1. Section 3 Selecting 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
Toyota 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 environmental management standards & 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 employees for 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

16. 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

17. 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