling machine. Another concern was that the coconut kernel was damaged slightly by the cross-cutter, the cutting wheel of the current machine. This damage is significant when a large-scale coconut processing plant with over 200,000 nuts daily capacity is considered. The scarcity of skilled laborers to operate the deshelling machines is another challenge. Training new laborers is both a time-consuming and costly process. Therefore, this research aims to develop a new mechanism for coconut deshelling to be used in an industrial setup. The mechanism intends to enhance the safety of the operation while reducing the damage to the kernel and to reduce human intervention in the process. The scope of this project is limited to deshelling a coconut starting from dehusked coconut and the intended output is kernel with brown skin while dehusking and paring will be out of the scope.
item: Conference-Abstract
Comfort study of work environment of apparel industry
Kosala, WVR; Vilasini, N; Gamage, JR
Diminution of workers' efficiency and increase of health and safety hazards are among the topmost problems faced by present manufacturing industry. Therefore manufacturing industries are continuously exploring new avenues to improve factors that affect workers' efficiency, health and safety while improving the overall productivity. The main objective of the research was to address such problems by introducing ergonomically sound work environment and practices through action based case study. This paper elaborates how thermal comfort, design of work places and practices influence the overall productivity of an apparel manufacturing factory in Sri Lanka. Data related to design of work environment and human comfort was gathered by means of a questionnaire survey and on-site experimental observations. Then the data were analysed by comparing them with the industry standards and theories of ergonomics. Based on the resulting conclusions an action plan was developed and recommended solutions for the identified issues.
item: Conference-Full-text
A comparative analysis of the environmental and structural performance of pet bottle designs in Sri Lanka
(IEEE, 2021-07) Jagoda, SUM; Gamage, JR; Karunathilake, H; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
Polyethylene Terephthalate (PET) has become the most commonly used material in the global beverage bottling industry. PET bottle production has increased by over seven times within the last three decades. However, the use of PET has a considerably detrimental effect on the environment, and many studies have been carried out on curbing this damage. Reducing the amount of material used, design for recycling, repurposing, and reusing are possible approaches for mitigating the negative environmental impacts of the PET bottle industry. The local PET bottle market has a range of products to cater the various customer requirements. To obtain a holistic vision of the actual impacts of this industry, life cycle thinking becomes necessary. The objective of this study is to present a methodological framework for comparing the environmental performance and structural performance of PET bottle designs, using case studies from the Sri Lankan market. A life cycle assessment and a finite element analysis were carried out to evaluate the overall environmental impacts of the PET supply chain and the structural performance of PET bottles. The outcomes of the study are used to provide recommendations on the short and long-term strategies to increase the eco-friendliness of the PET bottle industry.
item: Conference-Full-text
A conceptual framework for the identification of barriers in automotive remanufacturing industry in sri lanka
(IEEE, 2021-07) Kahingala, NM; Gamage, JR; Punchihewa, HKG; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
Automotive remanufacturing provides a sustainable solution for waste generation in the automotive industry. Although the automotive remanufacturing industry is prominently seen in countries such as the UK, USA and China, it is now expanding to other parts of the world including India, Japan, Malaysia, and Singapore. Being a country having an automotive industry with significant value addition, Sri Lanka also possesses a high potential for remanufacturing. However, evidence of such industries is hardly seen. Therefore, the aim of the presented research was to develop a conceptual framework to identify barriers and propose solutions in the automotive remanufacturing industry in Sri Lanka. In this pursuit, a comprehensive review of the literature was performed. This was followed by informal interviews with people involved in the automotive remanufacturing businesses. The conceptual framework was then developed based on the challenges in each stage of the remanufacturing process against the three levels of interventions: Educational, regulatory body, and prevailing market conditions. It was revealed from the framework that most of the challenges were linked to the prevailing market conditions. Therefore, this paper provides a basis for encouraging the stakeholders to find suitable strategies in addressing the barriers associated with automotive remanufacturing in Sri Lanka.
item: Conference-Full-text
Design of a sustainable automotive turbocharger remanufacturing system
(IEEE, 2020-07) Jayawardane, H; Wijesinghe, K; Wildeniya, P; Gamage, JR; Weeraddana, C; Edussooriya, CUS; Abeysooriya, RP
Remanufacturing has been identified as the process of returning of end-of-life products to original or better condition and performance with lower resource consumption, waste, and emissions compared to conventional manufacturing. Remanufacturing aids to reduce the economic, environmental, and social impacts of manufacturing. The purpose of this study is to investigate several product recovery cases performed at different levels to identify opportunities for developing remanufacturing systems in the Sri Lankan context. A literature review, semi-structured interviews, and case study visits were conducted for data collection. The analysis shows that the automotive sector in Sri Lanka is the most suitable sector to introduce remanufacturing, within which turbocharger has been identified as the most suitable component for remanufacturing. A model for the turbocharger remanufacturing system is proposed, and the sensitivity of the system to different operating scenarios is also analysed using plant simulations. The paper presents an economically viable and environmentally benign remanufacturing system with a business plan, which can be implemented in Sri Lanka.
item: Conference-Full-text
Developing a coconut de-shelling mechanism for improved safety and productivity in virgin coconut oil production
(IEEE, 2021-07) Pandipperuma, OGS; Niranjana, RPD; Kumarasiri, HKNU; Gamage, JR; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
Virgin coconut oil manufacturing is one of the major products for both export and local markets in Sri Lanka. Most of the large and small-scale manufacturers encounter many issues in the process of de-shelling in terms of both safety and productivity. On average at least 5 accidents are reported to have occurred in the industry per month. Therefore, the purpose of this paper is to introduce an improved de-shelling mechanism that helps coconut oil manufacturers to increase their operator safety and productivity. The safety and performance parameters of the de-shelling operation were established using a review of the literature. Then the existing coconut de-shelling operation was analyzed for its safety and productivity using an industrial case study. Basic concepts were generated and evaluated to develop a final design using the fundamental machine design principles. The developed concepts were tested by benchmarking against the safety and productivity Key Performance Indicators (KPIs) using 3D modelling, and experiments. The proposed solution offers promising results to address the safety and productivity issues. However, there is room for further improvements in bringing the design up to the commercial.
item: Conference-Extended-Abstract
Development of a scaled vehicle Model for dynamics testing
(2021-09-06) Hewavithana, RR; Ravihara, JPL; Wishwajith, KKS; Perera, ULS; Dasanayake, NP; Gamage, JR
The interest in using scaled models for dynamics testing of prototype vehicles is growing due to the high demand for autonomous driving. In the early design phases, vehicle testing is done using computer simulations. Even though computer simulations are proven to be extremely helpful in designing prototypes, simulation models need to be validated using realworld testing. There are high costs involved in vehicle testing and it’s dangerous to conduct aggressive driving manoeuvres with real drivers.
item: Conference-Extended-Abstract
Enhancement of students' learning experience through introduction of innovative methods of conducting and assessing laboratory classes: a case study
(2009) Ranaweera, RAMP; Gamage, JR; Kahangamage, UP; Dassanayake, VPC
This paper elaborates a successful attempt made for improved way of conducting and assessing of laboratory classes. The key aims were to improve the quality & effectiveness of laboratory classes, promote team work and increase relevance of the undergraduate practical programme that suits the industrial environment. In the design stage, problems of the existing methods, industrial requirements and expert views were carefully analysed. Finally it shown considerable improvement in quality and effectiveness of the practical programme and team working ability students.
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Environmentally sustainable plastic food packaging
(Elsevier, 2023) Jagoda, SUM; Gamage, JR; Karunathilake, HP
Enhancing the sustainability of food packaging (FP) is challenging due to the conflicting environmental and functional requirements, even though it leads to many negative environmental impacts over different life cycle phases. Sustainable FP aims to strike a balance in fulfilling protection, facilitation of handling, and communication functions while minimizing the environmental impacts and economic costs. Yet, there is a lack of holistic frameworks that support sustainable FP design decision-making processes based on life cycle thinking. Thus, the objective of this study is to develop a generalizable framework combining life cycle thinking with functional analysis for systematically and holistically comparing sustainable packaging design options, considering environmental, economic, and consumer preference dimensions. The proposed approach was applied to a rigid plastic packaging case study involving ketchup bottles. Kano's theory and Quality Function Deployment (QFD) were used to identify the user requirements, applicable design features, and prioritisation. Then, conjoint analysis, life cycle analysis (LCA), and analytical cost estimation were used to estimate the functional satisfaction, environmental impact, and costs incurred respectively. Finally, the values obtained for three criteria were aggregated using Fuzzy Analytical Hierarchy Process (AHP) and the overall sustainability of the design options was compared. The results show that both material quantity, type, and shape majorly influence the functional, environmental, and economic impacts. There is a disparity between the options with the highest functional satisfaction and the lowest environmental impacts respectively. The aggregated score indicates that an option currently available in the market has the highest performance, and yet there are other options with better environmental performance. However, even after the scores are aggregated, the inputs of packaging experts maybe necessary to successfully balance the sustainability requirements with the user expectations. The findings of this research, which proposes a systematic and holistic design process, can support packaging designers, industry decision-makers, and policy planners in enhancing the sustainability of FP.
item: Conference-Extended-Abstract
ERU Symposium 2023 proceedings 5th - 6th December 2023
(Engineering Research Unit, 2023-12) Gamage, JR; Nandasiri, GK; Herath, RP
item: Conference-Full-text
Framework to promote automotive remanufacturing: case study of automotive repairing, rebuilding, and remanufacturing industry in Sri Lanka
(IEEE, 2022-07) Karunarathna, KL; Gamage, JR; Rathnayake, M; Adhikariwatte, V; Hemachandra, K
The growth of remanufacturing has seen its application in automotive, electronic equipment, furniture, and medical devices in the global product portfolio. Remanufacturing is identified as a promising end-of-life/use product recovery strategy that has been used in the world for decades as a solitary value-adding process that upgrades a product from used condition to the like-new Original Equipment Manufacturer (OEM) condition. Remanufacturing could be an attractive option with the growing vehicle fleet in Sri Lanka. However, most of the existing recovery practices do not fall under the remanufacturing definition. The purpose of this study is to develop a framework to promote automotive remanufacturing among the repairers, re-builders, and other stakeholders. A case study-based approach was used with semi-structured interviews that were conducted physically and remotely. The study derives and presents a remanufacturing closeness factor for each case company by considering product type, process steps, degree of salvage, and performance testing were considered as key elements. Prioritized Internal and external factors were used as construct variables in the framework. Key constructors were core acquisition, Skill labour availability, remanufacturing process steps, technology, market knowledge, and policy requirements. The developed framework can be used as a guide to promote the efficient adaptation of remanufacturing.
item: Conference-Full-text
A framework to promote mould remanufacturing in Sri Lankan sme
(IEEE, 2022-07) Wanaguru, BK; Gamage, JR; Rathnayake, M; Adhikariwatte, V; Hemachandra, K
The global mould manufacturing market amounts to USD 26.21 billion in 2020 and is expected to increase to USD 38.62 billion in 2025 at a Compound Annual Growth Rate (CAGR) of 8%. This growing demand for moulds urges to develop sustainable methods to recover used moulds. Remanufacturing of moulds offers a promising solution in the industry which extends the useful life of end-of-use moulds. However, there is a lack of evidence that mould remanufacturing is used to reap its potential benefits in Sri Lankan Small and Medium-sized Enterprises (SME). Literature review and semi-structured interviews were used to establish the current knowledge, identify barriers, and to identify key elements in developing the framework. The paper presents a conceptual framework developed for promoting mould remanufacturing in Sri Lankan SME.
item: Article-Full-text
Implementing value stream mapping tool in the construction industry
Vilasini, N; Gamage, JR
The purpose of this is paper is to understand the applicability and adoption of the value stream mapping technique in the construction industry. The applicability of the adopted value stream mapping methodology was tested in a pre cast concrete yard which supplies pre cast concrete yard which Supplied pre cast concrete segments to a bridge construction site. A process mapping tool has been used for value stream mapping since it contains high correlation to the existing wastes at the sites. A detailed value stream mapping procedure was developed and validated within this case study. The effectiveness of the value stream mapping methodology was also evaluated at the same site as it was producing approximately five hundred units continuously. The research findings will contribute to a better understanding of the applicability and potential benefits of value stream mapping tool in terms of cycle time reductions and quality improvements.
item: Conference-Abstract
Implementing value stream mapping tool in the construction industry
Vilasini, N; Gamage, JR
The purpose of this is paper is to understand the applicability and adoption of the value stream mapping technique in the construction industry. The applicability of the adopted value stream mapping methodology was tested in a pre cast concrete yard which supplies pre cast concrete segments to a bridge construction site. A process mapping tool has been used for value stream mapping since it contains high correlation to the existing wastes at the sites. A detailed value stream mapping procedure was developed and validated within this case study. The effectiveness of the value stream mapping methodology was also evaluated at the same site as it was producing approximately five hundred units continuously. The research findings will contribute to a better understanding of the applicability and potential benefits of value stream mapping tool in terms of cycle time reductions and quality improvements.
item: Article-Full-text
Investigating the ‘techno-eco-efficiency’ performance of pump impellers: metal 3D printing vs. CNC machining
(Springer, 2022) Jayawardane, H; Davies, IJ; Gamage, JR; John, M; Biswas, WK
The economic, environmental, and social impacts caused by the extensive resource consumption and harmful emissions from the metal manufacturing industry should be lowered through innovative sustainable manufacturing strategies. This study aims to investigate the techno-eco-efficiency performance of metal 3D-printed parts in comparison with CNC-machined parts to determine the technical, economic, and environmental performance as a decision support tool for selecting the most techno-eco-efficient manufacturing method. In this study, a novel metal extrusion 3D printing technology has been used to create a centrifugal semi-open pump impeller in 316L stainless steel material. The technical feasibility of the impellers has been determined by evaluating the geometry, build material, mechanics, morphology, and functional performance of the impellers. The eco-efficiency performance of technically feasible impellers was evaluated through environmental life cycle assessment, life cycle costing, and portfolio analysis. This eco-efficiency analysis helped ascertain the cost-competitiveness and environmentally friendliness of the 3D-printed impellers by comparing it with the conventional impellers. The findings reveal that the AM impeller is eco-efficient mainly due to lower normalised environmental impacts (54.6%) compared to the SM impeller. The functional parts made by metal extrusion 3D printing are technically feasible, cost-effective, and environmentally friendly compared to the SM counterparts.
item: Conference-Abstract
Lean methodology to reduce waste in a construction environment
Vilasini, N; Neitzert, TR; Gamage, JR
Productivity and waste factors are interdependent of each other. Waste is a major problem in the construction industry which amounts to 60% of the construction effort. A study focused on the construction efficiency by the National Institute of Standards and Technology in the UK has documented 25% - 50 % of waste relates to coordinating labour and managing, moving, and installing materials. Therefore the main aim of this study is to find out the possibilities of waste reduction in the construction industry through lean construction applications. The method adopted for this study is a case study research approach where it concludes the results obtained from a major construction project in New Zealand. A pilot case study was carried out to understand the existing practices. The research study substantially followed the process mapping method to identify the level of concern in waste minimisation on a construction site. Outcomes from the studies indicate that one third of non value adding activities are resulting from factors under the control of management. This study concludes that there are more opportunities to eliminate waste and add value to the construction process. Hence by improving management practices through a lean implementation the non value adding time of a construction project can be reduced and thereby productivity can be improved significantly.
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Life cycle thinking for packaging
(2021) Jagoda, S; Karunathilake, H; Gamage, JR
Unsustainable packaging practices are one of the leading problems in today’s world, leading to unnecessary resource consumption, increased waste generation, environmental pollution, and an overall negative impact on ecosystems. Global statistics show that 8 million metric tons of plastic ends up in the oceans every year. It has been estimated that approximately 79% of plastic produced since 1950 has been sent to landfills or otherwise released to the environment. With the current trends, the United Nations predicts that the plastic content will overweigh the fish in the ocean by 2050 [1].
item: Conference-Abstract
Resource utilisation and availability analysis as a productivity improvement tool: A case study of a food manufacturing company
Vilasini, N; Kahangamage, UP; Gamage, JR
The purpose of this paper is to elaborate how resource utilisation concept influences to the overall productivity of a manufacturing organisation. Effective resource utilisation increases profitability by optimising utilisation and minimising bench time and generates goodwill and loyalty among staff that translates to competitive advantages in recruiting and retaining the best talent in the future. A manufacturing company uses resources of various kinds such as manufacturing resources (machines, material handlers, tools, Energy etc.), storage resources (warehouses, automated storage and retrieval systems), logistics resources (trucks, rail transport, air-cargo carriers, etc.), human resources (labour, scientific and technical personnel) and financial (working capital, stocks, etc.). The objective is to utilise these assets or resources efficiently so that the overall productivity of the organisation can be maximised. Resource utilisation is the percentage of time that a resource component is actually occupied, as compared to the total time that the resource component is available for use. In order to apply the resource utilisation concept, generic losses adhered to the various work centres were identified and categorised according to the above mentioned resource categories. This generic loss structure was then applied to selected work centres of a food manufacturing plant. The generic loss structure for work centre was categorised in to two major categories, equipment losses and man power losses. Several Industrial Engineering tools were used to identify prevailing losses and to quantify them. The results show that when resource utilisation concept is applied according to the generic model, the productivity of the work centres has been improved. The resultant productivity improvement has been estimated and presented.
item: Conference-Full-text
A reverse vending machine for sorting yoghurt cups and pet bottles
(IEEE, 2021-07) Athukorala, SC; Hennayaka, HMAL; Rathnayake, SMLP; Hariluxman, M; Gamage, JR; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
With the ever-increasing amount of waste disposal by mankind, the requirement for waste management is paramount. Apart from dumping waste in landfills, recycling is another popular solution adopted by the world to manage waste. As an effective collection mechanism of plastic waste, automatic recycle bins are employed in many countries in common places like subways and, malls. Furthermore, different rewarding mechanisms are in place to motivate the consumers to return the plastic waste. Reverse vending machines which encourage the collection of plastic waste and provide rewards are used in some countries. However, existing reverse vending machines lack features like separating plastic based on their plastic category. PET bottles and Yoghurt cups are some of the mostly disposed plastic containers in Sri Lanka. There are companies that use these types only to recycle and manufacture unique recycled products. This paper focuses on developing a reverse vending machine with plastic type sorting function to be used in the Sri Lankan context. The existing mechanisms were reviewed and a solution is designed to operate with Near-infrared (MR) plastic sorting and gravity transfer method. Furthermore, an appropriate rewarding mechanism is also proposed.