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An industrial application of the lean and agile model for product development: a manufacturing case study
No full textManufacturing organisations face pressure to develop effective engineering solutions while maintaining their competitiveness in rapidly evolving markets. This challenge necessitates product development approaches that balance rigorous knowledge-driven methodswith responsive adaptation to changing requirements. This research presents an empirical application of the Lean and Agile Model for Product Development (LAMPD) in a manufacturing environment, addressing critical gaps in integrated methodologies for hardware contexts. LAMPD was implemented through a 4-month case study at Atlas Copco Henrob, a UK manufacturer of self-piercing riveting systems, focusing on enhancing a rivet feeder system used in automotive manufacturing that had not previously undergone dedicated design optimisation. The research aimed to document LAMPD implementation processes, determine its impact on design efficiency, identify process benefits and challenges, and explore implications for manufacturing product development practices. The LAMPD framework systematically integrated Set-Based Concurrent Engineering principles with Agile methodologies including Scrum ceremonies and Kanban visualisation techniques across three development phases: Project Definition, Project Feasibility, and Project Realisation. The integrated approach facilitated evidence-based decision-making, which resulted in a 53% component reduction, eliminated two sensors from the original design, and improved system reliability by reducing false readings from 12% to near zero principally through the rigorous application of SBCE methodology combined with continuous integration cycles. Challenges identified included harmonising sprint cadences with traditional phase boundaries and balancing multiple methodological frameworks without compromising their individual strengths. Despite these implementation complexities, the research demonstrates that combining Lean knowledge management principles with Agile responsiveness creates substantial value in manufacturing product development. The LAMPD model provides organisations with practical mechanisms to enhance both design efficiency and process adaptability, contributing to theory and practice by showing how integrated approaches can significantly improve product development outcomes in hardware manufacturing contexts.Concurrent Engineerin
Estimation of residual stress in carbon fibre composite laminate using the contour method
No full textExperimental analysis of residual stress in carbon-fibre-reinforced polymer (CFRP) composites is rare owing to the difficulties of determining residual stress accurately in these materials. This can lead to non-conservatism in design and poor understanding of potential failure mechanisms. In this study we have determined the residual stress in a cross-ply CFRP laminate. For the first time, the contour method of residual stress measurement was applied using wire electric-discharge machining (WEDM), the process that is accepted as the best way to ensure an accurate relaxed surface profile is obtained to back calculate the residual stress. A novel incremental linear smoothing approach was introduced for the measured displacement data which gave better approximation than the conventional spline smoothing method used in the standard contour method for metals. Measurements show tensile residual stress in the direction transverse to the fibres with a maximum value of 40 MPa, and compressive residual stress along the fibre direction with a maximum value of –130 MPa. The accuracy of the calculated residual stress was improved by considering the measured thickness of each ply cluster rather than the nominal thickness. The results of modified contour method are compared with an analytical solution based on the classical laminate theory.Composite Structure
Impact of integration on procurement of urgent goods and serviceswithin the public healthcare sector
No full textSaghiri, Soroosh - Associate SupervisorUrgent procurement in healthcare has been under-researched despite its critical
role in ensuring business continuity and timely patient care. This study explores
how procurement integration impacts urgent procurement by combining a
systematic literature review with secondary data analysis from the UK
government’s Model Hospital database. The findings indicate that while
procurement integration is well understood in planned contexts, it remains
insufficiently addressed in urgent situations, particularly unpredictable, patient-
specific requirements.
Two key contributions emerge from this research: first, it differentiates between
standard and urgent procurement processes, emphasising the latter's unique
challenges in healthcare. Second, it highlights the limited integration of urgency
within procurement strategies, with procurement often overriding clinical input. A
theoretical framework is proposed to bridge this gap, drawing on case studies of
eight healthcare providers (five public and three private) and interviews with 30
professionals, including clinicians and procurement managers.
The results show that effective communication integration is essential for
improving urgent procurement outcomes, enabling faster response times and
fostering stakeholder collaboration. The study underscores that previous
procurement successes enhance future urgent procurement performance, while
failures reduce responsiveness. Additionally, conflicting objectives between
clinical and procurement teams and a lack of tailored decision support systems
(DSS) hinder urgent procurement efficiency.
This PhD thesis calls for developing a DSS designed to streamline urgent
procurement processes by improving communication, transparency, and
alignment of objectives. Integrating contingency and socio-technical systems
frameworks with qualitative data offers a robust foundation for future research
and practical solutions to optimise healthcare procurement, particularly in the UK
public healthcare sector.PhD in Leadership and Managemen
Integrated NDI-based Controller and Incremental Control Allocation for an eVTOL
No full textLu, Linghai - Associate supervisorThe concept of urban air mobility (UAM) has been proposed to address the transport problems of congestion and pollution in ever-growing urban conurbations. Mature fixed wing aircraft technologies have many constraints that limit their applicability for UAM hence piloted all electric vertical take-off and landing (eVTOL) vehicles known as eVTOL ‘air-taxis’ provide a
promising option being lighter, quieter, potentially having net zero emissions and with lower
operating costs. Furthermore, their higher bandwidth thrust actuation allows for novel config urations. However, one challenge of eVTOL aircraft operation is their strong nonlinear flight
dynamics since they operate over a wide range of operating envelope. One particularly chal lenging eVTOL configuration is the Lilium jet, a fixed-wing, over-actuated vectored thrust,
canard light sports aircraft. However, its canard configuration can destabilize the short-period
mode requiring fly-by-wire stability augmented flight control systems. A second challenge of
this configuration is the coupling between the aerodynamic surface control and the vectored
thrust makes control allocation (CA) during transition very difficult. A third challenge of this
configuration is its high degree of over-actuation presents a challenging CA. Finally, a fourth
challenge of the eVTOL configuration is that the vectored thrust results in nonlinear effector
mapping preventing the direct use of classical CA approaches. In order to address the control
challenges of the Lilium-style eVTOL, a novel full-envelope controller is presented which em ploys a generic control architecture applicable to piloted, semi-automatic and fully automated
flight. The full-envelope controller consist of an aircraft-level controller which produces an
overall control demand and a CA scheme which allocates the overall control demand to indi vidual redundant effectors. The CA scheme also performs control error minimisation, control
channel prioritization and control effort minimization. The aircraft-level controller adopts a
modular approach, consisting of a main inner-loop nonlinear dynamic inversion (NDI) con troller which cancels the bare airframe dynamics and an outer-loop proportional-integral (PI)
linear controller which together addresses several of the eVTOL operation challenges. The
inner-loop NDI controller is a velocity controller while the outer-loop PI controller is an at titude and navigation position controller which together are used for hover/low speed control
and forward flight. This thesis proposes and initially conceptually tests three real-time CA ap proaches for transforming a nonlinear CA problem to a linear problem and then applies active
set linear CA technique to address all the remaining challenges of the eVTOL configuration.
This thesis fully verifies one of the CA approaches on a full six-degrees-of-freedom model
version of the eVTOL aircraft. Simulation results clearly demonstrates that the controller has
reasonable disturbance rejection, can guarantee stable flight in case of severe actuator satura tion and has satisfactory compliance to typical mission tasks for this class of vehiclePhD in Aerospac
On a novel co-rotating synchronous turbine mode operation in a centrifugal compressor
No full textSee also: https://doi.org/10.1115/1.4070125
Copyright © 2025 by Rolls-Royce plcA novel co-rotating, synchronous, reverse flow (RF) turbine mode operation in a centrifugal compressor (CC) is investigated, and methods to enable this mode, its working principles, flow field features, and key performance characteristics are described. This is done by using three-dimensional (3D) Reynolds–averaged Navier–Stokes (RANS) flow field simulations on a simplified variant of the NASA High Efficiency Centrifugal Compressor (HECC) geometry, which represents a typical state-of-the-art design practice. The novel co-rotating turbine mode is elucidated by first considering the baseline contra-rotating, reverse flow turbine mode as would be expected from the conventional four-quadrant CC operation map. This baseline contra-rotating turbine mode is also hitherto undescribed in the literature for CC. Therefore, the flow field and performance metrics in the baseline contra-rotating mode are utilized to provide insights into the possibility of engineering design elements that can enable the novel co-rotating turbine mode. The novel co-rotating, turbine mode is found to be enabled by the introduction of a suitable swirl generation mechanism that will direct the flow onto the impeller wheel suction side to give it a rotational impulse to spin from the suction to the pressure side as in nominal operation. The flow expansion through the reversed impeller wheel flow path with radius reduction enables power production. In the novel co-rotating, turbine mode, the flow leaves the impeller wheel in the same direction as it enters because of the direction of rotation and impeller inlet flow angle. However, this does not significantly impact power production because of the reduced radius weighting of the absolute swirl at the impeller inlet. An exemplary co-rotating turbine mode enabling configuration with 45 deg rotated diffuser vanes is found to handle up to 46% higher reverse flow and yield 6.25% higher peak power output even with a 16% lower absolute swirl velocity change as compared to the baseline contra-rotating mode. Additionally, the novel mode indicates better low speed power profile and wheel terminal speed as well. Alternative embodiments to enable the co-rotating mode like drilled feed ports and guide vane arrangements are discussed in the work. The hitherto undescribed co-rotating turbine mode operation is unique in its ability to produce and absorb power in the same shaft for bladed turbomachinery. Therefore, purposeful utilization of this mode could enable the design of better, robust, optimized systems for aerospace and energy applications.The authors would like to express their gratitude to Rolls-Royce plc. for supporting this research. The work was carried out under InnovateUK—Aerospace Technology Institute (ATI) Project PINES, Reference No. 113263.Journal of Engineering for Gas Turbines and Powe
De-risking of a high-speed intake distortion facility using a small-scale pilot rig
No full textSession: High-Speed Inlets, Isolators and Nozzles I
Copyright © 2026 by Cranfield University.This paper presents the development of a sub-scale pilot rig (Mini HI-Sim) designed to de risk the operation of a large-scale, high-speed intake distortion facility (HI-Sim). The Mini HI-Sim replicates key aerodynamic features using a vacuum-driven aspirated configuration able to provide onset Mach numbers up to 1.65. This paper assesses the operating performance of the rig and compares it to estimates of operational runtime based on compressible flow theory and polytropic expansion. The study demonstrates that the runtime and flow uniformity are sensitive to vacuum level and speed of the fast-acting valve. Flow visualization using tuft tracking and image processing confirmed the presence of counter-rotating vortices in the radial exhaust which had been observed in previous computational work of the full-scale rig, offering a preliminary and qualitative validation of the radial exhaust design. Preliminary CFD analysis showed that re-pressurization of the working section was caused by an excessive geometric contraction in the exhaust, which increased the static pressure around the enclosed jet in the working section and prevented the normal shock from being fully displaced downstream. Removing this contraction yielded a uniformly low plenum pressure, improved flow extraction, and enabled the intended Mach-number distribution in the working section. Overall, the Mini HI-Sim offers a cost-effective platform for aerodynamic and instrumentation de-risking, supporting the development of robust supersonic intake systems for future propulsion applications.The authors would like to thank the Defence Science and Technology Laboratory (Dstl) and Rolls-Royce plc. for supporting this research.AIAA SCITECH 2026 Foru
Data for manuscript titled "Defect depth estimation using through-transmission pulsed thermography: A numerical and experimental investigation"
No full textRaw thermograms for pulsed thermography in the reflection and transmission modes. Grant number: EP/P027121/1Through-transmission pulsed thermography is widely recognised for offering higher defect resolution than reflection mode, yet its development has been hindered by challenges such as quantifying defect depth. This study addresses the depth quantification gap by introducing a novel depth estimation technique based on the relationship between defect depth and the Fourier number. The method is validated through both finite element modelling and laboratory experiments using calibration samples with embedded air-gap defects at known depths. Results show that depth estimation accuracy improves as defects approach the backwall, consistently across both simulation and experimental environments. Finite element analysis also demonstrates that the proposed technique outperforms the log second derivative method typically used in reflection mode. These findings advance the capability of through-transmission thermography for precise subsurface defect characterisation.Sun Resource
Beets beyond sugar: potential and limitations of sugar beet pulp as a feedstock for biorefineries
No full textSugar beet (SB) is a major sugar crop in the European Union and the United States, primarily cultivated for the commercial production of table sugar. Post-extraction of sucrose, the fibrous fraction which remains is called sugar beet pulp (SBP). SBP is rich in structural carbohydrates such as cellulose, hemicellulose and pectin containing glucose, arabinose and galactouronic acid as their respective monomeric units. SBP is a renewable source of fermentable sugars that constitute about 85 % of total carbohydrates. Leveraging SBP as a substrate for a biorefinery supports circular bioeconomy principles by simultaneously reducing agricultural waste and enabling the sustainable production of value-added chemicals. This review highlights current advances in SBP valorization, beginning with an overview of SB processing and waste generation, followed by a critical assessment of pretreatment strategies that enhance carbohydrate accessibility. Particular attention is given to emerging routes for the bioconversion of arabinose and galacturonic acid, which together represent more than half of SBP’s fermentable fraction yet remain significantly underutilized in industrial biotechnology. Microbial pathways, metabolic engineering interventions, and fermentation approaches enabling the production of value-added compounds such as arabitol, 2,3-butanediol, ascorbic acid, mucic acid and prebiotics are examined in detail. The review concludes by addressing current challenges and identifying research gaps to unlock the full potential of SBP within integrated biorefinery systems.VK and RPS acknowledge support from Magan Centre for Applied Mycology [Research England Expanding Excellence in England (E3) by UKRI (UK Research and Innovation)].VK and FC are grateful to UKRI Biological Sciences Research Council (BBSRC) grant BB/Y008332/1.Industrial Crops and Product
Top management involvement in key account management: a contingency model
No full textPrior, Daniel - Associate SupervisorKey Account Management (KAM) plays a strategic role in driving long-term
customer value, yet its implementation remains challenging. While prior research
recognises the importance of Top Management Involvement (TMI) in KAM,
limited attention has been paid to what drives such involvement, how it manifests
in practice, and how it is shaped by contextual contingencies. This study
addresses these gaps through an abductive, multi-case research design
involving seven organisations. It identifies 19 drivers of TMI, categorised along
proactive–reactive and strategic–operational–individual dimensions. TMI is found
to manifest across three behavioural domains: displayed commitment, decision-
making approach, and interaction style. Importantly, the study demonstrates that
structural, environmental, cognitive, and operational contingency factors
moderate the relationship between TMI drivers and executive behaviours. These
findings make theoretical contributions by refining and extending the
conceptualisation of TMI, increasing our understanding of how personal traits
influence TMI, illustrating its dynamic nature, and challenging the assumption that
TMI is inherently beneficial to KAM performance. The study also offers practical
insights for aligning executive involvement with KAM demands. It presents a set
of ten role templates for executive involvement in KAM and concludes with
limitations and suggestions for future research.PhD in Leadership and Managemen
Space based infrared observations for space situational awareness
No full textSpiller, Dario - Industrial Supervisor - Arca DynamicsThis thesis explores the feasibility of using infrared sensors for space-based space situ- ational awareness in low earth orbit. The goal is to assess if the thermal radiation of targets can be detected, therefore rendering them visible, even under unfavourable illu- mination conditions i.e. during eclipse. This thesis is done in collaboration with Arca Dynamics. After a literature review, the relevant sensor requirements are outlined and bolometer cameras are chosen because of their cost effectiveness. INO’s High-Definition Infrared Space Camera Core is selected as the chosen sensor. Next, the radiometric signa- tures of targets are modelled and a simplified model to assess detectability is constructed. This model is used to assess the limitations of the technology showing that detectability is highly dependent on target temperature and detection is feasible only for large objects (at least larger than 8 m2) at temperatures reached during eclipse. Next, a more complete bo- lometer model is developed that includes important effects such as point spread function, thermal time constant, integration and amplification, and a noise model. This model is then used in the simulation pipeline that allows us to simulate different target and observer scenarios, assess detectability, and generate synthetic images. A case study is presented using the satellite Cartosat-1 which shows that the object is detectable at distances up to 238 km. This study shows that detection of objects during eclipse is feasible, but only for relatively large objects at limited ranges. Target temperatures and relative kinematics are also crucial factors that influence detection. The model still needs to be validated to ensure its fidelity to reality. However, the behaviour of this model is in agreement with similar work in the literature.MSc in Astronautics and Space Engineerin