Download - Section 3 Selecting Appropriate Materials
SECTION 3SELECTING APPROPRIATE MATERIALS
Chapter 8
Behavior and Characteristics of Manufacturing Materials
• Many manufactured products• Products designed for many markets
• Baby products• Children's toys• Consumer products• Tools and equipment• Electronics
• Designed to serve a purpose and not be a safety risk• Some products are poor designs, made from
inappropriate materials or are poorly constructed• Consumer Product Safety Commission (CPSC)
• Government group that oversees product safety
• In 2005 CPSC recalled 2.6 million Rival Slow Cookers• Poorly designed handle was breaking and causing burns
• 2009-2011Toyota vehicle recalls• In 2010• 5.2 million vehicles-pedal entrapment/floor mat problem• 2.3 million vehicles-accelerator problems• 1.7 million vehicles-affected by both• Affected vehicles under Toyota, Lexus and Pontiac brands
Why Some Materials are Used Instead of Others
• Thousands of materials used to make hard goods• Several items influence material selection
• Company Tradition• Company has used a material in the past they have invested in:
• Equipment• Knowledge• Training
• For that material
• Market research• Make products out of materials consumers want• Use surveys, focus groups
• New materials require a significant investment
• Materials must meet requirements for performance and reliability
• Cannot have a failure• Evaluated under the same conditions expected in the
user’s environment
Three Performance Criteria1.Mechanical Properties
• Hardness• Tensile strength• Wearability• Toughness
• Screwdriver shaft cannot bend
• Heat treated
2.Chemical Properties• Density• Corrosion resistance• Flammability
3.Physical Properties• Melting point• Boiling point• Reaction to light• Reaction to heat• Reaction to electricity
Cost• After a material is selected for it’s properties cost is
analyzed• May have to have more than one possible material choice• Material cost directly affects product cost• Explore many providers
• Offshore providers may seem less expensive• Hidden costs in:
• Transportation• Storage and protecting• Waste (damaged, expired)
• Materials not used are also waste• Excess metal in stamping operation
• Defective parts• Anything that doesn’t end up in the product
Life Cycle Analysis (LCA)• Materials can be reliably and safely used in a product for
a limited time before they may eventually fail and cause the product to be taken out of service
• Failure due to:• Way the product is used• Extent product is used• Conditions impacting the product• Design
• Critical to Green Manufacturing• Also determines the environmental impact of the product from
manufacture to when it is taken out of service, recycled or disposed of
• ISO 14000 environmental management standards 14040 & 14044
Environmental and Safety Aspects of Materials
• OSHA (Occupational Safety and Health Administration)• 1983
• Hazcom Standard or Right-to-Know Law• Requires employers to identify hazardous chemicals in the
workplace• Train employees how to recognize, use, and handle hazardous
chemicals or products• Includes commonly used products:
• Lubricants• Diesel fuel• Pesticides• Etc.
• Companies must have:• Written hazard communication plan• Up-to-date inventory of hazardous materials• Labels on containers• MSDS (Materials Safety Data Sheets)• Provide training to employees for handling hazardous materials
• Melting point• Boiling point• Flash point• Toxicity• Health effects• First aid treatment• Storage• Disposal• Protective equipment
• MSDS sheets not required for:• Materials not chemically or physically hazardous
• Water• Ice• Saline solution
• Drugs in solid, tablet or capsule form• Solid products
• Tools• Electronic components• Fasteners• Fabricated parts
MSDS contents• Section 1: Chemical Identity• Section 2: Hazardous Ingredients• Section 3: Physical and Chemical Characteristics• Section 4: Fire and Explosion Data• Section 5: Reactivity Data• Section 6: Health Hazards• Section 7: Precautions for Safe Handling and Use• Section 8: Control Measures
Types of Hazardous Materials2 methods to determine
EPA Notification of Hazardous Waste Activity
• A list of materials established by the EPA
• If it’s on the list classified as a “listed waste”
Characteristic Waste
• Characteristics when humans and animals are exposed
• Materials that are:• Readily ignitable• Corrosive• Reactive, undergoes violent
change• Toxic
Hazardous Waste Generation by Manufacturers
• Resource Conservation and Recovery Act of 1976 controls the generation, storage, transportation, management, and disposal of hazardous wastes
Hazardous Waste-a waste with properties that make it dangerous or capable of having a harmful effect on human health and the environment