Manufacture Of New Products Research Articles

Reprocessing of Buildings’ Demolition Waste and Utilization for the Manufacturing of New Products

Concrete is multicomponent composite material, consisting of coarse aggregate, fine aggregate, cement and water. Natural aggregates, as well as aggregates obtained after the reprocessing of buildings' demolition waste, can be used as coarse and fine aggregates. Characteristics of the hardened concrete depend on the raw materials, used for the preparation of concrete mixture, and their characteristics. The objective of the research is to analyse the sources of demolition waste, to describe the reprocessing technology of concrete waste, to investigate the production of the aggregate from the concrete waste, to analyse the main properties of these aggregates — particles' density, bulk density, granulometric composition, hollowness and other properties, as well as to compare the obtained results with the requirements applicable to the aggregates based on natural materials.

General Framework for Latent Variable Model Inversion for the Design and Manufacturing of New Products

Latent variable regression model (LVRM) inversion is a useful tool to support the development of new products and their manufacturing conditions. The objective of the model inversion exercise is that of finding the best combination of regressors (e.g., raw material properties, process parameters) that are needed to obtain a desired response (e.g., product quality) from the model. Each of the published applications where model inversion has been applied utilizes a tailored approach to achieve the inversion, given the specific objectives and needs. These approaches range from the direct inversion of the LVRM to the formulation of an objective function that is optimized using nonlinear programming. In this paper we present a framework that aims to give a holistic view of the optimization formulations that can arise from the need to invert an LVRM. The different sets of equations that become relevant (either as a term within the objective function or as a constraint) are discussed, and an example of these scenarios is also provided. Additional to the formulation of the different scenarios and their objective functions, this work proposes a new metric (the P2 statistic) to cross-validate the ability of the model to reconstruct the regressor vector (analogous to the Q2 statistic aimed at the predictability of the response). This new metric comes from the need to not only predict the response from the regressor, but to also reconstruct the regressors from the scores values. In this context, a discussion is provided on the effect of uncertainty in the reconstruction of the regressor (the actual design) as these values are normally given upstream as targets to the supplier of materials, or as set points to the process.

Drivers for international innovation activities in developed and emerging countries

This paper aims to shed light on firm-specific drivers that lead firms to internationalise their innovation activities. The paper paints a comprehensive picture of driving forces by including firm capabilities, characteristics of the firm’s competitive environment and the influence of innovation obstacles in the home country. In particular the influence of potential driving forces on the probability to carry out different innovative activities abroad is assessed (R&D, design/conception of new products, manufacturing of innovative products and implementation of new processes). In a second stage these driving forces are observed with regard to their impact on the decision to locate innovation activities in various countries and regions (China, Eastern Europe, Western Europe and North America) as well as in groups of countries with similar levels of knowledge (“country clubs”). The analysis is based on the Mannheim Innovation Panel survey which represents the German CIS (Community Innovation Survey) contribution. Two survey waves have been combined, resulting in a sample of about 1,400 firms. The results show that the decision to perform innovation activities abroad is mainly driven by organisational capabilities such as absorptive capacities, international experience and existing technological competences of the respective firm. Innovation barriers at the German home base such as lack of labour and high innovation costs prompt the set-up of later-stage innovation activities abroad while the lack of demand demonstrates a barrier to the internationalisation decision for the development and manufacturing of new products. Location decisions receive the strongest influencing effects from the international experience of the firm. Firms which innovate in developing countries seem to require a more extensive level of international experience through international R&D cooperation.

Design of micromixer for emulsification and application to conventional commercial plant for cosmetic

In the manufacture of cosmetics, the characteristics of the final product strongly depend on the degree of emulsification, but the current commercial process cannot achieve the desired droplet diameter. To overcome this disadvantage, we used a micromixer (K-JET mixer) originally developed for use as an in-line mixer. The K-JET mixer has a simple orifice-based design and offers three main advantages: it can be used for a wide range of products, achieves good mixing, and can be easily adjusted for a wide range of throughputs. It was clarified that the droplet diameter of the emulsion was well correlated with the energy dissipation rate, which was easily controlled by adjusting the orifice diameter and flow rate. On the basis of this relationship, we built a full-scale mixer suitable for a commercial plant and identified the necessary specifications for the gel capsule. Thus, we found that the commercial process can be successfully expanded for the manufacture of new products by just using a high-throughput micromixer.

Recycling of packaging multilayer films: New materials for technical products

Multilayer foils are approximately 17% of all produced packaging films. Most produced multilayer film is based on the composition of polyethylene–polyamide (type PAPE). Previous experiences in the recycling of these materials showed that recyclate of these films are heterogeneous materials, making them more difficult to use for manufacturing of new products. Modifications of recycled PAPE were carried out using recycled polyethylene (from 25 to 75 wt.% PE) and inorganic fillers in the form of ash (up to 30 wt.%). Obtained new materials have been characterized, their properties were determined and their usability in the direction of technical products was evaluated. It has been demonstrated that the new plastic composites based on recycled materials after modifying them with special fillers can be used instead of the original plastic material.

Drivers for International Innovation Activities in Developed and Emerging Countries

The internationalisation of corporate R&D is an opportunity for firms to reach local knowledge and expertise which is distributed globally. Firms' innovation activities which are carried out abroad comprise either the localization of uniform products to local needs with locally available knowledge or the whole product development process including R&D. The aim of the paper is to show how internal firm capabilities as well as external forces from the firm’s business and national innovation environment impact on the firm's decision to carry out different innovation activities abroad. The analysis is based on around 1200 firms headquartered in Germany. A second step observes whether the effects of the potential internal and external driving factors vary by the host country. The results show that especially firms with developed absorptive capacities and international experience are more likely to shift R&D intensive innovation activities abroad such as research and the conception/construction of new products. For the internationalisation of later stage innovation activities such as the manufacturing of new products or the implementation of new processes international experience as well as experience with intellectual property rights are required firm capabilities. The national innovation environment with high innovation costs and lack of labour contributes to the firm’s decision to set up manufacturing capacities for new products abroad. The competition in the home market has a limited influence or even hinders firms to internationalise their innovation activities. For the effect of the analysed internationalisation drivers per host country it could be shown that firms that innovate in countries with medium developed knowledge levels need pronounced export experience and in-house R&D activities than firms that innovate in advanced countries or nations with marginal knowledge levels. However, firms that plan to innovate in China should also engage in international R&D activities to further develop their international contacts. High innovation costs in the home country seem to motivate firms to innovate in medium knowledge countries while price competition fosters innovation activities in advanced knowledge economies but hinders firms to innovate in China. The overall conclusion emphasizes the capability driven decisions of firms to innovate abroad and not being forced predominantly by fierce competition or the lack of innovation resources in the home country.

Identification and management of risks at introduction of new products into manufacture

A process of overall risk management when organizing manufacture of new products is considered. A number of factors that exert an influence upon the deviation of finance indicators from the planned ones are revealed. Also described are the techniques for levelling of the influence of these factors and attaining least deviations from planned finance indicators.

Use of the quality function deployment methodology in the development of a novel training system for cricket

The ‘quality function deployment’ (QFD) methodology, a quality system used in the planning, design, and manufacture of new products and services, has been adopted throughout the development of a novel training system for cricket. Four basic phases are contained within QFD, which are concerned with every stage of the development process, from the initial product design through to planning the production of the finalized system. The primary focus of the research presented within this paper has been the use of the ‘House of Quality’ (HoQ) product planning matrix, a tool based on the QFD approach, to understand the needs of the future system users (the ‘voice of the customer’ (VOC)), identify the technical characteristics required to fulfil the VOC, evaluate existing technologies, and manufacture a working prototype system. This prototype system has been tested extensively and has been shown to fulfil the needs of the future system users (‘customers’) more fully than those offered by the leading competitors. Further development of the prototype system is ongoing, with a view to expanding the system functionality and better fulfilling the needs of the future system users as identified in the VOC.

Impact strength of recycled thermoplastic composites subjected to corrosive environment

AbstractThe objective of the present study is to investigate the effect of hygrothermal aging on the impact strength of virgin and recycled commercial polyphenylenesulfide (PPS) matrix composites reinforced with 40% by weight of short glass fibres after water absorption at different pH and temperature environments. This study is part of a long‐term strategy for developing a sound methodology for reusing short fiber‐reinforced thermoplastic materials. Hygrothermal aging has been conducted so as to represent actual service conditions identified for the components made from these recycled materials. Taking into account the corrosive nature of the service environment in which the aforementioned components are required to operate, a study of the recycled material impact strength as a function of the environmental conditions to which they are subjected, is deemed indispensable before using them for the manufacturing of new products. The results of the present study showed a great effect of the various parameters studied such as, water temperature, alkaline or acidic nature of the environment, andtype of the coupling agent used on the impact behavior of the PPS‐glass fiber composites investigated. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers

Commercialising HARMST-LIGA technologies

This paper outlines the strategy and issues for the commercialisation of HARMST-LIGA process technologies. Part of this strategy is the setting up of an international HARMST-LIGA Commercialisation Group to identify and bring together people and organisations to advance industrial up-take and drive development and manufacturing of new product for the growing global markets.

Quality Concepts for the Improved Use of Recycled Polymeric Materials: A Review

AbstractPolymeric waste materials should be considered resources for the manufacture of new products through recycling processes, with a similar status to virgin fossil‐based plastics and biopolymers from renewable resources. Several efforts can be made to achieve this qualitative quantum leap in plastics recycling, and consequently introduce recycled products, with competitive performance, to the market. Scientific knowledge about the degradation processes during the life cycle and the development of fast and reliable analytical methods for the quality assessment of recycled plastics are fundamental to guarantee their performance in new applications. Different strategies—restabilisation, rebuilding, compatibilisation, and addition of elastomers and fillers—can be used to upgrade the structure and properties of polymeric waste streams. This review discusses recent developments in the mechanical recycling of plastics, focusing on how to produce quality materials from waste streams and, thus, contribute to a sustainable management of resources and energy.magnified image

Cleaning the Medical Electronic Environment: How You Can Contribute

There is a renewed and concerted movement in the United States to acknowledge and decrease the quantity of hazardous electronic materials entering the environment through the electronic waste, or e-waste, process. This movement is credited to the European Union (EU), which has adopted two important policies since 2002: the Waste Electrical and Electronic Equipment directive (WEEE) and the Restriction of Hazardous Substances (RoHS—pronounced “Ross”) directive in July 2006. The two directives require that all 27 EU member states adopt and enforce these policies as law. To comply, they must set up programs for the collection, recycling, and recovery of six hazardous materials used in the manufacture of electronic and electrical equipment, including medical devices. Current policies are also in place to eliminate the use of these substances in the manufacture of new products. The materials covered under WEEE and RoHS are: • Lead (Pb): A heavy metal used in batteries, solder, and fusible alloys that acts as a potent neurotoxin on the body. • Mercury (Hg): A heavy liquid transition metal used in thermometers, switches, and fl uorescent lighting and established as a biological toxin to humans and wildlife. • Cadmium (Cd): A transitional metal found as an impurity in zinc that is used in batteries and printed circuit boards; it is identifi ed as a carcinogen. • Hexavalent chromium (Cr6+): A carcinogenic corrosion inhibitor used in the manufacture of stainless steel and chrome. Exposure is usually established during working with or handling this material (grinding, cutting, skin contact, etc.). • Polybrominated biphenyls (PBBs): A manufactured chemical added to plastics to be used as a fl ame retardant; it is linked to various health problems. Current study data of the health effects of PBBs warranted inclusion on the RoHS list. • Polybrominated diphenyl ethers (PBDE): A group of halogenated bromides used in electronic manufacturing found to be absorbed in fi sh and wildlife populations. Studies on the absorption of these compounds found that they may possess liver, thyroid, and neurodevelopmental toxicity.

AN EVALUATION OF PROCESSABILITY BY INJECTION MOLDING OF ABS/PC BLENDS OBTAINED FROM RECYCLED MATERIALS

Injection molding of recycled thermoplastic materials is a possible alternative for the manufacture of new products and is becoming increasingly important in the industrial sector. Due to the ease with which recycled materials can be mixed, and as so little is known about the process characteristics required to obtain products in optimum conditions, this paper proposes an evaluation criterion for the processability of different blends of recycled materials (ABS/PC blends). With this aim in view, a multicriteria optimization methodology has been developed to evaluate and determine the optimum process conditions that guarantee the ideal final qualities of the products considered from different aspects. The results'obtained are used to determine the material processability index of the blend (MPI).

Economic Lot Scheduling Problem with Returns

Motivated by a case study of a company that produces car parts, we study the multi‐product economic lot scheduling problem for a hybrid production line with manufacturing of new products and remanufacturing of returned products. For this economic lot scheduling problem with returns (ELSPR), we consider policies with a common cycle time for all products, and with one manufacturing lot and one remanufacturing lot for each product during a cycle. For a given cycle time, the problem is formulated as a mixed integer linear programming (MIP) problem, which provides the basis for an exact solution. The application of this model for one of the core products of the case study company indicates a 16% reduction in cost compared to the current lot scheduling policy.

Utilization of Steel Slag Aggregate for Road Bases

Abstract Industrial wastes and byproducts have to be disposed off properly so that their environmental impacts are minimized. Alternatively, some of these materials can be utilized in recycling processes, manufacturing of new products, or as construction materials. This paper presents an effective way of utilizing the steel slag aggregate (SSA), which is a byproduct of the steel manufacturing process, in road construction. A comprehensive study was conducted to characterize SSA and determine the potential for its use in road bases. Testing results indicated that SSA is an environmentally safe product and has physical and chemical properties that make it an excellent candidate for road base construction. Laboratory and field data have shown the superior performance of SSA over the locally available calcareous sediments. The resulting California Bearing Ratio values are doubled and the water sensitivity is much less when using SSA instead of the local calcareous material.

Commercialising nanotechnology concepts products markets

Is nanotechnology driving a manufacturing revolution and producing new products and systems that will change society? Will it fulfil the promise of creating new industries, solutions to health and environmental problems or will it threaten our very existence? This paper is intended to give the non-expert a realistic and broad overview of the current position and future expectations of nanotechnology with particular emphasis on applications, the manufacturing of new products and the paths to market.

Employ NMP Extraction for Value Addition of Waxy Streams

With rising crude oil prices, coupled with tightening product specifications and environmental concerns, the refining industry will continue to see many changes during the times to come. In order to maintain/improve their margins, refiners are obliged to upgrade the low value streams into more profitable products. For upgrading the existing product slate, or manufacture of new products, huge investments are needed for new facilities. This involves logistic and proper evaluation of all the possible upgrading technologies and optimal processing schemes in order to arrive at the best option for a particular unit. This study deals with NMP extraction studies on two vacuum cuts; namely, pressible and heavy waxy distillates (PWD and HWD) for their up-gradation into raffinates of desired hydrocarbon composition and extracts of high aromaticity (BMCI). Solvent extraction studies were carried out on multistage extraction column in countercurrent mode. The water content in the solvent was optimized and kept the same for both the streams for ease of solvent recovery. The extraction conditions such as temperature, solvent-to-feed ratio, and water content in solvent were optimized for high quality raffinate and high quality aromatic extract (BMCI > 105). Studies reveal that the processing of PWD and HWD produces raffinate that could be used as feedstocks to solvent dewaxing/de-oiling unit for paraffin wax production. The high BMCI extract can be used as feed for high value industrial carbons such as pitches and needle coke. An added advantage of following this scheme is that the filtration rates of the NMP extracted PWD and HWD raffinates increase by ∼ 50% in comparison to that of raw distillates, thereby leading to capacity enhancement besides easy finishing of the wax. Moreover, withdrawal of about 25% of aromatic extracts from PWD and HWD feed stocks would lead to increase in capacity of the wax dewaxing/deoiling unit.

Improving the Quality of Information Flows in the Backend of a Product Development Process: a Case Study

Considerable research has gone into designing effective product development processes. This, coupled with the increasing need for products that are able to deliver reliable, complex functionality with a high degree of innovation, presents a major challenge to modern day industries in the business of developing products. In order to incorporate relevant field experience in the design and manufacturing of new products, increasingly detailed information needs to be retrieved from the market in a very short amount of time. In one particular consumer electronics industry, business process models describing the information flow in the backend of the product development process indicated massive data loss and also serious data quality degradation. This paper attempts to show how such losses can be mitigated and also proposes a business model that can adequately capture information of a higher quality and in a more structured manner. The end result will be a product development process that provides better feedback on current product performance and is more responsive to future market needs. Copyright © 2005 John Wiley & Sons, Ltd.

Sustainable product development and manufacturing by considering environmental requirements

Sustainability in the development and manufacture of new products is a strategy that is widely accepted in principle, although not yet widely practiced. The integration of environmental requirements throughout the entire lifetime of a product needs a new way of thinking and new decision tools to be applied. This paper describes the concept of an approach to product development, based on a paradigm for sustainable manufacturing. Four examples of methodologies and decision tools are discussed, representing the most important sources of environmental impacts of a product. The emphasis lies on the integrating concept rather than on the details of the methodologies.

Assessing the validity of new product development techniques in Spanish firms

Recent articles in the business press and academic literature affirm that one of the primary means for achieving competitive advantage through product development is by accelerating the development process. A wide range of advanced technologies and techniques have become available to accelerate the design, engineering and manufacture of new products. However, much attention has been focused on new product development techniques but little empirical research has been conducted to validate these techniques. In this exploratory study, we try to identify those techniques that are more useful to accelerating the product development process. Our findings, based on data from 54 Spanish firms, suggest that some available techniques are not effective in achieving this goal of reducing the time to market. Implications for researchers and managers are discussed.