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 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 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

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 Materials 2 methods to determine EPA Notification of Hazardous Waste Activity Characteristic Waste A list of materials established by the EPA If it’s on the list classified as a “listed 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