DEPARTMENT OF PRODUCTION ENGINEERING

Melon seed is an important oil seed crop which serves several food purposes. Shelling of this crop is vital, prior to its vast applications. To address the challenges associated with shelling melon, a design for shelling melon seeds on a small scale was presented and evaluated. Parameters evaluated include shelling efficiency, percentage seed shelled and damaged, throughput and machine capacity.The machine was constructed using locally available materials and consists of a hopper, frame, shelling and cleaning unit. Shelling operation was carried using melon seeds of three different moisture contents(6.99, 11.90and18.32%) and at different shelling speeds of 1500 and 1450rpm, while performance evaluation were evaluated. Results obtained showed that shelling speed of 1500rpm for seed A has the best average shelling efficiency of 53.75% and least percentage seed damage of 22.6%, compared to shelling speed of 2500rpm seed B which had average shelling efficiency of 37%. This design and set of conditions selected were the most preferred because of the low-cost, rapid operation, lesser seed damage and minimal human energy expenditure. The melon seed sheller is user friendly, does not require skilled labour. The equipment design was found suitable for rural development.

This study presents the design, fabrication, and performance evaluation of an electric yam blending machine developed to improve the efficiency and hygiene of yam processing. Traditional pounding methods are labor-intensive, time-consuming, and yield inconsistent product quality, while existing mechanized systems are often costly and prone to leakage and maintenance challenges. The machine was engineered using standard design principles, incorporating a 1 hp electric motor (1440 rpm), belt-pulley transmission, stainless steel (SS304) blending chamber, and a rotating blade mechanism. Design analysis established a torque requirement of 7 Nm and a minimum power demand of 734 W to effectively process the high-density, viscoelastic yam
mass. Leakage prevention was achieved through the integration of food-grade sealing elements, including silicone and EPDM gaskets, at critical interfaces. Performance testing using 300–500 g yam samples showed an average processing time of 2.71 minutes for 500 g, with a throughput capacity of 16.18 kg/hr and an efficiency of 97%. Sensory evaluation confirmed high-quality output in terms of smoothness, cohesiveness, and elasticity. The developed system demonstrates enhanced processing efficiency, improved hygiene, and operational reliability, offering a cost-effective solution for small- to medium-scale yam processing applications

The machine is developed to cut different metal materials with high precision using plasma arc technology controlled by a computer system. The CNC plasma cutter improves cutting accuracy, reduces manual effort, and increases productivity in metal fabrication industries. The project includes the design process, material selection, fabrication of the frame, installation of electronic components, and testing of the machine

This project focuses on the design, fabrication, and evaluation of an electrically powered grain crusher for small-scale farmers and rural communities. The primary aim is to develop an efficient, durable, and affordable machine capable of crushing dried maize grains into smaller particle sizes suitable for food processing and livestock feed production. The objectives include improving crushing efficiency, reducing manual labour, and promoting the use of locally developed technologies to enhance agricultural productivity and support rural development. The machine is powered by an electric motor that transmits motion to the crushing chamber through a belt and pulley system. Engineering design calculations were conducted to determine key parameters such as motor power, shaft diameter, pulley ratio, and crushing force required for effective operation. Locally sourced materials were used in the fabrication process to reduce cost and ensure ease of maintenance. The design and construction followed standard engineering principles to achieve structural stability, operational safety, and reliable performance. The performance results showed that the grain crusher achieved a throughput capacity of approximately 15 kg/h with a crushing efficiency of about 92%. Sieve analysis revealed that the crushed output consisted predominantly of particle sizes in the range of 0.71 mm to 1.40 mm, making it suitable for food processing and livestock feed preparation. The machine effectively crushed dry maize grains and is adaptable for processing similar dry grains such as sorghum and millet. The crusher operated smoothly with minimal vibration and reduced processing time compared to manual methods, demonstrating that it is a practical, affordable, and reliable solution for small-scale grain processing in rural communities

The aim of this study is to optimize the impact energy of Tungsten Inert Gas (TIG) mild steel welds by identifying the most effective combination of welding parameters current, voltage, and gas flow rate to achieve the best mechanical performance. The specific objectives include developing a mathematical model to describe the relationship between these parameters and impact energy, applying a metaheuristic algorithm to determine the optimal settings, and validating the optimized results against existing experimental data. This research seeks to address the limitations of traditional trial-and-error and local statistical optimization techniques, which often fail to locate the true global optimum. The study employed a hybrid computational optimization approach that combines Response Surface Methodology (RSM) and Particle Swarm Optimization (PSO). RSM was first used to develop a second-order regression model of impact energy based on existing experimental data from TIG welding of mild steel. This model served as the objective function for the PSO algorithm, which was implemented in MATLAB. The PSO algorithm iteratively adjusted welding parameters to maximize the predicted impact energy, thereby exploring the solution space beyond the limits of conventional statistical methods. The results showed that the optimal welding parameters were 192.73 A (current), 19.12 V (voltage), and 20.23 L/min (gas flow rate), corresponding to a maximum predicted impact energy of 118.52 J. This value slightly exceeded the best experimental result of 116.48 J reported in literature, confirming the effectiveness and accuracy of the hybrid RSM–PSO framework. The optimized results not only align closely with existing research trends but also demonstrate that integrating metaheuristic algorithms into welding parameter selection can enhance weld toughness, minimize experimental effort, and improve process reliability

The food and beverage manufacturing sector in Edo State is an important part of Nigeria’s industrial economy but faces major inefficiencies, including spoilage, defects, and overproduction. Lean manufacturing, derived from the Toyota Production System, offers a structured approach to eliminating waste and improving performance. Tools such as 5S, Kaizen, Just-in-Time (JIT), and Total Productive Maintenance (TPM) have proven effective in boosting productivity, although lean adoption in developing countries remains limited by infrastructural weaknesses, supply chain issues, and resistance to change. This study evaluates the contribution of lean practices to waste reduction and operational efficiency in selected food and beverage firms in Edo State. A mixed-methods design was adopted, using descriptive and analytical approaches. Data were obtained from 30 purposively selected firms through questionnaires, interviews, and direct observations. Descriptive statistics were used to categorize waste types, while regression and correlation analyses assessed the relationship between lean practices and waste reduction. Thematic analysis further examined barriers to implementation, and SPSS with Microsoft Excel ensured accurate data analysis. Findings indicated that spoilage was the most widespread form of waste, followed by defects and overproduction. Lean practices, especially 5S and JIT, significantly improved waste reduction, accounting for 67% of the variation in performance. However, unstable electricity supply, insufficient employee training, and unreliable suppliers weakened overall lean adoption. The study recommends a gradual implementation of lean, starting with easier-to-apply tools such as 5S and Kaizen, along with capacity-building programs and strengthened supply chain collaboration. Policy support for infrastructure and industry-focused training is essential to improve lean outcomes and support long-term sustainability.

This study aimed to evaluate and enhance the efficiency of a tile production facility in Benin City, Nigeria through MATLAB-based simulation and optimization. The research was conducted in response to persistent challenges in local tile manufacturing, including high energy consumption, low throughput, and significant defect rates. The study sought to develop a robust simulation model capable of analyzing the plant’s operational performance, identifying critical inefficiencies, and proposing optimization strategies that align with real-world production constraints. The methodology involved systematic data collection on machine utilization, downtime, energy consumption, and defect levels from the facility. These data were used to design a MATLAB simulation model that replicated the major stages of tile manufacturing mixing, pressing, drying, glazing, and firing. The model evaluated baseline performance conditions and tested multiple optimization scenarios such as load balancing, batch size adjustment, and preventive maintenance scheduling. The simulation outputs were analyzed to determine their operational feasibility within existing equipment and workforce limitations. The results showed substantial improvements across key production metrics. Daily output increased by approximately 20%, machine utilization rose from 85% to 92%, and defect rates decreased from 6.0% to 3.5%. Energy consumption per tile dropped by 7%, contributing to a 4.8% reduction in production cost. Financial projections indicated a 37% increase in monthly gross profit following optimization. These findings confirm that MATLAB simulation provides a cost-effective and practical approach for improving efficiency, product quality, and profitability in Nigeria’s tile manufacturing sector

Nigeria's unreliable power supply is a well-documented challenge that creates one of the most difficult business environments globally, undermining the country's competitiveness. The consequences are evident. To cope with the erratic electricity supply, individuals and businesses are forced to resort to expensive self-generated power solutions. One of ths Business adversely affected by the state of Power Generation and Distribution in Nigeria is the manufacturing industry. Most welders rely on the epileptic nature of power to carry out their jobs and meet consumer demands. In most instances, the business loss the goodwill/confidence of her customers as job completion schedules are not met. This project focuses on the design, development, and optimization of an inverter-based arc welding system. This work aims at helping small scale Welders Busneses Meet their need for power. Inveter Welding Systems can be deployed in rural and semi urban areas that are off-grid. With this improvement, skilled workers can carry out their job near the target use location with minimal transportation cost. With proper funding, this project can be expanded for large industial use. The optimized system demonstrates potential for applications in various industries, including automotive, aerospace, and construction

This project focuses on creating an eco-friendly and energy-efficient transportation option for urban areas. The main objective is to develop a solar-powered tricycle that leverages renewable energy to lower the carbon emissions typically associated with traditional urban transport. The tricycle is equipped with a high-efficiency AC motor powered by energy collected from a solar panel system on the vehicle. The design prioritizes optimal energy use, enhanced efficiency, and the capability to meet urban commuting demands. Key elements of the project include a solar panel array, a power distribution controller for effective energy management, and a durable battery storage system for energy reserves. The AC motor is chosen for its reliability and effective performance at low speeds, providing a smooth and stable ride. Furthermore, the tricycle features a lightweight and user-friendly design to improve comfort and maneuverability in busy urban environments. This initiative presents a novel solution for sustainable urban mobility, serving as a clean alternative to conventional vehicles. It seeks to help mitigate air pollution, reduce reliance on fossil fuels, and encourage the integration of solar energy in transportation. The final tricycle will exemplify the feasibility of solar-powered mobility options in contemporary cities, marking a significant advancement toward green and sustainable urban transportation

Efficient water management is essential for both domestic and industrial applications, particularly in regions where water scarcity and irregular supply are prevalent. This study presents the design and development of an automatic water pump controller system aimed at optimizing water usage and preventing wastage caused by overflow and dry running of pumps. The system is designed to automatically monitor water levels in storage tanks and control the operation of the pump without the need for human intervention.
The controller integrates sensors for water level detection, a control unit for signal processing, and a switching mechanism to activate or deactivate the pump based on predefined thresholds. When the water level in the tank falls below a minimum level, the system automatically switches on the pump, and it switches off the pump once the tank is full. Additionally, protective features such as dry-run protection and power fluctuation safeguards are incorporated to enhance system reliability and extend pump lifespan.
The prototype was constructed using cost-effective and locally available components and was tested under different operating conditions. Results demonstrate that the system effectively maintains desired water levels, reduces energy consumption, and minimizes water wastage. The developed automatic water pump controller provides a reliable, affordable, and user-friendly solution for improving water management in households and small-scale facilities