3.5 Project Management

Project management is a method or tool used to project activities and to meet the requirements. A good

project management determines a successful project that delivers the aims and objectives, within the

given budget and timeframe. It helps to ensure that the final year project can be completed within the

timeframe and allocated budget. There were total of five stages in project management. Starting from

initiation, planning, execution, monitoring and controlling, and lastly closing. Different types of project

management tools were used in every individual stage which would be further elaborated in the

following sections. Figure 3.2 shows the sequence of five stages in project management.

Figure 3.2: Five Stages in Project Management

3.5.1 Project Initiation

Project initiation is the first stage of the project cycle and where the complexity of the project was

measured. The project management tool that was applied to this stage is the complexity assessment tool

which basically helps to determine the level of the project complexity. Two common types of

complexities assessment were conducted for this project which are the technical and business

complexities. The rating of 1 to 5 was indicated the level of complexity which 1 as the least complex

while 5 as the most complex level. Tables 3.1 and 3.2 show the technical complexity assessment and

the business complexity assessment of the project.

Table 3.1: Technical Complexity Assessment

Technical

Assessment

Complexity

Rating

Justification

Resources Availability 2 The resources here included recycled graphite and

polypropylene resin. Recycled graphite can be obtained in a

form of graphite electrode scrap from EDM workshop.

However, it was required to undergo crushing, grinding,

sieving with sieve meshes and ultrasonication processes to

obtain the fine recycled graphite powder. Polypropylene

resin can be easily obtained from local vendor.

Knowledges and

Understandings

4 The knowledges required such as the production of CPC

through melt mixing and compression moulding processes

as well as the ultrasonication process for recycled graphite

powder could be study through online published journal or

library. However, the study of CPC made of recycled

graphite scrap is still a novel.

Skills 3 This project required a certain level of hands on skills to

operate various machines and equipment for mixing,

moulding processes as well as other experiment testing such

as tensile testing and TGA analysis. Safety precautions were

emphasized especially conducting the melt mixing and

compression moudling which involved very high

temperature. Soft and analytical skills were also required to

analyze, interpret data and plot graphs for testing such as

tensile test and TGA analysis.

Technology and Tools 3 The technology and tools needed in this project are available

in Taylor’s University such as the compression moulding

machine, Instron Universal Test Machine and dumbbell

specimen cutter. The other technology and tools required

such as internal mixer and surface resistivity meter can also

be found from TARUC and University of Malaya

respectively.

Project Scope 3 The project scope was to produced CPC by recycled

graphite from EDM mixed with polypropylene resin.

Ultrasonication method was also used to reduce the graphite

size thus reduce the percolation threshold of CPC. Several

testing were also conducted to investigate the properties of

CPC due to the effect of ultrasonication process.

Table 3.2: Business Complexity Assessment

Business Assessment Complexity

Rating

Justification

Budget Allocation 1 The graphite electrode scraps from EDM are abundant

which could be obtained free of charge. The Polypropylene

resin are ready in Taylors University Laboratory therefore

does not require to purchase. The Equipment and facilities

needed for conducting experiments could also be accessed

free of charge from TARUC and University of Malaya due

to the research collaboration.

Market Value Creation 4 The market demand for CPC is increasing annually due to

its unique properties for applications. By using recycled

graphite scrap which is abandon from EDM process, the

cost of purchasing conductive filler could be reduced.

Therefore, the research has a great market value as it

decreases the cost while meeting the high market demand.

Timeframe 4 The project was set within 1 year of timeframe. However,

due to the Covid-19 pandemic during FYP2, some of the

experiments could not be conducted. Thus, the project could

not be completely finished in one-year period.

Real World

Application

4 The resulting conductive composite material made from

recycled graphite was suitable for anti-static and charge

dissipative applications. Then, these applications widely

used in electronic industry.

Publication 4 The project could be published as an open source journal.

𝑇𝑒𝑐ℎ𝑛𝑖𝑐𝑎𝑙 𝑎𝑠𝑠𝑒𝑠𝑠𝑚𝑒𝑛𝑡 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑎𝑡𝑖𝑛𝑔 =

2 + 4 + 3 + 3 + 3

5= 3.0

(3.1)

𝐵𝑢𝑠𝑖𝑛𝑒𝑠𝑠 𝑎𝑠𝑠𝑒𝑠𝑠𝑚𝑒𝑛𝑡 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑎𝑡𝑖𝑛𝑔 =

1 + 4 + 4 + 4 + 4

5= 3.4

(3.2)

Equations 3.1 and 3.2 were used to calculate the average complexity rating for both technical

and business assessment. Figure 3.3 shows the average complexity level graph which was plotted

accordingly to the calculation in Eq. 3.1 and 3.2. Based on the graph in Figure 3.3, the complexity level

of this project falls under the region of very high complexity quadrant.

Figure 3.3: Average Complexity Level Graph

3.5.2 Project Planning

Project planning refers to a solid plan that report the progress of the project and keep things on time and

within the budget. In this stage, the project management tool selected was the Gantt Chart. The Gantt

Chart listed down the tasks distributed in week 1 to week 14 for both FYP1 and FYP2 with a proper

timeline so that the progress could be monitored in weekly basis without delaying the task. Figures 3.4

and 3.5 show the Gantt Chart that included all the planned activities throughout the entire project. Each

Gantt Chart consists of the planned activities (Yellow), completed activities (Green) and the milestones

(Red) to ease the tracking process. The milestones for FYP1 were set at week 6 for the submission of

initial proposal, week 12 for both submissions of interim project report and abstract for EURECA

conference, week 13 for oral presentation and week 14 for the submissions of EURECA poster and

meeting records throughout the semester’s meetings. Furthermore, the milestones of FYP2 were

affected and adjusted due to the Covid-19 pandemic, the EURECA Conference was cancelled and the

submission of EURECA conference paper in week 8 was postponed to week 12, submissions of thesis

and EURECA slides in week 13, meeting records throughout the semester in week 14 and lastly the

revised EURECA Conference paper and oral defence on thesis both in week 15.

Figure 3.4: Gantt Chart for FYP1

Figure 3.5: Gantt Chart for FYP2

A proper budget is required to complete the project by purchasing the necessary raw materials.

Table 3.3 shows the total budget required for the project. Table 3.4 shows the list of equipment needed

for the project. Most of the testing machines and equipment are available in laboratory of Taylor’s

University Lakeside Campus. Some of the machines such as internal mixer and scanning electron

microscope are available in Tunku Abdul Rahman University College (TARUC). While University of

Malaya has provided the use of surface resistivity meter for the surface resistivity test. Therefore, the

budget of this project only spends on the consumable materials and particle analysis with a total budget

of RM400.00.

Table 3.3: Total Project Budget

Materials Venue Quantity Unit Cost (RM) Total (RM)

PET film for

compression

moulding

- 2 RM50/pack 100

Particle analysis Quantum Skynet

Solution

3 RM100/sample 300

Total 400

Table 3.4: List of Equipment Needed

Equipment Venue Quantity Unit Cost (RM) Total (RM)

Internal mixer TARUC 1 FOC FOC

Scanning Electron

Microscope

TARUC 1 FOC FOC

Compression

moulding machine

Taylor’s University

Laboratory

1 FOC FOC

Surface resistivity

meter

University of Malaya 1 FOC FOC

Instron Universal

Test Machine

Taylor’s University

Laboratory

1 FOC FOC

Dumbbell specimen

cutter

Taylor’s University

Laboratory

1 FOC FOC

Differential Scanning

Calorimetry (DSC)

Taylor’s University

Laboratory

1 FOC FOC

Besides, another project management tool which is Precedence Diagram Method (PDM) was

also applied to the planning stage of the project. It was to determine fastest route of the project, also

known as the critical project path. Table 3.5 and 3.6 show the PDM activities for FYP1 and FYP2

respectively while Figure 3.6 and 3.7 show the PDM diagram for FYP1 and FYP2 respectively.

Table 3.5: PDM Activities for FYP1

Activity Task Predecessor Duration

(week)

Introduction to FYP and project title selection A None 1

Project confirmation B A 1

Research on related topics C A 1

Background and Introduction D B 1

Literature Review E B 3

Research Methodology F B 2

Expected Outcomes, Budget, Timeframe G B 1

Submission of Initial Proposal H C,D,E,F,G 1

Further research of Literature Review I H 3

Confirmation of Research Methodology J I 1

Submission of Interim Report K I,J 1

EURECA Abstract L I,J 1

Oral Presentation M K,L 1

EURECA Poster N M 1

EURECA Presentation O N 1

Figure 3.6: PDM Diagram for FYP1

Table 3.6: PDM Activities for FYP2

Activity Task Predecessor Duration

(week)

Preparation of materials A None 1

Preparation of fine recycled graphite (Ultrasonication) B A 1

Preparation of CPC C A,B 1

Compression Moudling of CPC D C 1

Tensile Testing E D 1

Thermogravimetric Analysis F D 1

Surface Resistivity Test G D 1

Data compiling and analysis H E,F,G 2

Results & Discussions I H 3

Conclusion & Findings J I 1

Thesis submission K J 1

EURECA Conference Paper L J 1

EURECA Conference Paper submission M L 1

Oral Defence on Thesis N K,M 1

Figure 3.7: PDM Diagram for FYP2

According to the PDM diagrams in Figures 3.6 and 3.7, the critical path for FYP1 was A-C-H-

I-L-M-N-O while the critical path of FYP2 was A-C-D-F-H-I-J-K-N. Both the critical paths show a

total duration of 14 weeks which is same with the duration of each semester. This indicated that all the

tasks must be completed without any delaying in order to finish the project successfully on time.

3.5.3 Project Execution Monitoring and Controlling

Project execution is a stage that is most associated with the project management which helps to deliver

the expected project results. Therefore, this project stage also requires close monitoring as to identify

the possible drawbacks and ensure the project can be completed within the designated timeframe and

allocated budget. To ensure that the project is on right track, weekly basis meetings were conducted

with supervisor to update the progress of the project. In this stage, the project management tool used

was the Earned Value Analysis (EVA). EVA is used to monitor and evaluate the task based on the

duration, planned cost and the budget spent which was tabulated in Table 3.7 and the graph of EVA

was plotted in Figure 3.8.

Table 3.7: Project Cost at Ninth Month

Tasks Duration

(months)

Planned Cost

(RM)

Status (At the Ninth Month)

Research 5 100 Completed, amount spent RM0

Materials 1 400 Completed, amount spent RM0

Experiment 2 200 Completed, amount spent RM0

Documentation 1 150 75% completed, amount spend 70

According to Table 3.7, the amount of cost planned for tasks of researching, purchasing

materials, conducting experiment was estimated at total of RM850. However, these tasks were managed

to complete with no cost at the ninth month. The researching was sufficient from the Taylor’s University

Online Library and other online published journal instead of purchasing the journal pass through

Research Gate. EDM graphite electrode scrap and polypropylene resin were in stock and thus were

obtained with zero spending. For the experiment part, all the required equipment was available in

laboratory of Taylor’s University, TARUC and University of Malaya with no charge. Furthermore,

testing which requires cost such as the particle analysis was forced to cancel due to the Covid-19

pandemic. Thus, the experiments were completed with zero amount spent. The documentation task was

allocated with a budget of RM150 for the printing and binding cost of initial proposal, interim report,

posters and thesis report within the 1-year project. The documentation cost was reduced as the report

submissions in FYP2 were changed to softcopy submission except for the thesis report. The thesis report

was completed at 75% at the ninth month and RM70 was spent on all the documentation. From here,

the EVA was conducted and tabulated in Table 3.8.

Table 3.8: Earned Value Analysis (EVA)

Name Formula Value (RM) Justification

Planned Value

(PV)

- 100+400+200+150

= 850

Estimated value of work planned to

be done was RM850

Estimated Value

(EV)

- 100+400+200+112.5

= 812.5

Estimated value of work actually

completed was RM812.5

Actual Cost (AC) - 70 Actual cost of work was RM70

Budget At

Completion (BAC)

- 100+400+200+150

= 850

The budget allocated for the project

was RM850

Cost Variance (CV) EV – AC 812.5 – 70 = 742.5 The project was under allocated

budget

Schedule Variance

(SV)

EV – PV 812.5 – 850 = -37.5 The project was behind schedule

Cost Performance

Index (CPI)

EV / AC 812.5 / 70 = 11.61 RM11.61 worth of work for every

RM1 spent. Budget was properly

used

Schedule

Performance Index

(SPI)

EV / PV 812.5 / 850 = 0.96 The project progressing at 96% of

original planned.

Estimated at

Completion (EAC)

BAC / CPI 850 / 11.61 = 73.22 As for now, the project will cost

RM73.22 at completion

Estimated to

Complete (ETC)

EAC – AC 73.22 – 70 = 3.22 Expected to cost RM3.22 more to

complete the project

Variance at

Completion (VAC)

BAC – EAC 850 – 73.22 =

776.78

The project will be under budget by

RM776.78

Figure 3.8: Graph of Earned Value Analysis

3.5.4 Project Closure

Project closure is the last stage of project management which represents the completed project. The

project management tool used in this stage is the PLAN-DO-CHECK-ACT cycle (PDCA), mainly to

improve the process, resolve the issue and make recommendation for future cycles. PLAN involves

identifying challenge and collecting relevant information. DO is to implement the solutions and perform

testing. Whereas CHECK is to confirm the results and ensure that the hypotheses are matched and lastly

ACT, to document the result and make recommendation. The cycle was repeated if the solution was not

successful. Figure 3.9 shows the PDCA diagram for the entire final year project.

Figure 3.9: PDCA Diagram for FYP

3.5.5 Sustainable Development and Impact on Society

Sustainable development can be defined as the development that meets the needs of present without

compromising the ability of future generation to meet their own needs. It is made up of a total of three

pillars which are the economy, environment and society. In this section discusses on how the project

was able to fulfil the sustainable development.

In term of the environmental aspect, the conductive filler used in this project was the recycled

graphite scrap from EDM process. For EDM process, the graphite electrode was required to be replaced

after a period of service due to the wearing of electrode occurs. As the process continues, the graphite

electrode scrap will eventually increase and turn into scrap. Huge amount of scraps will be generated

at the end which causes environmental issue whereby there will be accumulated waste that occupied

land and spaces or even cause pollution after a decompose period. As until today, there is still no

research found on the recycling of this electrode graphite scrap. However, this project utilized the

recycled graphite and turn it into conductive filler for CPC. This does not only save cost but also

effectively solve the disposing of graphite scraps.

Due to the great electrical conductivity and thermal properties of graphite, it is widely used in

many industry applications. To obtain graphite, high temperature treatment is conducted for the carbon-

based material such as petroleum or coal. However, the needs of producing graphite from raw material

could be reduced by reusing the recycled graphite from EDM electrode scrap. This ensures that the

same outcome could be achieve by producing less graphite from the raw materials. Therefore in term

of economy, the cost of producing graphite could be greatly reduced in this project by reusing the

recycled graphite as the conductive filler for CPC.

For the society, a new sustainable resource for the conductive filler from recycled material was

provided in this project. At the same time, it might also propose a new route for the recycling industry

which is to turn the electrode scrap from EDM into useful recycled conductive filler. This indirectly

provided a great opportunity to expend the recycling industry which could be benefits to the social and

economy as well.

In term of the impact on society, this project solves the issue of the waste generated by graphite

scraps and also reduced the space and land occupied to dispose the graphite electrode scraps. This at

the same time prevent the possible environmental issue as no pollution will occur due the graphite waste

over long period of decomposition. All the processes were conducted accordingly to the safety and

instruction rules to ensure the safety aspect. Also, it does not violate the law as no illegal actions or

activities were carried out in this project. As the use of recycled graphite could reduce the cost of

production, it is said that the project could bring benefits to the economic and public.