Process techniques for engineering high-performance materials

494 Pages·2013·41.928 MB·English

by  Tim Oberle

PROCESS
TECHNIQUES FOR
ENGINEERING
HIGH-PERFORMANCE
MATERIALS

PROCESS
TECHNIQUES FOR
ENGINEERING
HIGH-PERFORMANCE
MATERIALS
TIM OBERLE
Boca Raton London New York
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Contents
Acknowledgments .................................................................................................ix
Introduction to Process Dependency ..................................................................xi
Author .................................................................................................................xxxi
1. The Process, the Product, and Its Ultimate Life Span ............................1
The Process .......................................................................................................4
The Product.......................................................................................................7
The Knobs .......................................................................................................10
Product Life Span...........................................................................................14
Types of Process Deficiencies .......................................................................17
Summary .........................................................................................................20
2. Fitness-for-Use Testing ................................................................................23
Finding the Critical Properties of Process-Dependent Products ............27
FFU Tests .........................................................................................................29
Getting Creative with FFU ...........................................................................37
Know Thy Customer .....................................................................................41
Summary .........................................................................................................46
3. Technical Creativity and Idea Generation ..............................................49
Creativity in an Industrial Environment ...................................................51
Reality Check on the Innovation Climate ..................................................54
Fostering Technical Innovation ...................................................................57
Formalized Brainstorming ...........................................................................63
Mechanics of Creative Development ..........................................................66
Organizational Hostility ...............................................................................70
Overcoming Systematic Barriers to Innovation ........................................75
Needs Bank and Opportunity List..............................................................82
Summary .........................................................................................................84
4. Finding Product Opportunity ....................................................................89
Market-Driven Organizations ......................................................................92
Manufacturing/Process-Centric Approaches ...........................................95
Balanced Approach .......................................................................................99
Paradox of Product Evolution ....................................................................103
What to Look for in a Product Opportunity ............................................107
Cold Calls by Outsiders ..............................................................................114
Customer Requests ......................................................................................116
Customer Modification of Your Product ..................................................119
Summary .......................................................................................................121
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vi Contents
5. Prioritizing Project Proposals ..................................................................123
Prioritization Styles .....................................................................................126
Considering Risk ..........................................................................................129
Considering Process Factors When Prioritizing .....................................131
Project Review ..............................................................................................133
Summary .......................................................................................................138
6. Evaluating Critical Parameters in the Process ......................................143
Things We Want to Understand ................................................................146
Proactive Record Keeping ..........................................................................152
End-to-End Data Collection........................................................................155
Auditing Product Performance ..................................................................158
Active Experimentation ..............................................................................160
Customizing Products for Niche Markets ................................................163
Tracing the Process Paths ...........................................................................166
Summary .......................................................................................................170
7. Organizing Development Projects..........................................................175
Defining the Product ...................................................................................180
Conflicts in Creating Specifications ..........................................................186
Costing Concerns for Dynamic Products ................................................192
Planning for a Quality Outcome ...............................................................194
Summary .......................................................................................................198
8. Project Execution and Oversight .............................................................203
Project Problems ..........................................................................................204
Project Organization ...................................................................................208
Project Execution Guidelines .....................................................................213
Basic Steps .....................................................................................................219
Intellectual Property ...................................................................................222
Development Resources ..............................................................................227
Summary .......................................................................................................230
9. Small-Scale Trials .......................................................................................235
Tools for Small-Scale Development ...........................................................239
Procedures for Small-Scale Development ................................................242
Barriers to Effective Projects ......................................................................247
Managing the Development Organization ..............................................251
Retaining Samples and Information .........................................................257
Scalability ......................................................................................................262
Summary .......................................................................................................266
10. Development Trials on Large-Scale Equipment ..................................273
Trials from the Manufacturing Point of View .........................................277
Preparing for a Plant Trial ..........................................................................282
Contents vii
Running a Plant Trial ..................................................................................286
Follow-Through ............................................................................................290
Types of Plant Trials (From the Plant Perspective) .................................291
Types of Plant Trials (From the R&D Perspective) ..................................299
Equipment Considerations for Plant Trials ..............................................303
Summary .......................................................................................................308
11. Managing and Controlling the Process .................................................311
Detecting Process Variability .....................................................................312
State of the Process ......................................................................................313
Asking the Right Questions .......................................................................316
Functional Responsibilities ........................................................................321
Dealing with Trade-offs ..............................................................................326
Technical Decision Making ........................................................................328
Anticipating Risk .........................................................................................334
Failure Analysis and Corrective Action ...................................................339
Summary .......................................................................................................344
12. Controlling Raw Materials .......................................................................347
Material Guidelines in the Development Phase ......................................349
Material Rules for Industrial Scale-up ......................................................355
Material Considerations During the Specification Writing Step ..........360
Qualifying Second-Source Raw Materials ...............................................364
Summary .......................................................................................................367
13. Complex Manufacturing Situations .......................................................369
In-Line Process Trains .................................................................................375
Considering Outsourced Production ........................................................380
Qualifying a Toll Vendor ............................................................................382
Managing the Relationship ........................................................................386
Summary .......................................................................................................390
14. Human Factors ............................................................................................393
Human Input on the Plant Floor ...............................................................395
Organizational Behavior .............................................................................399
Technical Behavior .......................................................................................403
Marketing/Sales Behavior ..........................................................................407
Economics of Scarcity ..................................................................................410
Summary .......................................................................................................412
15. Managing Customer Expectations ..........................................................415
Customer Mentality .....................................................................................417
Customer Input ............................................................................................421
Knowing Where You Stand ........................................................................424
Getting the Business ....................................................................................427
viii Contents
Keeping the Business ..................................................................................430
Summary .......................................................................................................432
16. Proprietary Systems ...................................................................................435
System Trade-offs .........................................................................................439
Developing Products for Proprietary Systems ........................................443
Summary .......................................................................................................449
Index .....................................................................................................................453
Acknowledgments
Thanks to Rita, Helen, Claire, and Michelle for putting up with this project
for so long. I love you all. Thanks also to the many colleagues who helped
me bring this book to life.
ix