The effects of material variations in high value manufacturing industries

It has never been easy for manufacturing companies to understand their confidence level in terms of how accurate and to what degree of flexibility parts can be made. This brings uncertainty in finding the most suitable manufacturing method as well as in controlling their product and process verification systems. The aim of this research is to develop a system for capturing the company’s knowledge and expertise and then reflect it into an MRP (Manufacturing Resource Planning) system. A key activity here is measuring manufacturing and machining capabilities to a reasonable confidence level. For this purpose an in-line control measurement system is introduced to the company. Using SPC (Statistical Process Control) not only helps to predict the trend in manufacturing of parts but also minimises the human error in measurement. Gauge R&R (Repeatability and Reproducibility) study identifies problems in measurement systems. Measurement is like any other process in terms of variability. Reducing this variation via an automated machine probing system helps to avoid defects in future products.Developments in aerospace, nuclear, oil and gas industries demand materials with high performance and high temperature resistance under corrosive and oxidising environments. Superalloys were developed in the latter half of the 20th century as high strength materials for such purposes. For the same characteristics superalloys are considered as difficult-to-cut alloys when it comes to formation and machining. Furthermore due to the sensitivity of superalloy applications, in many cases they should be manufactured with tight tolerances. In addition superalloys, specifically Nickel based, have unique features such as low thermal conductivity due to having a high amount of Nickel in their material composition. This causes a high surface temperature on the work-piece at the machining stage which leads to deformation in the final product.Like every process, the material variations have a significant impact on machining quality. The main cause of variations can originate from chemical composition and mechanical hardness. The non-uniform distribution of metal elements is a major source of variation in metallurgical structures. Different heat treatment standards are designed for processing the material to the desired hardness levels based on application. In order to take corrective actions, a study on the material aspects of superalloys has been conducted. In this study samples from different batches of material have been analysed. This involved material preparation for microscopy analysis, and the effect of chemical compositions on hardness (before and after heat treatment). Some of the results are discussed and presented in this paper.

Modelação e análise de um sistema flexível de produção

A modelação dos sistemas industriais apresenta para as organizações uma vantagem estratégica no domínio do estudo dos seus processos produtivos. Através da modelação será possível aumentar o conhecimento sobre os sistemas podendo permitir, quando possível, melhorias na gestão e planeamento da produção. Este conhecimento poderá permitir também um aumento da eficiência dos processos produtivos, através da melhoria ou eliminação das principais perdas detetadas no processo. Este trabalho tem como principal objetivo o desenvolvimento e validação de uma ferramenta de modelação, previsão e análise para sistemas produtivos industriais, tendo em vista o aumento do conhecimento sobre estes. Para a execução e desenvolvimento deste trabalho, foram utilizadas e desenvolvidas várias ferramentas, conceitos, metodologias e fundamentos teóricos conhecidos da bibliografia, como OEE (Overall Equipment Effectiveness), RdP (Redes de Petri), Séries Temporais, Kmeans, ou SPC (Statistical Process Control). A ferramenta de modelação, previsão e análise desenvolvida e descrita neste trabalho, mostrou-se capaz de auxiliar na deteção e interpretação das causas que influenciam os resultados do sistema produtivo e originam perdas, demonstrando as vantagens esperadas. Estes resultados foram baseados em dados reais de um sistema produtivo.

Delivering enhanced efficiency in the synthesis of α-diazosulfoxides by exploiting the process control enabled in flow

Continuous-flow generation of α-diazosulfoxides results in a two- to three-fold increase in yields and decreased reaction times compared to standard batch synthesis methods. These high yielding reactions are enabled by flowing through a bed of polystyrene-supported base (PS-DBU or PS-NMe2) with highly controlled residence times. This engineered solution allows the α-diazosulfoxides to be rapidly synthesized while limiting exposure of the products to basic reaction conditions, which have been found to cause rapid decomposition. In addition to improved yields, this work has the added advantage of ease of processing, increased safety profile, and scale-up potential.

Growth and Characterization of III-V Semiconductor Materials for MOCVD Reactor Qualification and Process Control

Metalorganic chemical vapor deposition is examined as a technique for growing compound semiconductor structures. Material analysis techniques for characterizing the quality and properties of compound semiconductor material are explained and data from recent commissioning work on a newly installed reactor at the University of Illinois is presented.

Estudo e melhoria da capacidade de um processo industrial de panificação

Esta dissertação apresenta um estudo da capacidade do processo inserido uma empresa de panificação. Antes de iniciar o estudo propriamente dito, foi realizada uma calibração à balança na qual este estudo seria realizado. Os índices de capacidade do processo têm como principal finalidade verificar se a média e a variabilidade do processo estão em concordância com o alvo e os limites de especificação. Esta verificação permite o ajustamento do processo de maneira a reduzir a produção de produtos defeituosos. Neste trabalho foram utilizados os índices de capacidade considerando que as condições são ideais, isto é, quando existe normalidade nas amostras. Quando as condições não são ideais, como foi verificado, foram utilizadas técnicas para o cálculo dos índices de capacidade para este tipo de situações. A aplicação da metodologia de análise da capacidade do processo foi realizada com sucesso com recurso a amostras retiradas numa balança calibrada para o efeito.

C. difficile surveillance quarterly report: October-December 2010

This quarterly report provides epidemiological data on C. difficile in Northern Ireland, and includes key points, a comprehensiveoverview of all C. diff infections, rates, trends, age-specific informationand statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

S. aureus bacteraemia surveillance quarterly report: October-December 2010

This quarterly report provides epidemiological data onS. aureusin Northern Ireland, including overall infectionfigures as well as those specific to MRSA and MSSA. The report highlights key points, rates, trends and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

C. difficile surveillance quarterly report: January-March 2011

This quarterly report provides epidemiological data on C. difficile in Northern Ireland, and includes key points, a comprehensive�overview of all C. diff infections, rates, trends, age-specific information�and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

S. aureus bacteraemia surveillance quarterly report: January-March 2011

This quarterly report provides epidemiological data on�S. aureus�in Northern Ireland, including overall infection�figures as well as those specific to MRSA and MSSA. The report highlights key points, rates, trends and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

C. difficle surveillance quarterly report: April - June 2011

This quarterly report provides epidemiological data on C. difficile in Northern Ireland, and includes key points, a comprehensive�overview of all C. diff infections, rates, trends, age-specific information�and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

S.aureus bacteraemia surveillance quarterly report

This quarterly report provides epidemiological data on�S. aureus�in Northern Ireland, including overall infection�figures as well as those specific to MRSA and MSSA. The report highlights key points, rates, trends and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland

C. difficile surveillance quarterly report: July - September 2011

This quarterly report provides epidemiological data on C. difficile in Northern Ireland, and includes key points, a comprehensive�overview of all C. diff infections, rates, trends, age-specific information�and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

S.aureus bacteraemia surveillance quarterly report: July - September 2011

This quarterly report provides epidemiological data on�S. aureus�in Northern Ireland, including overall infection�figures as well as those specific to MRSA and MSSA. The report highlights key points, rates, trends and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland

C. difficile surveillance quarterly report: October - December 2011

This quarterly report provides epidemiological data on C. difficile in Northern Ireland, and includes key points, a comprehensive�overview of all C. diff infections, rates, trends, age-specific information�and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland.

S.aureus bacteraemia surveillance quarterly report: October - December 2011

This quarterly report provides epidemiological data on�S. aureus�in Northern Ireland, including overall infection�figures as well as those specific to MRSA and MSSA. The report highlights key points, rates, trends and statistical process control charts. The report also provides information on surveillance methods and data for each hospital and Health and Social Care Trust in Northern Ireland