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Section 3 Selecting Appropriate Materials

Section 3 Selecting 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

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Section 3 Selecting Appropriate Materials

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  1. Section 3Selecting Appropriate Materials Chapter 8 Behavior and Characteristics of Manufacturing Materials

  2. 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

  3. 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

  4. 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

  5. Materials must meet requirements for performance and reliability • Cannot have a failure • Evaluated under the same conditions expected in the user’s environment

  6. Three Performance Criteria 1.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

  7. 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)

  8. Materials not used are also waste • Excess metal in stamping operation • Defective parts • Anything that doesn’t end up in the product

  9. 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

  10. 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

  11. 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.

  12. 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 employeesfor handling hazardous materials • Melting point • Boiling point • Flash point • Toxicity • Health effects • First aid treatment • Storage • Disposal • Protective equipment

  13. 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

  14. 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

  15. Types of Hazardous Materials2 methods to determine EPA Notification of Hazardous Waste Activity Characteristic Waste Characteristics when humans and animals are exposed Materials that are: Readily ignitable Corrosive Reactive, undergoes violent change Toxic • A list of materials established by the EPA • If it’s on the list classified as a “listed waste”

  16. 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

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