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