Quality Control Perspectives during Mass Production with a Focus on the Chemical Industry

Mass production was part of the industrial revolution in 1870 and, with it, a huge step change in manufacturing processes. Its impact was ground breaking and became even more remarkable with automation in a business production environment. The chemical industry is one of the manufacturing sectors that has benefited from the technology of mass production achieved through automating the business process. In this era of industry 4.0 and with the associated advanced technologies of smart manufacturing, cloud computing, cyber physical systems and internet of things, mass production has been revolutionised but still faced issues such as quality control of the production process which was affected by supply chain management, customised production of commodity and specialty chemicals and huge demand from other chemical industry manufacturers. This chapter has reviewed the evolution of mass production during traditional manufacturing to the present day and carried out a risk assessment to quality of production in a mass production environment with a view to recommending adequate quality control of the production process. The chapter also included a case study for mass production of a pharmaceutical drug—Amoxicillin which was partly batch produced into dry powder and then mass produced using tableting and encapsulating machine, highlighting sources of contamination and inconsistency in tablet weight if adequate control measures were not put in place

Electrochemical evaluation of corrosion resistance of chromium plated nickel and copper tin alloys. A comparative study

Engineering materials and composites are frequently exposed to aggressive and chemically toxic environments with high probability for rapid corrosion and consequent deterioration and catastrophic degradation. Occasionally, a new legislation regulates against the use of existing materials, necessitating thus development of new methodologies or new materials in order to reduce material corrosion rates. The aim of this study is to test the corrosion resistance of the copper tin alloy, a material that could replace nickel compounds, recently reclassified as suspected carcinogens. Standard sizes of pre-cut nickel and brass panels were produced and then plated with different thicknesses of copper tin alloy and chromium for additional protection. Evaluation of plated materials for corrosion rate and resistance was carried out using linear polarisation, electrochemical impedance and accelerated destructive testing. Corrosion testing of the materials assessed qualitatively and quantitatively, showed that corrosion resistance was dependent on a combination of factors, including the thickness of chromium plating, type of material, type of testing and duration in a corrosion chamber. While linear polarisation experiment was useful in establishing corrosion rate of sample, electrochemical impedance and accelerated destructive testing experiments assessed corrosion resistance of the materials

Lean-excellence business management for manufacturing SMEs focusing on KRI

Purpose The purpose of this paper is to develop an effective framework for implementing Lean strategies in small- and medium-sized enterprises (SMEs) in the Kurdistan Region of Iraq (KRI). Design/methodology/approach Based on the integration of LM tools and techniques with the Malcolm Baldrige National Quality Award (MBNQA) criteria a systematic Lean implementation framework for manufacturing SMEs has been proposed. The core values, drivers and tools of the proposed framework were further developed based on case studies in three SMEs in the KRI. Findings Proposed framework is able to provide a simple pathway for SMEs to systematically implement Lean techniques in seven functional areas in order to create Lean culture in the organisation. Business performance measurement in terms of profitability, customer satisfaction, employee’s satisfaction, competitiveness growth and ergonomic improvement is presented in favour of evaluating Lean outcomes appropriately. It also presents the experience of small firms in implementing Lean programmes to show that Lean is valid in SMEs. Research limitations/implications The framework concentrates only on the internal issues of the organisation, while external variables such as national culture and external support are excluded. Practical implications The framework assists improvements in SMEs that either initially attempt to start Lean journey or those that are at more advanced levels towards excellent-Lean manufacturing. The framework can also be used as a self-assessment model to determine the degree of Lean readiness. Originality/value To the best knowledge of the author, it is the first framework that integrates Lean techniques with MBNQA criteria to support Lean implementation in SMEs. It is also the first study regarding Lean-excellence in the KRI.Published onlin

Key risks in construction projects in Italy: contractors’ perspective

Purpose Risks play an important role in the success of construction projects. Failure in identification and assessment of risks can lead to inadequacy in the process of managing risks, which in turn can critically affect the projects’ resources. A formal risk management is rarely practised in construction projects due to the lack of contractors’ awareness of key risks. The purpose of this paper is to focus on the investigation of risk factors in construction projects in Italy from contractors’ perspective. Design/methodology/approach Semi-structured interviews were conducted to collect data, based on which a total of ten key risks were ascertained. The identified risks were compared with the findings of the surveys conducted in the Australian and Chinese construction industry to address the unique risks associated with construction projects in Italy. Findings The key risks included delays in payments, client variations, design variations, inaccurate cost estimates, and tight project schedules. The comparison between those three countries specified the delays in payments and project funding problems as the most critical factors that are related to cultural influences and behaviour of clients. The findings assist contractors in the risk identification process, and can be applied to the development of a risk management framework for construction projects. Research limitations/implications The findings of this study cannot be generalised statistically for the whole of Italy as it was constrained geographically, with respondents drawn only from a self-selection sample of construction projects in the Veneto region of Northern Italy. The findings represent a snapshot of the key potential internal and external risks from the perspective of contractors. Originality/value The results of the study specified the key risks of construction projects from the perspective of contractors which can contribute to risk management for construction projects

Impact of inter-metallic compound thickness on thermo-mechanical reliability of solder joints in solar cell assembly

This is an accepted manuscript of an article published by Elsevier in Microelectronics Reliability on 13/11/2020, available online: https://doi.org/10.1016/j.microrel.2020.114008 The accepted version of the publication may differ from the final published version.This study evaluates the impact of intermetallic compound (IMC) thickness on thermo-mechanical reliability of lead-free SnAgCu solder joints in crystalline silicon solar cell assembly with regard to fatigue life. Finite element modelling is used to simulate the non-linear thermo-mechanical deformation of the joints. Five geometric models of solar cell assemblies with different IMC thickness layers in the range of 1 to 4 μm are utilized. The models were subjected to accelerated thermal cycling from 40 °C to 85 °C employing IEC 61215 standard for photovoltaic panels. Creep response of each of the assembly's solder joints to the induced thermal load were simulated using Garofalo-Arrhenius creep model. Simulation results indicate that when IMC thickness grows incrementally to 1, 2, 2.5, 3 and 4 μm, thermo-mechanical fatigue life of solder joints diminishes to 13,800, 11,800, 10,600, 9400 and 7800 cycles to failure respectively. Thus, solder joint fatigue life decreases as the IMC thickness increases during service lifetime. Therefore, proper design of solder joint in crystalline silicon solar cell assembly must include consideration of IMC layer thickness to prevent premature failure and to ensure fulfilment of desired functional lifetime of 13,688 cycles to failure (25 years).Accepted versio

Characterisation of potential replacements for nickel compounds used in decorative chromium plating

The electroplating industries use soluble nickel salts in numerous applications. Over the past few years this has become problematic due to the reclassification of these salts from a harmful substance to now a toxic substance. The introduction of the legislation REACH (Registration, Evaluation, Authorisation & restriction of CHemicals) has meant the electroplating industry has had to use less harmful chemicals where possible, thus meaning companies are investing in research to find an alternative to the nickel deposit. In this study, alternative deposits under investigation as a potential replacement to the nickel deposit under the decorative chromium deposit has been characterised in terms of the appearance, surface topography and corrosion resistance by using spectrophotometry, scanning electron microscopy (SEM), atomic force microscopy (AFM), linear polarisation, electrochemical impedance spectroscopy (EIS) and accelerated corrosion salt spray methods. Spectrophotometry identified that a white Cu-Sn alloy gave a bluer appearance in comparison to the nickel deposit, when the chromium deposit was plated on top this modified the colour slightly giving the white Cu-Sn alloy with chromium a similar appearance to the nickel and chromium deposit. The yellow Cu-Sn alloy was yellow in colour with a visibly dull appearance, but when chromium was plated on top of the yellow Cu-Sn alloy the colour was improved but still remained dull. The SEM and AFM results identified that the white Cu-Sn alloy deposit had similar nodulated topography to the nickel deposit and when the chromium was plated on top the topography changed only slightly. While the yellow Cu-Sn alloy deposits showed a more crystalline structure and increased roughness in comparison to the nickel deposit, the chromium deposit plated on top did not change the structure of the underlying deposit but it did reduce the roughness slightly. Electrochemical corrosion tests showed the white Cu-Sn alloy to have a higher polarisation resistance compared to the nickel deposit, thus suggesting it would provide similar corrosion protection to the nickel deposit. The yellow Cu-Sn alloy proved to have a faster corrosion rate in comparison to the nickel deposit. Accelerated corrosion tests proved the white Cu-Sn alloy to be more corrosive than the nickel despite the electrochemical test results, it was concluded that the white Cu-Sn alloy deposit was porous and therefore provided less corrosion protection to the substrate in comparison to the nickel deposit. The yellow Cu-Sn alloy had a lower corrosion protection than the nickel deposit and when combined as a duplex Cu-Sn alloy with the white Cu-Sn alloy deposit there was no improvement in corrosion performance. The plated chromium deposit did improve the corrosion protection for most deposits but none of the alternatives could match the corrosion protection offered by the standard nickel with chromium deposit. This study concluded that the white Cu-Sn alloy with chromium deposit was found to be a potential alternative to the nickel with chromium deposit for applications where appearance is primary, no alternative could be found to match the corrosion protection provided by the standard nickel and chromium process.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Risk Management Treatise for Engineering Practitioners

This book ""Risk Management Treatise for Engineering Practitioners"" has been published by academic researchers and experts on risk management concepts mainly in the construction engineering sector. It addresses basic theories and principles of risk management backed up, in most cases, with case studies. The contributions for this book came from authors in Europe, the Far East and Africa, and it is hoped that the contents of this book will be useful to anyone interested in understanding the principles and applications of risk management, especially within the construction engineering sector. Researchers and postgraduate students in science and engineering disciplines, especially those interested in project management, will find this book useful

Influence of Lean Practice on Performance of Manufacturing SMEs in Kurdistan Region of Iraq (KRI)

28th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2018), June 11-14, 2018, Columbus, OH, USALean Manufacturing (LM) is a global initiative that can create continuous improvement in business performance by eliminating waste, reducing cycle time and promoting value-added activities. This study aims to examine empirically the influences of LM practices on the performance of SMEs. A comprehensive review of the LM literature was conducted, and seven variables were presented that dominate LM practices in Kurdistan Region of Iraq (KRI). Data was collected and analysed from 207 manufacturing SMEs showing that LM practices partially influence the business performance. The findings could be a good driver for introducing Lean techniques to the manufacturing SMEs within developing countries. It also provides valuable information for SMEs managers to improve the performance of their business in terms of increasing customer satisfaction, profitability, employee satisfaction, competitiveness and ergonomic design

Chromium electroplating of aluminium alloys using electroless nickel as underlayer

© 2014The Authors. Published by Scientific Research. This is an open access article available under a Creative Commons licence. The published version can be accessed at the following link on the publisher’s website: http://dx.doi.org/10.4236/msce.2014.27007The growing demand for chromium coated aluminium components especially for the automotive industry is due to their favourable physical properties (density, strength to weight ratio etc.). However, their frequent use under harsh environmental conditions renders them corrosion sensitive and consequently they need to be protected. An approach that has been applied in industry is to directly electroplate nickel onto aluminium substrate prior to a top metallic finish; however, in components with complex geometry, certain areas could become exposed to corrosion attack due to poor surface coverage during plating. In this study, a modified electroless nickel undercoat was applied to pre-treated aluminium alloys prior to duplex nickel and chromium plating with a view to enhance corrosion resistance, improve coating adherence and durability, and overall, to achieve substrate protection. Hexavalent and trivalent chromium were applied to pre-treated Al 1050 and Al 6061 following electroless nickel deposition, and plating performance was assessed by surface and corrosion techniques, while durability was measured by scratch, adhesion and hardness tests. Overall, while chromium plating with an electroless nickel undercoat did not improve corrosion resistance or hardness of the materials, it provided an additional protective layer for the substrate with a potential for longer term durability.Published versio