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The purpose of this paper includes results of some of the tests involved for the design and implementation of low-cost crash anthropomorphics (ATPs) fitted with sensory systems to measure forces that would have been experienced by passengers in the vehicle, commonly used for public transport within South Africa.

This paper presents the description of the implemented low cost ATPs and the analysis of the data obtained from the sensory system within the torso of the ATPs and in the head of a single ATP, to identify if a documented threshold is exceeded. The autopsy of the ATPs is performed to identify injuries.

The recorded results showed the type of injuries that could have occurred when an accident has occurred with occupant in the minibus taxi. The autopsy performed on the ATPs showed feasible injuries that could be obtained by a person in a similar scenario.

The ATPs were to be designed and constructed with the sensory system, with a budget of ZAR13,000/US$1,000.

The contributions of this paper are as follows: present the test results of two ATPs, and discuss them, for a loss of control of a minibus on a wet surface, which has been indicated as a world first test; And identify the need for a data fusion of sensory information to evaluate the injuries with the autopsy performed.

Quality control and part inspection add no monetary value to a product, yet are essential processes for manufacturers who want to maintain product quality. Mass‐produced custom parts require processes that are able to perform high frequency of inspection, whilst providing rapid response to unanticipated changes in parameters such as throughputs, dimensions and tolerances. Frequent inspection of these parts significantly impacts inspection times involved. A method of reducing the impact of high‐frequency inspection on production rates is needed. This paper addresses these issues.

This paper involves the research, design, construction, assembly and implementation of an automated apparatus, used for the visual inspection of moving custom parts. Inspection occurred at user‐defined regions of interest (ROIs). Mechatronic Engineering principles are used to integrate sensor articulation, image acquisition and image‐processing systems. The apparatus is tested in a computer‐integrated manufacturing (CIM) cell for quantifying results.

Specified production rates are maintained whilst performing high frequencies of inspection, without stoppage of parts along the production line.

The limitations of these results lie in the fact that they are suited only to the speed of the CIM cell. Higher inspection rates may be achieved, and changes in the design may be required in order to make the apparatus more suitable to industrial applications.

The paper shows that it is possible to maintain high standards of quality control without significantly affecting production rates.

Current research does not focus on maintaining production rates whilst inspecting custom parts. The use of ROI inspection for moving custom parts is a relatively new concept.

Production of a high variety of products introduces complexities in the quality processes involved in a manufacturing system. Previous methods of quality assurance and control are not sufficient to manage the quality characteristics that are significant to each customer. Research into quality management for these environments has been isolated and segmented. No framework exists to holistically manage product quality within an unstable manufacturing environment. This paper seeks to propose a method of holistically managing product quality in a manufacturing environment with high customer input and product variety. The development of a reconfigurable inspection apparatus is discussed as a technological requirement for performing the quality control aspect of the management system.

The quality requirements of modern manufacturing systems were established. The required flow of information for an advanced quality management system was proposed and compared to the information flow in a traditional quality management system. The developed reconfigurable inspection apparatus was tested by performing an inspection of a product configuration within a part family of torches. Commercial products were used for the construction of the apparatus, including the electrical and software aspects. A commercially available simulation package was used to simulate the effects of a random customer order on production flow whilst implementing the developed apparatus.

Modular inspection equipment would prove essential to the implementation of quality control when considering advanced manufacturing environments. An overall management system is also needed for the verification of product quality as per individual customer requirements. Quality needs to be integrated as per TQM principles.

Traditional quality control tools may not always be applicable for unstable market demand. The research indicated the required progression of quality systems to successfully manage the quality for advanced manufacturing. The widespread availability of commercial components for the inspection apparatus verified the shift in supplier focus to meet the needs of shifting manufacturing requirements.

The proposed approach to assure and control quality, as well as the researched inspection apparatus, provided the capability of being implemented in a manufacturing environment that involves production of a variety of products as opposed to being limited to one part family. The use of modular mechanical, electrical and software components will ease the implementation of reconfigurable inspection stations into existing manufacturing setups.

Research indicated that quality systems need to be further developed for assuring and controlling product quality of products with high customer input. No system existed that could holistically consider the quality requirements of a product from design to delivery.