Search Results for factorial experiments

The hidden factory refers to the activities associated with scrap and rework. This chapter presents a rudimentary understanding of what sorts of things the hidden factory is doing, focusing on how to get one's arms around the rejections that occur most frequently or have the highest cost. It provides information on the use of Pareto analyses from both frequency-of-occurrence and cost perspectives to target specific areas for improvement.

This chapter presents the history of stainless steel and provides an overview of the key concepts discussed in this book. This book covers a broad spectrum of historical events, many of which have not been touched upon in other works on stainless steel. It includes the discoveries of the various metallic elements that are used in the various alloys of stainless steel and discusses numerous experiments conducted during the 19th century with iron-base alloys containing chromium and carbon.

Casting quality and consistency need to be carefully controlled. This chapter discusses the procedures that describe the process and product quality controls. In addition, it provides information on quality assurance programs.

This chapter provides insights into the work of a stainless steel pioneer, Harry Brearley. It explains how Brearley's early life and experience led him to become a self-trained chemist and metallurgist.

Statistics, data analysis, root cause analysis, and problem-solving processes play a key role in failure investigations. This chapter explains how to collect failure investigation data, how to build and maintain a database for company-related failures, and how to use corresponding statistics including type of failure, material, and root cause. It describes the purpose and benefits of conducting a root cause analysis and the factors, namely relative failure importance and company value, that determine when an investigation should be performed. The chapter also discusses the four-step problem-solving process as it applies to failure investigation, how to assemble an investigation team, and the details of organization and planning. It concludes with a case history of the Firestone 500 steel-belted tire failure, stressing the importance of a systematic approach to failure investigations.

The increased use of advanced high-strength steels to achieve weight reduction in automobiles has led to the development of innovative tool designs and manufacturing processes. Among these technologies and processes are: real-time process control, active drawbeads, active binders, flexible binders, and flexible rolling. This chapter presents the implementation, advantages, disadvantages, and applications of these processes and technologies.

Quantifying a fault-tree analysis is a useful tool for assessing the most likely causes of a system failure. This chapter addresses fault-tree analysis event probabilities and ranking of failure causes based on these probabilities. Failure rates, failure-rate sources, probability determinations, mean times between failure, and related topics are also discussed. The discussion covers the practices observed in fault-tree analysis quantification and processes involved in calculating the probability of the top undesired event.

The increased use of advanced high-strength steels (AHSS) to achieve weight reduction in automobiles has led to the development of tool designs and innovative manufacturing processes. These technologies and processes include: real-time process control, active drawbeads, active binders, flexible binders, flexible rolling, and additive manufacturing. This chapter focuses on these processes and technologies.

This chapter provides information on the biennial International Wear of Materials Conference, which is the inspiration for this book. It reviews the fundamentals of tribology, tribosystems, and related terminology. The glossary at the end of this chapter is intended to familiarize readers with some of the fundamental tribology terms that will be repeated throughout this book.

This chapter addresses the general effects of composition, mechanical treatment, surface treatment, processing, and fabrication operations on the corrosion resistance of aluminum and its alloys. Different types of surface treatments covered include claddings, anodizing, and conversion coatings. The processing steps that can have relatively significant impact on corrosion resistance are homogenization, rolling, extrusion, quenching, aging, and annealing.

This chapter discusses the work of a famous stainless steel pioneer, Edward G. Budd. The discussion covers his early years, his automobile body business, the arrival of novel kind of stainless steel in America, Earl Ragsdale's shot weld patent, the world's first stainless steel airplane, the world's first stainless steel rubber-tired train, the Flying Yankee, the Mark Twain Zephyr, the development of the Budd Company in the war years and postwar years, and a review of the Budd Era.

This chapter presents examples of aluminum infrastructure applications and their benefits to society. Infrastructure applications covered within this chapter include: electrical conductors; roads and bridges; highway signs, traffic signals, and license plates; railroad and highway crossings; solar energy generation; and agriculture and industrial applications.

This article presents a simple cost/pricing system that is reasonably accurate and could easily be recalculated if the yearly cost of any of the basic cost components change. Using the example of a commercial heat treating facility, the operational details are categorized as atmosphere processes, induction processes, aluminum processes, high-heat processes, and secondary processes. For the purpose of calculating the heat treatment processing cost per hour and the selling price for a piece of equipment, the costs are separated into direct costs, allocated costs, capitalized cost, and general and administrative costs. The article discusses the techniques involved in allocating costs to the group of equipment, and presents a description on the cost analysis of endothermic gas.

Root cause of failure in automotive electronics cannot be explained by the failure signatures of failed devices. Deeper investigations in these cases reveals that a superimposition of impact factors, which can never be represented by usual qualification testing, caused the failure. This article highlights some of the most frequent early life failure types in automotive applications. It describes some of the critical things to be considered while handling packages and printed circuit board layout. The article also provides information on failure anamnesis that shows how to use history, failure signatures, environmental conditions, regional failure occurrences, user profile issues, and more in the failure analysis process to improve root cause findings.

Stainless steels have a wide variety of applications for household products, food-handling equipment, major appliances, medical equipment, and industrial equipment. Stainless is also featured in many architectural designs and monuments. Many of the most important applications of stainless steel can be found in the transportation industry, where both the cutlery martensitic and the chromium-nickel austenitic stainless steels have been used. This chapter provides a detailed discussion on these applications.

The technology of fabricating composite hardware and structures by filament winding has evolved empirically through the development and manufacturing of specific components. This chapter reviews areas of technology used in building composite parts and discusses the processes from which the current technology was derived. The discussion covers quality control requirements for composite fabrication technology and cleanliness standards in the workplace. It describes technology developed for specific components, including satellites struts, aircraft hydraulic cylinders, drill pipe, drive shafts, couplings, and cryogenic tubing.

The aim of every extrusion plant is the efficient production of competitive products that meet the appropriate quality requirements. This chapter discusses the processes involved in the selection and introduction of a quality management system, along with its application, advantages, and disadvantages. It describes the process chain for order processing within the quality circle and provides information on product liability legal issues. In addition, the chapter discusses the processes involved in quality control, along with its organization, responsibilities, audits, and testing.

This chapter summarizes the various kinds of gear wear and failure and how gear life in service is estimated and discusses the kinds of flaws in material that may lead to premature gear fatigue failure. The topics covered are alignment, gear tooth, surface durability and breakage of gear tooth, life determined by contact stress and bending stress, analysis of gear tooth failure by breakage after pitting, and metallurgical flaws that reduce the life of gears. The chapter briefly reviews some components in the design and structure of each gear and/or gear train that must be considered in conjunction with the teeth to enhance fatigue life.

This introduction presents an overview of the discovery of aluminum, the origins of the aluminum industry, and the evolution of the industry.

This chapter examines the early literature on stainless steel to gain an understanding of the state-of-the-art of stainless steel as it progressed through the first 37 years after the discoveries made in Sheffield and Essen.