 Good afternoon. Can you all hear me? You will have forgotten my name by the time you have your dinner tonight But you will not forget this in the next two or three days this introduction Why because I am different and I stand out That's why you will not forget it So how did and that's the first item in my professional toolkit Doesn't matter whether you're an engineer lawyer or scientist or whatever You have to stand out What did I do? How did I discover this? I got myself a first-class honors from Manchester University, and it was sheer Hard work. What did I do to get that first-class honors? We did a very simple experiment just boiled exactly like that. You can see from the date This is half a century ago Boiled the water measured the temperature put some salt in it boiled it again and measure the temperature again Even p6 Students in Singapore know that the temperature of the second is higher than the temperature of pure water so Fine, that's great, but then I have to explain why does it behave like that? Well, that was easy went to the library hundreds of books tell you Why does the temperature change and it's something to do with? Energy of solution great Then I said to myself Can I predict the temperature of the water based on the properties of the salt? nothing, I Don't know. I've not looked recently whether there's anything in there in the literature nothing So I did that little bit actual that's a little bit extra and put that in my report Consequence I got noticed I got noticed by my tutor by my lecturer by my professor by the dean Just that little bit and I got my first-class honors and my career was off At a trajectory like that who's hand bolt is he's no faster than my career Right, so two things I learned at Manchester University. I learned engineering they say But more importantly, I learned how to learn Because you don't know what you learn today and you don't know what you might want to use tomorrow So I learned how to learn being a member of the institution of mechanical engineers They put some pressure on me to put some discipline on continue to learn. I Have to continue to learn Doesn't matter whether you're an engineer as I said earlier a dentist or a doctor You've got to continue to learn and now even faster because things are moving so fast Right. So what did I do with my education? I went to work for a company? American company based in the UK making materials handling equipment and They were making this innocent looking pallet truck is called a pallet truck has got two fingers and that Was a design imported from USA and it wouldn't work in Europe because The these fingers were so wide. They wouldn't enter the European pallet here the US spec was ten inch one ton capacity Europe wanted seven inch one ton capacity US offered seven inch three-quarter ton and I designed it Seven inch one ton. Those of you are an engineer might understand this But I'll explain it in layman's. So what I did was very simple not rocket science. It's very simple theory of structures I Just redistributed the material so that the top layer and the bottom layer equally shared the work Done to support the load. That's all This was very imbalanced the bottom layer was like working like crazy three four times harder than the top layer And you're costing a bomb result Went into production sales of that truck for my company rocketed But before we got to that step I had to prove it I had to prove it Here I am nearly a fresh graduate from University Telling designers in USA of materials only equipment how they can design a pallet truck to Meet the specification. I had to prove it I'll show you the next slide, but you don't have to really listen. It's an engineering slide But I'll illustrate it by using this Hanger What the slide says is That if you deform an item, which they're called the elastic range elastic range It'll come back to its original shape. If you deform it beyond the elective range. It's useless Fit for the bin Imagine your car goes over a pothole You don't want it to come out all bent and twisted. Do you? So it is the science behind that I used to make Analog simulations. There are digital simulations these days. I used analog simulation Because that was the only tool available to me. I'll show you two more things before I I Demonstrate what I actually did this will this this is not invented. This is real stuff. I Have a piece of metal here. I Bend it can anybody see it bending now because you need Strain gauges data loggers Transducer and God knows what else to find out whether this is bending are a piece of foam You can probably just about see it bending a polystyrene form Now I have this So right at the back. Can you see it bending? Can you see it come back straight? This is the material behaving like any of the engineering material, but it's got a Mechanical amplifier built into it. I don't need data loggers. I don't need transducers and strain gauges so I Make my models Using these materials and I'll demonstrate to you here and now What the effect was? Those of your engineers will understand what's a simply supported beam is this I'm gonna make a simply supported beam I put this beam in there simply supported means is only supported on two sides. I Put this beam in I put a weight on it This tip in fact you can see this on the next slide as well This deflects more And this and this is this represent the shape of the finger This is the shape. I showed you the top, which is very inefficient. This is a shape, which is very efficient right then To make it more dramatic I made it out of my amplifier built in the amplifier material But I wait on it Where I wait on that which one deflects more right Argument was finished No more argument. How can he prove it? Is he qualified enough and old enough to be able to make these recommendations and I Got some additions to my toolkit. I grabbed the opportunity to redesign something Opportunities are there in all directions if you look and if you're hungry enough They're there. I am the respect of the marketing and you say, how do you know? because I Got into the Christmas mailing list of the marketing and the sales department and they don't give you anything for free No, never not the employees customers. Yes, I won the trust of the people in the company How do I know I won the trust? Because now they would come to me seek my opinion seek my advice and listen to me Great stuff. I'm happy. They're happy And I got noticed And you'll say how do I know I got noticed The vice president of the American company offered me to go and manage his design office. Now, that's some notice So I increase my toolkit to add those as I keep saying doesn't have to be engineering I use my engineering knowledge to sell the idea But these are required by any professional No matter which field Or any employee Right in my infinite wisdom. I did not take the job to go to America I took a job to go to Redland which make one billion tiles a year 18,000 employees four billion turnover big company when I joined I Was a tadpole in a big Redland ocean when I during my tenure I Became a whale in the Redland technical pond Now this is a question about you go work for a big company or a small company That doesn't matter. It's where you are working which part of the work company you are working is important. I and What happened next before I tell you what happens next I have to give you a very 30 second or one minute lesson on tile making tiles are Otherwise the context doesn't work Many different shapes But this is the important bit here a tile is sitting on a roof looks very innocent the shape nothing But when you look under say underneath it is As complex as any article you can name to me any article is Got very complex shapes. It's got very complex mold to build Make the shape on very complex tools to build the Match any industry aerospace automotive Shipping you name it. It'll match it and this is the The punch line These concrete tiles are sitting on your roof if you got Singapore has them as well sitting on your roof with no sealant is Tile on tile guaranteed to last 75 years in Durability and guaranteed that there will be no water penetration for 75 years when Once in 75 year event means there's only one storm comes every 75 years is so severe it destroys things Water won't penetrate. They're that accurate not only that Tile made in year one Has to fit with a tile made in year 20 maybe year 10 because People have the heartbeat of renovating extending They do break people do silly things on them. You got to repair them So this tile which was installed 15 years ago You go to a factory buy a tile and it'll fit and it'll still keep the water out Not many industries can claim that And I'll talk about that a bit later as well. So that's about the tiles So it's important that it may not sound very sexy. I tell you it's got challenges Now that a bit about the tile plant a tile plant is a fairly long building If you're at this end and something is going on on this end, you don't know what's going on unless somebody tells you No cameras in those days. I arrived at my new work suited booted My boss gave me the car of my new the keys of my new car and he said Kogi, I'm sorry, but I haven't got a job for you. Oh So I say well you go and visit some tile plants two three days and I love fixed it Cut a long story short. I ended up in a tile factory for three months three months and That had impact on my toolkit The first thing thing was I grabbed the opportunity to go and work. I didn't complain Hey, I'm a manager. I can't work in a tile factory Now So I grabbed the opportunity When I first arrived the workers were very very suspicious of me because They said oh another boy or from the center come to tell us what we should do in time I started to dress like them have the same safety clothes helmet or tacto I work their shift. I ate in their canteen work their time and they started to trust me Now they would tell me if there's a stoppage at the other end of the factory And I'm the other why it has stopped not only that They shared with me with information on how to run the tile plan 24-7 which is not in the manuals It's in their heads and that is difficult to get out So I won that trust and I got help from them. I earned the respect of my colleagues When I finally went to manage the design office, which I'd come My colleagues knew that probably I knew more about tile making than they did because they even in 20 years wouldn't have spent a Collection of 30 three months work of time in a tile works So one the respect instantly no problem. I got noticed HR were watching me the tile plant manager was watching me the board was watching me Yeah, they've given me a brand new flashy car and writing my paycheck. I'm doing nothing for three months So somebody was paying attention Watching me So I got noticed and Most of all my knowledge increased By a step change Completely new field of knowledge. I had it Nobody could take it away from me. So what did I do next? Okay, I Then started I migrated from designing machinery and plant to Designing the concrete product itself now. That's a completely new feel for me. So there. This is where new learning comes in When I started tiles were weighing 5.3 kilograms each and by the time I left we could make the same performance tile at 4.3 kilograms And it was done with introducing new technologies and new tools CAD computer computer design computer that manufacturing finite element analysis genetic algorithms new terms Very very new terms quarter of a century ago They are everyday tools now Okay Had to justify all that lot was very very very expensive so This slide is full of equations. I'm not going to teach you equations I'll only make a few points if you have a big problem How does one solve a big problem? Cut it up. Thank you very much, sir You cut it up into smaller Sections and solve that that's what finite element element analysis is it breaks it up into small parts Analyzes it and then Measures the effect of that onto the next part When I've designed the first style, I didn't have a computer. I didn't even have a calculator. I Had to use my slide rule. I don't know whether you've ever seen a slide rule and this was my Google So I did cut it up into small segments But I couldn't cut it up too small because I'd be wearing my slide rule out to calculate it CAD argument one Make a CAD model you can slice it up as many times as you want F e a We have an expert in amongst us on F. Yeah at the back here Clive will introduce me I'll tell you a story. I attended a symposium Organized by Clive nafam symposium. It had speakers talking about a fear simulation design tools and all that all from all over the world and There was a gentleman very clever gentleman who introduced a novel way of designing a beam and he was using nature the lattice System the nature uses to design a beam very light very strong. I Talked to him during the coffee break and I said to him Assume I have a perfect material that the material has no defects and I want to design a Component to the factor of safety of one What are my risks? I? Still strive to work towards that. I haven't got an answer But I'm still working at it, and I'm going to challenge you guys to think about it. He didn't have an answer obviously Then I said, how do you validate it? I say we would do strain energy calculations and ah Now that's where the problem lies This is a fundamental equation for the theory of structures 99.9 percent times people use it to find applications And it goes in that direction F e a you make parts you go to Google you go to a To a lecture theater. They'll say that's the formula if you want to calculate the stress strain and all that Right, and you use that However I Thought in this direction. How did the formula come out in the first place? It's a mathematical formula pure mathematician solve it in 10 seconds flat no problem But to apply to engineering solutions There are 10 assumptions built up in to arriving at that And if you want to design to a factor of safety of one You want to address those assumptions? If you cannot address those assumptions you cannot design We had a fairly friendly chat after that Genetic algorithms Again, I was on the same platform giving a talk at NTU and no at one of the universities of forgot And there was a professor for NTU. We were both waiting for our tons to come and we started talking And he mentioned genetic algorithms. Yeah. Oh, I said, okay. Yeah, what about it? We are trying to promote this I told me I introduced that as a tool in my company 25 years ago. He nearly fell off his chair Point here is There are opportunities if you're hungry enough, you will find them. I found genetic algorithms by Accident and I won't go through that because I've got very short time in this presentation But I can talk to any one of you if you wish to talk to me after the event They're quite happy to talk to you Right next. Ah, this is a Zuna. I've got lots of stories to this is a nice one Rudlin built a brand new tile factory on a Greenfield site costing 12 million sterling we're talking of those there's 50 million Singapore brand-new factory they could make What we call the main tile because main tile on a roof bulk of the roof is covered with the main tile But to finish the roof you have to have fittings they complete the edges of the roof without that Roof doesn't work. It leaks They could make the Tiles main tiles no problem fitting tiles the mold just cracked in the tile machine yard is filling up making half a million tiles a week at 140 pieces per minute three shift and Nothing is going on because we haven't got the fittings Panic panic panic brainstorm session. Let's talk to university. Let's talk to consultants Anybody anybody who knows anything about tile making or tile design talk to them Everything looked six to eight months away with a Ton of scrap at the end of it all those crap molds and whatever I Used my friend This material here These are actual photos of what I showed to my CEO That's how they were in a bit of cardboard and a form model And I demonstrated by the form model that the failure was occurring here You can see the spending and that's how exactly the real molds were failing and I Said we can reinforce it to stop that failure And I've got those models here outside of the meeting if you want to look we can look at them Within a month all the molds in the factory were modified Factory was running. You have to have respect. You will have to have earned Respect you will have to have won the trust to be able to do that type of thing then I taught myself automation self taught myself Removed all the clouds of release agent from the time machine made a proper machine tool Remove the dust clouds from the cement mixer in fact even removed the man from it But all the proper dust control saved money Each tile plant could make a very various shapes Stranging from anywhere of these and when they change the profile from one shape to the other it used to take 30 minutes or more Reduce that time to four minutes and there was a record the built They printed these shut in honor of the work we did one minute and 38 second was the fastest Anybody ever change the profile in a tile work All that was achieved with automation at that time solicitors switches were coming plcs DC drives Controls using those all the bang-bang systems were removed and controlled acceleration control deceleration control the product Exactly where you want it to stop or start from So plant speeds increase from 90 to 140 pieces per minute huge impact on profit Inverted drive plc control solid state switching increase my knowledge certainly improved The efficiency of the plant Breakage, you know remind you're running with your sandcastle on your hand. You'd stop suddenly Breakage would use by 2% One billion tiles. They are making Remember 2% may be not a very big number profile change times change from 30 to 4 minutes and The one which I really savor out of that is We made it change to the quality of the life of the workers and their families I didn't like to work in there. Why should I expect? Anybody else to be working in that So that is what engineers can do Change the quality of life Save the environment save the planet by using glass resource and all that. What about the people? Okay? I Haven't got the slide next. Okay. I was going to show you a sandpit where the I'll skip that the sliders got misgum missing now. This is a an example of communications and Empowerment and sharing I was working on a Project which was my patent. I don't know. I've got about 20 patterns. I forget lose count of them And I needed half a million pounds sterling to do the development in one trance and Normal submission for such request was 50,000 60,000. I wanted half a million The idea was not novel the idea was to put Very good material at the top, which is the aesthetics part of it which you guys see every day and Put functional material at the bottom, but the extrusion process or the making process was so violent that it makes it all up and The invention was to find a solution to that It so happened that the main board visited the technical division one afternoon lots of presentations were set up and Mine was one of them. I Chose to make my presentation at the tile machine. We were working on and my MD said Kogia Give you one piece of advice Get your points out in the first 45 seconds if you don't you'll lose them these captains of industry are smart people If you throw a lot of jargon at them, they'll see through that fog You cannot fool them 45 seconds. So I wrote this one slide and wrote it at the time We make 1 million tiles 1 billion tiles 4.5 billion concrete and each ton of tile This is the cost of this material. This is the composition We put 4 pounds of sand 16 pounds of cement and 12 pounds of pigment in it and I said I'm going to save 4 to 40 percent of the 12 because I'm not gonna put pigment here Immediately the question came Kogi. How are you gonna do it? Great they were hooked No That I could take all my time to tell everything now. This is where the sharing and the empowerment come I Had my technicians and my design colleagues at the site. I wanted to give them the opportunity Their two minutes of glory with the board most of my patents although I'm the inventor We have Co Patent ease on it Just imagine a technician working in a shop the technician can have very good ideas. No problem Whether they will be able to have a patented very very difficult because to patent something You have to have a very very narrow find the world is full of very many clever people and To patent something is extremely difficult and now these people got their name on a patent There's no better. Thank you than that These guys would do anything for me Honestly, they would do anything in terms of work after no problem with them. That's the last slide of my presentation So that's my toolkit Get noticed Take opportunities opportunities are there educate yourself Increase your knowledge and respect when trust and ethics Very important one last story. I was developing a product in the USA and The USA has a very very stringent fire test What they do is they take a tile put a ton of coal or They call it brand when it's pieces of wood dried up pieces of wood Light fire to the wood and the tile should withstand that for 45 minutes Very tough test And our tiles were not doing that and one time luckily we had a marginal pass The certifier said I can pass it and I said no, I wouldn't have those tiles on my house There was tremendous pressure from the The peers saying look we have passed the test. Let's get on and start making them I think I wouldn't have that on my time house. Why should I let others have it on their house and of my presentation? Any questions no because yeah, I don't release the product because it's marginal Just imagine we put it on the roof and the roof they have forest fires in California's for example something falls on it burns it and the house burns down Well mentality well, it depends No, it depends on the individual. I'm saying I I Had high ethics ethical standards My institution says I should have very high ethical standards if you join IES Institute of engineers in Singapore they say you should have a high ethical standard And you won't be certified as a chartered engineer if you don't But there would be people who would take a chance I wouldn't That's the difference Okay, if you're not completely bored by now I I'll I'll show you this last slide and I'll You seen these on the streets of Singapore, right? When the first came out I looked at the first bike Good grief would I ride it? Because this is one bike which is going to hit the curbs on and off the curbs more than any other bike Not we're not looking at BMX riders who will do crazy things and this tube Was so small Who worried me? So I went home And the way I am First I built a base reference model and looked at where is the weakest point of the bike Did that and there's the answer I don't need CAD cam or whatever I got tons of them more of them if you want to talk to them, but you have been a tremendous audience. Thank you very much Okay, oh Nobody wants to go, right? You want more oh Well, okay, if you have time I don't think I'm pushed to be because I didn't know whether I'll be allowed to stay in the room or not I can I can carry on yeah because I might have been I don't think not anybody is following us Okay, okay Look, this is the awful bike Usually I give this talk in 45 minutes. They allowed me only 25 I've taken 30 So I think this this was the first bike I saw I Think it's a bit unfair because these guys would design these are not slouches So they must have done some homework to make sure that they would work But it it certainly rang alarm bells in my mind Right after repair it so many times it keeps breaking It's now a lot more stiffer than it originally is because I had to put stiffness in there As you can see how to patch it up The hollow yeah, yeah No, they they are lighter for the same strength But the beauty of these types of models is as long as you do it the same to each Family it doesn't matter. It gives you the answer. It gives you the trend Right if I if I used a hollow there and a solid there that'll be unfair But I'm using solid and it tells me this is stronger than that Structure wise where the deflections are you try to calculate the deflection of that using one of the Solid modelers, which you got It'll take you a fair time to actually make the model first and then you have to apply the boundary conditions Where are the forces coming from where are they going? No, this is stronger And this this then I started to play with what would I do if I was to Just advance it from there Yeah, there were there are some bikes with the I beam on the on the street as well not many but there are some One of these members yes, yes Yeah, yeah, that's I've seen those Yeah, like that. Yeah there. Oh, yeah, I can't deliver can't deliver wheel. Yes. Yeah, can't deliver No, oh, it's a got a gear inside so the point here is that I'm not saying you shouldn't use but models and simulation is very rife, but I'm saying I Don't have that but I can't find the answers. Oh It's a it's so simple in terms of engineering Just shift you are engineers or studying to be engineers Yeah Okay, well, it's it's a matter of neutral axis if you understand neutral axis in the old one the neutral axis where high and I just brought the neutral axis to the middle That's all right. Well, I've enjoyed talking to you guys you