Abnormal Condition Monitoring of Workpieces Based on RFID for Wisdom Manufacturing Workshops

PubMed Central

Zhang, Cunji; Yao, Xifan; Zhang, Jianming

2015-01-01

Radio Frequency Identification (RFID) technology has been widely used in many fields. However, previous studies have mainly focused on product life cycle tracking, and there are few studies on real-time status monitoring of workpieces in manufacturing workshops. In this paper, a wisdom manufacturing model is introduced, a sensing-aware environment for a wisdom manufacturing workshop is constructed, and RFID event models are defined. A synthetic data cleaning method is applied to clean the raw RFID data. The Complex Event Processing (CEP) technology is adopted to monitor abnormal conditions of workpieces in real time. The RFID data cleaning method and data mining technology are examined by simulation and physical experiments. The results show that the synthetic data cleaning method preprocesses data well. The CEP based on the Rifidi® Edge Server technology completed abnormal condition monitoring of workpieces in real time. This paper reveals the importance of RFID spatial and temporal data analysis in real-time status monitoring of workpieces in wisdom manufacturing workshops. PMID:26633418

Designing an in-situ ultrasonic nondestructive evaluation system for ultrasonic additive manufacturing

NASA Astrophysics Data System (ADS)

Nadimpalli, Venkata K.; Nagy, Peter B.

2018-04-01

Ultrasonic Additive Manufacturing (UAM) is a solid-state layer by layer manufacturing process that utilizes vibration induced plastic deformation to form a metallurgical bond between a thin layer and an existing base structure. Due to the vibration based bonding mechanism, the quality of components at each layer depends on the geometry of the structure. In-situ monitoring during and between UAM manufacturing steps offers the potential for closed-loop control to optimize process parameters and to repair existing defects. One interface that is most prone to delamination is the base/build interface and often UAM component height and quality are limited by failure at the base/build interface. Low manufacturing temperatures and favorable orientation of typical interface defects in UAM make ultrasonic NDE an attractive candidate for online monitoring. Two approaches for in-situ NDE are discussed and the design of the monitoring system optimized so that the quality of UAM components is not affected by the addition of the NDE setup. Preliminary results from in-situ ultrasonic NDE indicate the potential to be utilized for online qualification, closed-loop control and offline certification of UAM components.

Process monitoring and visualization solutions for hot-melt extrusion: a review.

PubMed

Saerens, Lien; Vervaet, Chris; Remon, Jean Paul; De Beer, Thomas

2014-02-01

Hot-melt extrusion (HME) is applied as a continuous pharmaceutical manufacturing process for the production of a variety of dosage forms and formulations. To ensure the continuity of this process, the quality of the extrudates must be assessed continuously during manufacturing. The objective of this review is to provide an overview and evaluation of the available process analytical techniques which can be applied in hot-melt extrusion. Pharmaceutical extruders are equipped with traditional (univariate) process monitoring tools, observing barrel and die temperatures, throughput, screw speed, torque, drive amperage, melt pressure and melt temperature. The relevance of several spectroscopic process analytical techniques for monitoring and control of pharmaceutical HME has been explored recently. Nevertheless, many other sensors visualizing HME and measuring diverse critical product and process parameters with potential use in pharmaceutical extrusion are available, and were thoroughly studied in polymer extrusion. The implementation of process analytical tools in HME serves two purposes: (1) improving process understanding by monitoring and visualizing the material behaviour and (2) monitoring and analysing critical product and process parameters for process control, allowing to maintain a desired process state and guaranteeing the quality of the end product. This review is the first to provide an evaluation of the process analytical tools applied for pharmaceutical HME monitoring and control, and discusses techniques that have been used in polymer extrusion having potential for monitoring and control of pharmaceutical HME. © 2013 Royal Pharmaceutical Society.

Preliminary Investigation of Keyhole Phenomena during Single Layer Fabrication in Laser Additive Manufacturing of Stainless Steel

NASA Astrophysics Data System (ADS)

Matilainen, Ville-Pekka; Piili, Heidi; Salminen, Antti; Nyrhilä, Olli

Laser additive manufacturing (LAM) is a fabrication technology that enables production of complex parts from metallic materials with mechanical properties comparable to conventionally manufactured parts. In the LAM process, parts are manufactured by melting metallic powder layer-by-layer with a laser beam. This manufacturing technology is nowadays called powder bed fusion (PBF) according to the ASTM F2792-12a standard. This strategy involves several different independent and dependent thermal cycles, all of which have an influence on the final properties of the manufactured part. The quality of PBF parts depends strongly on the characteristics of each single laser-melted track and each single layer. This study consequently concentrates on investigating the effects of process parameters such as laser power on single track and layer formation and laser-material interaction phenomena occurring during the PBF process. Experimental tests were done with two different machines: a modified research machine based on an EOS EOSINT M-series system and an EOS EOSINT M280 system. The material used was EOS stainless steel 17-4 PH. Process monitoring was done with an active illuminated high speed camera system. After microscopy analysis, it was concluded that a keyhole can form during laser additive manufacturing of stainless steel. It was noted that heat input has an important effect on the likelihood of keyhole formation. The threshold intensity value for keyhole formation of 106 W/cm2 was exceeded in all manufactured single tracks. Laser interaction time was found to have an effect on penetration depth and keyhole formation, since the penetration depth increased with increased laser interaction time. It was also concluded that active illuminated high speed camera systems are suitable for monitoring of the manufacturing process and facilitate process control.

40 CFR 63.605 - Monitoring requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

...) National Emission Standards for Hazardous Air Pollutants From Phosphoric Acid Manufacturing Plants § 63.605 Monitoring requirements. (a)(1) Each owner or operator of a new or existing wet-process phosphoric acid process line or superphosphoric acid process line subject to the provisions of this subpart shall install...

Neural manufacturing: a novel concept for processing modeling, monitoring, and control

NASA Astrophysics Data System (ADS)

Fu, Chi Y.; Petrich, Loren; Law, Benjamin

1995-09-01

Semiconductor fabrication lines have become extremely costly, and achieving a good return from such a high capital investment requires efficient utilization of these expensive facilities. It is highly desirable to shorten processing development time, increase fabrication yield, enhance flexibility, improve quality, and minimize downtime. We propose that these ends can be achieved by applying recent advances in the areas of artificial neural networks, fuzzy logic, machine learning, and genetic algorithms. We use the term neural manufacturing to describe such applications. This paper describes our use of artificial neural networks to improve the monitoring and control of semiconductor process.

Intelligent monitoring and control of semiconductor manufacturing equipment

NASA Technical Reports Server (NTRS)

Murdock, Janet L.; Hayes-Roth, Barbara

1991-01-01

The use of AI methods to monitor and control semiconductor fabrication in a state-of-the-art manufacturing environment called the Rapid Thermal Multiprocessor is described. Semiconductor fabrication involves many complex processing steps with limited opportunities to measure process and product properties. By applying additional process and product knowledge to that limited data, AI methods augment classical control methods by detecting abnormalities and trends, predicting failures, diagnosing, planning corrective action sequences, explaining diagnoses or predictions, and reacting to anomalous conditions that classical control systems typically would not correct. Research methodology and issues are discussed, and two diagnosis scenarios are examined.

40 CFR 63.104 - Heat exchange system requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

... Standards for Organic Hazardous Air Pollutants From the Synthetic Organic Chemical Manufacturing Industry... subpart shall monitor each heat exchange system used to cool process equipment in a chemical manufacturing process unit meeting the conditions of § 63.100 (b)(1) through (b)(3) of this subpart, except for chemical...

40 CFR 63.104 - Heat exchange system requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

... Standards for Organic Hazardous Air Pollutants From the Synthetic Organic Chemical Manufacturing Industry... subpart shall monitor each heat exchange system used to cool process equipment in a chemical manufacturing process unit meeting the conditions of § 63.100 (b)(1) through (b)(3) of this subpart, except for chemical...

40 CFR 63.104 - Heat exchange system requirements.

Code of Federal Regulations, 2014 CFR

2014-07-01

... Standards for Organic Hazardous Air Pollutants From the Synthetic Organic Chemical Manufacturing Industry... subpart shall monitor each heat exchange system used to cool process equipment in a chemical manufacturing process unit meeting the conditions of § 63.100 (b)(1) through (b)(3) of this subpart, except for chemical...

Big Data Analysis of Manufacturing Processes

NASA Astrophysics Data System (ADS)

Windmann, Stefan; Maier, Alexander; Niggemann, Oliver; Frey, Christian; Bernardi, Ansgar; Gu, Ying; Pfrommer, Holger; Steckel, Thilo; Krüger, Michael; Kraus, Robert

2015-11-01

The high complexity of manufacturing processes and the continuously growing amount of data lead to excessive demands on the users with respect to process monitoring, data analysis and fault detection. For these reasons, problems and faults are often detected too late, maintenance intervals are chosen too short and optimization potential for higher output and increased energy efficiency is not sufficiently used. A possibility to cope with these challenges is the development of self-learning assistance systems, which identify relevant relationships by observation of complex manufacturing processes so that failures, anomalies and need for optimization are automatically detected. The assistance system developed in the present work accomplishes data acquisition, process monitoring and anomaly detection in industrial and agricultural processes. The assistance system is evaluated in three application cases: Large distillation columns, agricultural harvesting processes and large-scale sorting plants. In this paper, the developed infrastructures for data acquisition in these application cases are described as well as the developed algorithms and initial evaluation results.

Three-Axis Distributed Fiber Optic Strain Measurement in 3D Woven Composite Structures

NASA Technical Reports Server (NTRS)

Castellucci, Matt; Klute, Sandra; Lally, Evan M.; Froggatt, Mark E.; Lowry, David

2013-01-01

Recent advancements in composite materials technologies have broken further from traditional designs and require advanced instrumentation and analysis capabilities. Success or failure is highly dependent on design analysis and manufacturing processes. By monitoring smart structures throughout manufacturing and service life, residual and operational stresses can be assessed and structural integrity maintained. Composite smart structures can be manufactured by integrating fiber optic sensors into existing composite materials processes such as ply layup, filament winding and three-dimensional weaving. In this work optical fiber was integrated into 3D woven composite parts at a commercial woven products manufacturing facility. The fiber was then used to monitor the structures during a VARTM manufacturing process, and subsequent static and dynamic testing. Low cost telecommunications-grade optical fiber acts as the sensor using a high resolution commercial Optical Frequency Domain Reflectometer (OFDR) system providing distributed strain measurement at spatial resolutions as low as 2mm. Strain measurements using the optical fiber sensors are correlated to resistive strain gage measurements during static structural loading. Keywords: fiber optic, distributed strain sensing, Rayleigh scatter, optical frequency domain reflectometry

Laser beam welding quality monitoring system based in high-speed (10 kHz) uncooled MWIR imaging sensors

NASA Astrophysics Data System (ADS)

Linares, Rodrigo; Vergara, German; Gutiérrez, Raúl; Fernández, Carlos; Villamayor, Víctor; Gómez, Luis; González-Camino, Maria; Baldasano, Arturo; Castro, G.; Arias, R.; Lapido, Y.; Rodríguez, J.; Romero, Pablo

2015-05-01

The combination of flexibility, productivity, precision and zero-defect manufacturing in future laser-based equipment are a major challenge that faces this enabling technology. New sensors for online monitoring and real-time control of laserbased processes are necessary for improving products quality and increasing manufacture yields. New approaches to fully automate processes towards zero-defect manufacturing demand smarter heads where lasers, optics, actuators, sensors and electronics will be integrated in a unique compact and affordable device. Many defects arising in laser-based manufacturing processes come from instabilities in the dynamics of the laser process. Temperature and heat dynamics are key parameters to be monitored. Low cost infrared imagers with high-speed of response will constitute the next generation of sensors to be implemented in future monitoring and control systems for laser-based processes, capable to provide simultaneous information about heat dynamics and spatial distribution. This work describes the result of using an innovative low-cost high-speed infrared imager based on the first quantum infrared imager monolithically integrated with Si-CMOS ROIC of the market. The sensor is able to provide low resolution images at frame rates up to 10 KHz in uncooled operation at the same cost as traditional infrared spot detectors. In order to demonstrate the capabilities of the new sensor technology, a low-cost camera was assembled on a standard production laser welding head, allowing to register melting pool images at frame rates of 10 kHz. In addition, a specific software was developed for defect detection and classification. Multiple laser welding processes were recorded with the aim to study the performance of the system and its application to the real-time monitoring of laser welding processes. During the experiments, different types of defects were produced and monitored. The classifier was fed with the experimental images obtained. Self-learning strategies were implemented with very promising results, demonstrating the feasibility of using low-cost high-speed infrared imagers in advancing towards a real-time / in-line zero-defect production systems.

Nuclear Weapons: NNSA Needs to Establish a Cost and Schedule Baseline for Manufacturing a Critical Nuclear Weapon Component

DTIC Science & Technology

2008-05-01

building up to and beyond the 2013 time frame. However, in October 2007, the Defense Nuclear Facilities Safety Board, which monitors safety...manufacturing. They said that NNSA is still working through this process with the Defense Nuclear Facilities Safety Board. Processing of waste

Tribology symposium -- 1994. PD-Volume 61

DOE Office of Scientific and Technical Information (OSTI.GOV)

Masudi, H.

This year marks the first Tribology Symposium within the Energy-Sources Technology Conference, sponsored by the ASME Petroleum Division. The program was divided into five sessions: Tribology in High Technology, a historical discussion of some watershed events in tribology; Research/Development, design, research and development on modern manufacturing; Tribology in Manufacturing, the impact of tribology on modern manufacturing; Design/Design Representation, aspects of design related to tribological systems; and Failure Analysis, an analysis of failure, failure detection, and failure monitoring as relating to manufacturing processes. Eleven papers have been processed separately for inclusion on the data base.

40 CFR 60.473 - Monitoring of operations.

Code of Federal Regulations, 2013 CFR

2013-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Asphalt Processing and Asphalt Roofing Manufacture § 60.473 Monitoring of operations. (a) The owner or operator...

40 CFR 60.473 - Monitoring of operations.

Code of Federal Regulations, 2012 CFR

2012-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Asphalt Processing and Asphalt Roofing Manufacture § 60.473 Monitoring of operations. (a) The owner or operator...

40 CFR 60.473 - Monitoring of operations.

Code of Federal Regulations, 2014 CFR

2014-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Asphalt Processing and Asphalt Roofing Manufacture § 60.473 Monitoring of operations. (a) The owner or operator...

[Chinese medicine industry 4.0：advancing digital pharmaceutical manufacture toward intelligent pharmaceutical manufacture].

PubMed

Cheng, Yi-Yu; Qu, Hai-Bin; Zhang, Bo-Li

2016-01-01

A perspective analysis on the technological innovation in pharmaceutical engineering of Chinese medicine unveils a vision on "Future Factory" of Chinese medicine industry in mind. The strategy as well as the technical roadmap of "Chinese medicine industry 4.0" is proposed, with the projection of related core technology system. It is clarified that the technical development path of Chinese medicine industry from digital manufacture to intelligent manufacture. On the basis of precisely defining technical terms such as process control, on-line detection and process quality monitoring for Chinese medicine manufacture, the technical concepts and characteristics of intelligent pharmaceutical manufacture as well as digital pharmaceutical manufacture are elaborated. Promoting wide applications of digital manufacturing technology of Chinese medicine is strongly recommended. Through completely informationized manufacturing processes and multi-discipline cluster innovation, intelligent manufacturing technology of Chinese medicine should be developed, which would provide a new driving force for Chinese medicine industry in technology upgrade, product quality enhancement and efficiency improvement. Copyright© by the Chinese Pharmaceutical Association.

Evaluation of risk and benefit in thermal effusivity sensor for monitoring lubrication process in pharmaceutical product manufacturing.

PubMed

Uchiyama, Jumpei; Kato, Yoshiteru; Uemoto, Yoshifumi

2014-08-01

In the process design of tablet manufacturing, understanding and control of the lubrication process is important from various viewpoints. A detailed analysis of thermal effusivity data in the lubrication process was conducted in this study. In addition, we evaluated the risk and benefit in the lubrication process by a detailed investigation. It was found that monitoring of thermal effusivity detected mainly the physical change of bulk density, which was changed by dispersal of the lubricant and the coating powder particle by the lubricant. The monitoring of thermal effusivity was almost the monitoring of bulk density, thermal effusivity could have a high correlation with tablet hardness. Moreover, as thermal effusivity sensor could detect not only the change of the conventional bulk density but also the fractional change of thermal conductivity and thermal capacity, two-phase progress of lubrication process could be revealed. However, each contribution of density, thermal conductivity, or heat capacity to thermal effusivity has the risk of fluctuation by formulation. After carefully considering the change factor with the risk to be changed by formulation, thermal effusivity sensor can be a useful tool for monitoring as process analytical technology, estimating tablet hardness and investigating the detailed mechanism of the lubrication process.

40 CFR 63.11940 - What continuous monitoring requirements must I meet for control devices required to install CPMS...

Code of Federal Regulations, 2012 CFR

2012-07-01

... consistent with the manufacturer's recommendations within 15 days or by the next time any process vent stream... the manufacturer's recommendations within 15 days or by the next time any process vent stream is...) Determine gas stream flow using the design blower capacity, with appropriate adjustments for pressure drop...

40 CFR 761.185 - Certification program and retention of records by importers and persons generating PCBs in...

Code of Federal Regulations, 2010 CFR

2010-07-01

... manufacturing processes in which PCBs are generated when the PCB level in products leaving any manufacturing... imported products when the PCB concentration of products being imported is greater than 2 µg/g for any... process waste disposal. (2) Whether determinations of compliance are based on actual monitoring of PCB...

Mechanical impedance measurements for improved cost-effective process monitoring

NASA Astrophysics Data System (ADS)

Clopet, Caroline R.; Pullen, Deborah A.; Badcock, Rodney A.; Ralph, Brian; Fernando, Gerard F.; Mahon, Steve W.

1999-06-01

The aerospace industry has seen a considerably growth in composite usage over the past ten years, especially with the development of cost effective manufacturing techniques such as Resin Transfer Molding and Resin Infusion under Flexible Tooling. The relatively high cost of raw material and conservative processing schedules has limited their growth further in non-aerospace technologies. In-situ process monitoring has been explored for some time as a means to improving the cost efficiency of manufacturing with dielectric spectroscopy and optical fiber sensors being the two primary techniques developed to date. A new emerging technique is discussed here making use of piezoelectric wafers with the ability to sense not only aspects of resin flow but also to detect the change in properties of the resin as it cures. Experimental investigations to date have shown a correlation between mechanical impedance measurements and the mechanical properties of cured epoxy systems with potential for full process monitoring.

Advances in industrial biopharmaceutical batch process monitoring: Machine-learning methods for small data problems.

PubMed

Tulsyan, Aditya; Garvin, Christopher; Ündey, Cenk

2018-04-06

Biopharmaceutical manufacturing comprises of multiple distinct processing steps that require effective and efficient monitoring of many variables simultaneously in real-time. The state-of-the-art real-time multivariate statistical batch process monitoring (BPM) platforms have been in use in recent years to ensure comprehensive monitoring is in place as a complementary tool for continued process verification to detect weak signals. This article addresses a longstanding, industry-wide problem in BPM, referred to as the "Low-N" problem, wherein a product has a limited production history. The current best industrial practice to address the Low-N problem is to switch from a multivariate to a univariate BPM, until sufficient product history is available to build and deploy a multivariate BPM platform. Every batch run without a robust multivariate BPM platform poses risk of not detecting potential weak signals developing in the process that might have an impact on process and product performance. In this article, we propose an approach to solve the Low-N problem by generating an arbitrarily large number of in silico batches through a combination of hardware exploitation and machine-learning methods. To the best of authors' knowledge, this is the first article to provide a solution to the Low-N problem in biopharmaceutical manufacturing using machine-learning methods. Several industrial case studies from bulk drug substance manufacturing are presented to demonstrate the efficacy of the proposed approach for BPM under various Low-N scenarios. © 2018 Wiley Periodicals, Inc.

Tool path strategy and cutting process monitoring in intelligent machining

NASA Astrophysics Data System (ADS)

Chen, Ming; Wang, Chengdong; An, Qinglong; Ming, Weiwei

2018-06-01

Intelligent machining is a current focus in advanced manufacturing technology, and is characterized by high accuracy and efficiency. A central technology of intelligent machining—the cutting process online monitoring and optimization—is urgently needed for mass production. In this research, the cutting process online monitoring and optimization in jet engine impeller machining, cranio-maxillofacial surgery, and hydraulic servo valve deburring are introduced as examples of intelligent machining. Results show that intelligent tool path optimization and cutting process online monitoring are efficient techniques for improving the efficiency, quality, and reliability of machining.

Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision

NASA Astrophysics Data System (ADS)

Xiong, Jun; Zhang, Guangjun

2013-11-01

Additive manufacturing based on gas metal arc welding is an advanced technique for depositing fully dense components with low cost. Despite this fact, techniques to achieve accurate control and automation of the process have not yet been perfectly developed. The online measurement of the deposited bead geometry is a key problem for reliable control. In this work a passive vision-sensing system, comprising two cameras and composite filtering techniques, was proposed for real-time detection of the bead height and width through deposition of thin walls. The nozzle to the top surface distance was monitored for eliminating accumulated height errors during the multi-layer deposition process. Various image processing algorithms were applied and discussed for extracting feature parameters. A calibration procedure was presented for the monitoring system. Validation experiments confirmed the effectiveness of the online measurement system for bead geometry in layered additive manufacturing.

In-situ cure monitoring of isocyanate adhesives using microdielectric analysis

Treesearch

Micahel P. Wolcott; Timothy G. Rials

1995-01-01

Recent advances in microelectronics have produced small electrodes that can be used for remote dielectric measurements. These miniature sensors are small enough to be embedded in a composite panel during manufacture with little disturbance to the manufacturing process. Small particleboard panels (5 by 4.5 by 0.25 in.) were manufactured with 6 percent polymeric...

In-situ cure monitoring of isocyanate adhesives using microdielectric analysis

Treesearch

Michael P. Wolcott; Timothy G. Rials

1995-01-01

Recent advances in microelectronics have produced small electrodes that can be used for remote dielectric measurements. These miniature sensors are small enought to be embedded in a composite panel during manufacture with little disturbance to the manufacturing process. Small particleboard panels (5 by 4.5 by 0.25 in) were manufactured with 6 percent polymeric...

[Research on optimal modeling strategy for licorice extraction process based on near-infrared spectroscopy technology].

PubMed

Wang, Hai-Xia; Suo, Tong-Chuan; Yu, He-Shui; Li, Zheng

2016-10-01

The manufacture of traditional Chinese medicine (TCM) products is always accompanied by processing complex raw materials and real-time monitoring of the manufacturing process. In this study, we investigated different modeling strategies for the extraction process of licorice. Near-infrared spectra associate with the extraction time was used to detemine the states of the extraction processes. Three modeling approaches, i.e., principal component analysis (PCA), partial least squares regression (PLSR) and parallel factor analysis-PLSR (PARAFAC-PLSR), were adopted for the prediction of the real-time status of the process. The overall results indicated that PCA, PLSR and PARAFAC-PLSR can effectively detect the errors in the extraction procedure and predict the process trajectories, which has important significance for the monitoring and controlling of the extraction processes. Copyright© by the Chinese Pharmaceutical Association.

40 CFR 63.8690 - How do I monitor and collect data to demonstrate continuous compliance?

Code of Federal Regulations, 2011 CFR

2011-07-01

... SOURCE CATEGORIES (CONTINUED) National Emission Standards for Hazardous Air Pollutants: Asphalt Processing and Asphalt Roofing Manufacturing Continuous Compliance Requirements § 63.8690 How do I monitor...

40 CFR 63.8690 - How do I monitor and collect data to demonstrate continuous compliance?

Code of Federal Regulations, 2012 CFR

2012-07-01

... SOURCE CATEGORIES (CONTINUED) National Emission Standards for Hazardous Air Pollutants: Asphalt Processing and Asphalt Roofing Manufacturing Continuous Compliance Requirements § 63.8690 How do I monitor...

40 CFR 63.8690 - How do I monitor and collect data to demonstrate continuous compliance?

Code of Federal Regulations, 2014 CFR

2014-07-01

... SOURCE CATEGORIES (CONTINUED) National Emission Standards for Hazardous Air Pollutants: Asphalt Processing and Asphalt Roofing Manufacturing Continuous Compliance Requirements § 63.8690 How do I monitor...

40 CFR 63.8690 - How do I monitor and collect data to demonstrate continuous compliance?

Code of Federal Regulations, 2013 CFR

2013-07-01

... SOURCE CATEGORIES (CONTINUED) National Emission Standards for Hazardous Air Pollutants: Asphalt Processing and Asphalt Roofing Manufacturing Continuous Compliance Requirements § 63.8690 How do I monitor...

3D printed fluidics with embedded analytic functionality for automated reaction optimisation

PubMed Central

Capel, Andrew J; Wright, Andrew; Harding, Matthew J; Weaver, George W; Li, Yuqi; Harris, Russell A; Edmondson, Steve; Goodridge, Ruth D

2017-01-01

Additive manufacturing or ‘3D printing’ is being developed as a novel manufacturing process for the production of bespoke micro- and milliscale fluidic devices. When coupled with online monitoring and optimisation software, this offers an advanced, customised method for performing automated chemical synthesis. This paper reports the use of two additive manufacturing processes, stereolithography and selective laser melting, to create multifunctional fluidic devices with embedded reaction monitoring capability. The selectively laser melted parts are the first published examples of multifunctional 3D printed metal fluidic devices. These devices allow high temperature and pressure chemistry to be performed in solvent systems destructive to the majority of devices manufactured via stereolithography, polymer jetting and fused deposition modelling processes previously utilised for this application. These devices were integrated with commercially available flow chemistry, chromatographic and spectroscopic analysis equipment, allowing automated online and inline optimisation of the reaction medium. This set-up allowed the optimisation of two reactions, a ketone functional group interconversion and a fused polycyclic heterocycle formation, via spectroscopic and chromatographic analysis. PMID:28228852

Automatic visual monitoring of welding procedure in stainless steel kegs

NASA Astrophysics Data System (ADS)

Leo, Marco; Del Coco, Marco; Carcagnì, Pierluigi; Spagnolo, Paolo; Mazzeo, Pier Luigi; Distante, Cosimo; Zecca, Raffaele

2018-05-01

In this paper a system for automatic visual monitoring of welding process, in dry stainless steel kegs for food storage, is proposed. In the considered manufacturing process the upper and lower skirts are welded to the vessel by means of Tungsten Inert Gas (TIG) welding. During the process several problems can arise: 1) residuals on the bottom 2) darker weld 3) excessive/poor penetration and 4) outgrowths. The proposed system deals with all the four aforementioned problems and its inspection performances have been evaluated by using a large set of kegs demonstrating both the reliability in terms of defect detection and the suitability to be introduced in the manufacturing system in terms of computational costs.

Computational manufacturing as a bridge between design and production.

PubMed

Tikhonravov, Alexander V; Trubetskov, Michael K

2005-11-10

Computational manufacturing of optical coatings is a research area that can be placed between theoretical designing and practical manufacturing in the same way that computational physics can be placed between theoretical and experimental physics. Investigations in this area have been performed for more than 30 years under the name of computer simulation of manufacturing and monitoring processes. Our goal is to attract attention to the increasing importance of computational manufacturing at the current state of the art in the design and manufacture of optical coatings and to demonstrate possible applications of this research tool.

Computational manufacturing as a bridge between design and production

NASA Astrophysics Data System (ADS)

Tikhonravov, Alexander V.; Trubetskov, Michael K.

2005-11-01

Computational manufacturing of optical coatings is a research area that can be placed between theoretical designing and practical manufacturing in the same way that computational physics can be placed between theoretical and experimental physics. Investigations in this area have been performed for more than 30 years under the name of computer simulation of manufacturing and monitoring processes. Our goal is to attract attention to the increasing importance of computational manufacturing at the current state of the art in the design and manufacture of optical coatings and to demonstrate possible applications of this research tool.

40 CFR 63.7188 - What are my monitoring installation, operation, and maintenance requirements?

Code of Federal Regulations, 2011 CFR

2011-07-01

... Semiconductor Manufacturing Compliance Requirements § 63.7188 What are my monitoring installation, operation... emissions of your semiconductor process vent through a closed vent system to a control device, you must...

40 CFR 63.7188 - What are my monitoring installation, operation, and maintenance requirements?

Code of Federal Regulations, 2010 CFR

2010-07-01

... Semiconductor Manufacturing Compliance Requirements § 63.7188 What are my monitoring installation, operation... emissions of your semiconductor process vent through a closed vent system to a control device, you must...

Process monitoring and control with CHEMIN, a miniaturized CCD-based instrument for simultaneous XRD/XRF analysis

NASA Astrophysics Data System (ADS)

Vaniman, David T.; Bish, D.; Guthrie, G.; Chipera, S.; Blake, David E.; Collins, S. Andy; Elliott, S. T.; Sarrazin, P.

1999-10-01

There is a large variety of mining and manufacturing operations where process monitoring and control can benefit from on-site analysis of both chemical and mineralogic constituents. CHEMIN is a CCD-based instrument capable of both X-ray fluorescence (XRF; chemical) and X-ray diffraction (XRD; mineralogic) analysis. Monitoring and control with an instrument like CHEMIN can be applied to feedstocks, intermediate materials, and final products to optimize production. Examples include control of cement feedstock, of ore for smelting, and of minerals that pose inhalation hazards in the workplace. The combined XRD/XRF capability of CHEMIN can be used wherever a desired commodity is associated with unwanted constituents that may be similar in chemistry or structure but not both (e.g., Ca in both gypsum and feldspar, where only the gypsum is desired to make wallboard). In the mining industry, CHEMIN can determine mineral abundances on the spot and enable more economical mining by providing the means to assay when is being mined, quickly and frequently, at minimal cost. In manufacturing, CHEMIN could be used to spot-check the chemical composition and crystalline makeup of a product at any stage of production. Analysis by CHEMIN can be used as feedback in manufacturing processes where rates of heating, process temperature, mixture of feedstocks, and other variables must be adjusted in real time to correct structure and/or chemistry of the product (e.g., prevention of periclase and alkali sulfate coproduction in cement manufacture).

Real-time nondestructive monitoring of the gas tungsten arc welding (GTAW) process by combined airborne acoustic emission and non-contact ultrasonics

NASA Astrophysics Data System (ADS)

Zhang, Lu; Basantes-Defaz, Alexandra-Del-Carmen; Abbasi, Zeynab; Yuhas, Donald; Ozevin, Didem; Indacochea, Ernesto

2018-03-01

Welding is a key manufacturing process for many industries and may introduce defects into the welded parts causing significant negative impacts, potentially ruining high-cost pieces. Therefore, a real-time process monitoring method is important to implement for avoiding producing a low-quality weld. Due to high surface temperature and possible contamination of surface by contact transducers, the welding process should be monitored via non-contact transducers. In this paper, airborne acoustic emission (AE) transducers tuned at 60 kHz and non-contact ultrasonic testing (UT) transducers tuned at 500 kHz are implemented for real time weld monitoring. AE is a passive nondestructive evaluation method that listens for the process noise, and provides information about the uniformity of manufacturing process. UT provides more quantitative information about weld defects. One of the most common weld defects as burn-through is investigated. The influences of weld defects on AE signatures (time-driven data) and UT signals (received signal energy, change in peak frequency) are presented. The level of burn-through damage is defined by using single method or combine AE/UT methods.

Thermographic Microstructure Monitoring in Electron Beam Additive Manufacturing.

PubMed

Raplee, J; Plotkowski, A; Kirka, M M; Dinwiddie, R; Okello, A; Dehoff, R R; Babu, S S

2017-03-03

To reduce the uncertainty of build performance in metal additive manufacturing, robust process monitoring systems that can detect imperfections and improve repeatability are desired. One of the most promising methods for in situ monitoring is thermographic imaging. However, there is a challenge in using this technology due to the difference in surface emittance between the metal powder and solidified part being observed that affects the accuracy of the temperature data collected. The purpose of the present study was to develop a method for properly calibrating temperature profiles from thermographic data to account for this emittance change and to determine important characteristics of the build through additional processing. The thermographic data was analyzed to identify the transition of material from metal powder to a solid as-printed part. A corrected temperature profile was then assembled for each point using calibrations for these surface conditions. Using this data, the thermal gradient and solid-liquid interface velocity were approximated and correlated to experimentally observed microstructural variation within the part. This work shows that by using a method of process monitoring, repeatability of a build could be monitored specifically in relation to microstructure control.

Thermographic Microstructure Monitoring in Electron Beam Additive Manufacturing

DOE PAGES

Raplee, Jake B.; Plotkowski, Alex J.; Kirka, Michael M.; ...

2017-03-03

To reduce the uncertainty of build performance in metal additive manufacturing, robust process monitoring systems that can detect imperfections and improve repeatability are desired. One of the most promising methods for in-situ monitoring is thermographic imaging. However, there is a challenge in using this technology due to the difference in surface emittance between the metal powder and solidified part being observed that affects the accuracy of the temperature data collected. This developed a method for properly calibrating temperature profiles from thermographic data and then determining important characteristics of the build through additional processing. The thermographic data was analyzed to determinemore » the transition of material from metal powder to a solid as-printed part. A corrected temperature profile was then assembled for each point using calibrations for these surface conditions. Using this data, we calculated the thermal gradient and solid-liquid interface velocity and correlated it to microstructural variation within the part experimentally. This work shows that by using a method of process monitoring, repeatability of a build could be monitored specifically in relation to microstructure control.« less

Survey Available Computer Software for Automated Production Planning and Inventory Control, and Software and Hardware for Data Logging and Monitoring Shop Floor Activities

DTIC Science & Technology

1993-08-01

pricing and sales, order processing , and purchasing. The class of manufacturing planning functions include aggregate production planning, materials...level. I Depending on the application, each control level will have a number of functions associated with it. For instance, order processing , purchasing...include accounting, sales forecasting, product costing, pricing and sales, order processing , and purchasing. The class of manufacturing planning functions

A DMAIC approach for process capability improvement an engine crankshaft manufacturing process

NASA Astrophysics Data System (ADS)

Sharma, G. V. S. S.; Rao, P. Srinivasa

2014-05-01

The define-measure-analyze-improve-control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index ( C P) values improved from 1.29 to 2.02 and the process performance capability index ( C PK) values improved from 0.32 to 1.45, respectively.

Process tool monitoring and matching using interferometry technique

NASA Astrophysics Data System (ADS)

Anberg, Doug; Owen, David M.; Mileham, Jeffrey; Lee, Byoung-Ho; Bouche, Eric

2016-03-01

The semiconductor industry makes dramatic device technology changes over short time periods. As the semiconductor industry advances towards to the 10 nm device node, more precise management and control of processing tools has become a significant manufacturing challenge. Some processes require multiple tool sets and some tools have multiple chambers for mass production. Tool and chamber matching has become a critical consideration for meeting today's manufacturing requirements. Additionally, process tools and chamber conditions have to be monitored to ensure uniform process performance across the tool and chamber fleet. There are many parameters for managing and monitoring tools and chambers. Particle defect monitoring is a well-known and established example where defect inspection tools can directly detect particles on the wafer surface. However, leading edge processes are driving the need to also monitor invisible defects, i.e. stress, contamination, etc., because some device failures cannot be directly correlated with traditional visualized defect maps or other known sources. Some failure maps show the same signatures as stress or contamination maps, which implies correlation to device performance or yield. In this paper we present process tool monitoring and matching using an interferometry technique. There are many types of interferometry techniques used for various process monitoring applications. We use a Coherent Gradient Sensing (CGS) interferometer which is self-referencing and enables high throughput measurements. Using this technique, we can quickly measure the topography of an entire wafer surface and obtain stress and displacement data from the topography measurement. For improved tool and chamber matching and reduced device failure, wafer stress measurements can be implemented as a regular tool or chamber monitoring test for either unpatterned or patterned wafers as a good criteria for improved process stability.

Overview of PAT process analysers applicable in monitoring of film coating unit operations for manufacturing of solid oral dosage forms.

PubMed

Korasa, Klemen; Vrečer, Franc

2018-01-01

Over the last two decades, regulatory agencies have demanded better understanding of pharmaceutical products and processes by implementing new technological approaches, such as process analytical technology (PAT). Process analysers present a key PAT tool, which enables effective process monitoring, and thus improved process control of medicinal product manufacturing. Process analysers applicable in pharmaceutical coating unit operations are comprehensibly described in the present article. The review is focused on monitoring of solid oral dosage forms during film coating in two most commonly used coating systems, i.e. pan and fluid bed coaters. Brief theoretical background and critical overview of process analysers used for real-time or near real-time (in-, on-, at- line) monitoring of critical quality attributes of film coated dosage forms are presented. Besides well recognized spectroscopic methods (NIR and Raman spectroscopy), other techniques, which have made a significant breakthrough in recent years, are discussed (terahertz pulsed imaging (TPI), chord length distribution (CLD) analysis, and image analysis). Last part of the review is dedicated to novel techniques with high potential to become valuable PAT tools in the future (optical coherence tomography (OCT), acoustic emission (AE), microwave resonance (MR), and laser induced breakdown spectroscopy (LIBS)). Copyright © 2017 Elsevier B.V. All rights reserved.

Nickel-hydrogen capacity loss on storage

NASA Technical Reports Server (NTRS)

Manzo, Michelle A.

1989-01-01

A controlled experiment evaluating the capacity loss experienced by nickel electrodes stored under various conditions of temperature, hydrogen pressure, and electrolyte concentration was conducted using nickel electrodes from four different manufacturers. It was found that capacity loss varied with respect to hydrogen pressure, and storage temperature as well as with respect to electrode manufacturing processes. Impedance characteristics were monitored and found to be indicative of electrode manufacturing processes and capacity loss. Cell testing to evaluate state-of-charge effects on capacity loss were inconclusive as no loss was sustained by the cells tested in this experiment.

40 CFR 63.8690 - How do I monitor and collect data to demonstrate continuous compliance?

Code of Federal Regulations, 2010 CFR

2010-07-01

... Processing and Asphalt Roofing Manufacturing Continuous Compliance Requirements § 63.8690 How do I monitor... emission or operating levels, nor may such data be used in fulfilling a minimum data availability...

Application of pulsed-field gel electrophoresis to characterise and trace the prevalence of Enterobacter sakazakii in an infant formula processing facility.

PubMed

Mullane, N R; Whyte, P; Wall, P G; Quinn, T; Fanning, S

2007-05-01

Enterobacter sakazakii (E. sakazakii) contamination of powdered infant formula (PIF) and its processing environment was monitored between April 2005 and March 2006. The purpose of the monitoring programme was to locate points of contamination, investigate clonal persistence, and identify possible dissemination routes along the processing chain. A total of 80 E. sakazakii isolates were recovered from the manufacturing facility. The overall frequency of isolation of E. sakazakii in intermediate and final product was 2.5%, while specific locations in the processing environment were contaminated at frequencies up to 31%. All E. sakazakii isolates were characterised by pulsed-field gel electrophoresis (PFGE). XbaI macrorestriction digests yielded 19 unique pulse-types that could be grouped into 6 clusters of between 5 and 32 isolates. The formation of large clusters was consistent with the presence of a number of clones in the manufacturing environment. While the majority of isolates were of environmental origin (72.5%), no cluster was confined to one specific location and indistinguishable PFGE profiles were generated from isolates cultured from the manufacturing environment, sampling points along the processing chain and from intermediate and final product. These findings suggest that the manufacturing environment serves as a key route for sporadic contamination of PIF. These data will support the development of efficient intervention measures contributing to the reduction of E. sakazakii in the PIF processing chain.

Tribology symposium 1995. PD-Volume 72

DOE Office of Scientific and Technical Information (OSTI.GOV)

Masudi, H.

After the keynote presentation by Professor Aaron Cohen of Texas A and M University, entitled Processes Used in Design, the program is divided into five major sessions: Research and Development -- Recent research and development of tribological components; Tribology in Manufacturing -- The impact of tribology on modern manufacturing; Design/Design Representation -- Aspects of design related to tribological systems; Tribo-Chemistry/Tribo-Physics -- Discussion of chemical and physical behavior of substances as related to tribology; and Failure Analysis -- An analysis of failure, failure detection, and failure monitoring as related to manufacturing processes. Papers have been processed separately for inclusion on themore » data base.« less

Applicability of near-infrared spectroscopy in the monitoring of film coating and curing process of the prolonged release coated pellets.

PubMed

Korasa, Klemen; Hudovornik, Grega; Vrečer, Franc

2016-10-10

Although process analytical technology (PAT) guidance has been introduced to the pharmaceutical industry just a decade ago, this innovative approach has already become an important part of efficient pharmaceutical development, manufacturing, and quality assurance. PAT tools are especially important in technologically complex operations which require strict control of critical process parameters and have significant effect on final product quality. Manufacturing of prolonged release film coated pellets is definitely one of such processes. The aim of the present work was to study the applicability of the at-line near-infrared spectroscopy (NIR) approach in the monitoring of pellet film coating and curing steps. Film coated pellets were manufactured by coating the active ingredient containing pellets with film coating based on polymethacrylate polymers (Eudragit® RS/RL). The NIR proved as a useful tool for the monitoring of the curing process since it was able to determine the extent of the curing and hence predict drug release rate by using partial least square (PLS) model. However, such approach also showed a number of limitations, such as low reliability and high susceptibility to pellet moisture content, and was thus not able to predict drug release from pellets with high moisture content. On the other hand, the at-line NIR was capable to predict the thickness of Eudragit® RS/RL film coating in a wide range (up to 40μm) with good accuracy even in the pellets with high moisture content. To sum up, high applicability of the at-line NIR in the monitoring of the prolonged release pellets production was demonstrated in the present study. The present findings may contribute to more efficient and reliable PAT solutions in the manufacturing of prolonged release dosage forms. Copyright © 2016 Elsevier B.V. All rights reserved.

76 FR 46269 - Notice of Petitions by Firms for Determination of Eligibility To Apply for Trade Adjustment...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-08-02

... novel, simple to use automation and process monitoring products for industrial customers. Methods.... Nursery Supplies, Inc........ 1415 Orchard Drive, 26-Jul-11 The firm manufactures plastic containers... containers. Technautic International, 141 Robert E. Lee 22-Jul-11 The firm manufactures automated dissolved...

Automated plasma control with optical emission spectroscopy

NASA Astrophysics Data System (ADS)

Ward, P. P.

Plasma etching and desmear processes for printed wiring board (PWB) manufacture are difficult to predict and control. Non-uniformity of most plasma processes and sensitivity to environmental changes make it difficult to maintain process stability from day to day. To assure plasma process performance, weight loss coupons or post-plasma destructive testing must be used. These techniques are not real-time methods however, and do not allow for immediate diagnosis and process correction. These tests often require scrapping some fraction of a batch to insure the integrity of the rest. Since these tests verify a successful cycle with post-plasma diagnostics, poor test results often determine that a batch is substandard and the resulting parts unusable. These tests are a costly part of the overall fabrication cost. A more efficient method of testing would allow for constant monitoring of plasma conditions and process control. Process anomalies should be detected and corrected before the parts being treated are damaged. Real time monitoring would allow for instantaneous corrections. Multiple site monitoring would allow for process mapping within one system or simultaneous monitoring of multiple systems. Optical emission spectroscopy conducted external to the plasma apparatus would allow for this sort of multifunctional analysis without perturbing the glow discharge. In this paper, optical emission spectroscopy for non-intrusive, in situ process control will be explored along with applications of this technique to for process control, failure analysis and endpoint determination in PWB manufacture.

Regulatory Perspectives on Continuous Pharmaceutical Manufacturing: Moving From Theory to Practice: September 26-27, 2016, International Symposium on the Continuous Manufacturing of Pharmaceuticals.

PubMed

Nasr, Moheb M; Krumme, Markus; Matsuda, Yoshihiro; Trout, Bernhardt L; Badman, Clive; Mascia, Salvatore; Cooney, Charles L; Jensen, Keith D; Florence, Alastair; Johnston, Craig; Konstantinov, Konstantin; Lee, Sau L

2017-11-01

Continuous manufacturing plays a key role in enabling the modernization of pharmaceutical manufacturing. The fate of this emerging technology will rely, in large part, on the regulatory implementation of this novel technology. This paper, which is based on the 2nd International Symposium on the Continuous Manufacturing of Pharmaceuticals, describes not only the advances that have taken place since the first International Symposium on Continuous Manufacturing of Pharmaceuticals in 2014, but the regulatory landscape that exists today. Key regulatory concepts including quality risk management, batch definition, control strategy, process monitoring and control, real-time release testing, data processing and management, and process validation/verification are outlined. Support from regulatory agencies, particularly in the form of the harmonization of regulatory expectations, will be crucial to the successful implementation of continuous manufacturing. Collaborative efforts, among academia, industry, and regulatory agencies, are the optimal solution for ensuring a solid future for this promising manufacturing technology. Copyright © 2017 American Pharmacists Association®. All rights reserved.

A Roadmap for the Implementation of Continued Process Verification.

PubMed

Boyer, Marcus; Gampfer, Joerg; Zamamiri, Abdel; Payne, Robin

2016-01-01

In 2014, the members of the BioPhorum Operations Group (BPOG) produced a 100-page continued process verification case study, entitled "Continued Process Verification: An Industry Position Paper with Example Protocol". This case study captures the thought processes involved in creating a continued process verification plan for a new product in response to the U.S. Food and Drug Administration's guidance on the subject introduced in 2011. In so doing, it provided the specific example of a plan developed for a new molecular antibody product based on the "A MAb Case Study" that preceded it in 2009.This document provides a roadmap that draws on the content of the continued process verification case study to provide a step-by-step guide in a more accessible form, with reference to a process map of the product life cycle. It could be used as a basis for continued process verification implementation in a number of different scenarios: For a single product and process;For a single site;To assist in the sharing of data monitoring responsibilities among sites;To assist in establishing data monitoring agreements between a customer company and a contract manufacturing organization. The U.S. Food and Drug Administration issued guidance on the management of manufacturing processes designed to improve quality and control of drug products. This involved increased focus on regular monitoring of manufacturing processes, reporting of the results, and the taking of opportunities to improve. The guidance and practice associated with it is known as continued process verification This paper summarizes good practice in responding to continued process verification guidance, gathered from subject matter experts in the biopharmaceutical industry. © PDA, Inc. 2016.

On-line application of near-infrared spectroscopy for monitoring water levels in parts per million in a manufacturing-scale distillation process.

PubMed

Lambertus, Gordon; Shi, Zhenqi; Forbes, Robert; Kramer, Timothy T; Doherty, Steven; Hermiller, James; Scully, Norma; Wong, Sze Wing; LaPack, Mark

2014-01-01

An on-line analytical method based on transmission near-infrared spectroscopy (NIRS) for the quantitative determination of water concentrations (in parts per million) was developed and applied to the manufacture of a pharmaceutical intermediate. Calibration models for water analysis, built at the development site and applied at the manufacturing site, were successfully demonstrated during six manufacturing runs at a 250-gallon scale. The water measurements will be used as a forward-processing control point following distillation of a toluene product solution prior to use in a Grignard reaction. The most significant impact of using this NIRS-based process analytical technology (PAT) to replace off-line measurements is the significant reduction in the risk of operator exposure through the elimination of sampling of a severely lachrymatory and mutagenic compound. The work described in this report illustrates the development effort from proof-of-concept phase to manufacturing implementation.

Monitoring of an antigen manufacturing process.

PubMed

Zavatti, Vanessa; Budman, Hector; Legge, Raymond; Tamer, Melih

2016-06-01

Fluorescence spectroscopy in combination with multivariate statistical methods was employed as a tool for monitoring the manufacturing process of pertactin (PRN), one of the virulence factors of Bordetella pertussis utilized in whopping cough vaccines. Fluorophores such as amino acids and co-enzymes were detected throughout the process. The fluorescence data collected at different stages of the fermentation and purification process were treated employing principal component analysis (PCA). Through PCA, it was feasible to identify sources of variability in PRN production. Then, partial least square (PLS) was employed to correlate the fluorescence spectra obtained from pure PRN samples and the final protein content measured by a Kjeldahl test from these samples. In view that a statistically significant correlation was found between fluorescence and PRN levels, this approach could be further used as a method to predict the final protein content.

Production of erythrocytes from directly isolated or Delta1 Notch ligand expanded CD34+ hematopoietic progenitor cells: process characterization, monitoring and implications for manufacture.

PubMed

Glen, Katie E; Workman, Victoria L; Ahmed, Forhad; Ratcliffe, Elizabeth; Stacey, Adrian J; Thomas, Robert J

2013-09-01

Economic ex vivo manufacture of erythrocytes at 10(12) cell doses requires an efficiently controlled bio-process capable of extensive proliferation and high terminal density. High-resolution characterization of the process would identify production strategies for increased efficiency, monitoring and control. CD34(+) cord blood cells or equivalent cells that had been pre-expanded for 7 days with Delta1 Notch ligand were placed in erythroid expansion and differentiation conditions in a micro-scale ambr suspension bioreactor. Multiple culture parameters were varied, and phenotype markers and metabolites measured to identify conserved trends and robust monitoring markers. The cells exhibited a bi-modal erythroid differentiation pattern with an erythroid marker peak after 2 weeks and 3 weeks of culture; differentiation was comparatively weighted toward the second peak in Delta1 pre-expanded cells. Both differentiation events were strengthened by omission of stem cell factor and dexamethasone. The cumulative cell proliferation and death, or directly measured CD45 expression, enabled monitoring of proliferative rate of the cells. The metabolic activities of the cultures (glucose, glutamine and ammonia consumption or production) were highly variable but exhibited systematic change synchronized with the change in differentiation state. Erythroid differentiation chronology is partly determined by the heterogeneous CD34(+) progenitor compartment with implications for input control; Delta1 ligand-mediated progenitor culture can alter differentiation profile with control benefits for engineering production strategy. Differentiation correlated changes in cytokine response, markers and metabolic state will enable scientifically designed monitoring and timing of manufacturing process steps. Copyright © 2013 International Society for Cellular Therapy. Published by Elsevier Inc. All rights reserved.

Thermographic Microstructure Monitoring in Electron Beam Additive Manufacturing

PubMed Central

Raplee, J.; Plotkowski, A.; Kirka, M. M.; Dinwiddie, R.; Okello, A.; Dehoff, R. R.; Babu, S. S.

2017-01-01

To reduce the uncertainty of build performance in metal additive manufacturing, robust process monitoring systems that can detect imperfections and improve repeatability are desired. One of the most promising methods for in situ monitoring is thermographic imaging. However, there is a challenge in using this technology due to the difference in surface emittance between the metal powder and solidified part being observed that affects the accuracy of the temperature data collected. The purpose of the present study was to develop a method for properly calibrating temperature profiles from thermographic data to account for this emittance change and to determine important characteristics of the build through additional processing. The thermographic data was analyzed to identify the transition of material from metal powder to a solid as-printed part. A corrected temperature profile was then assembled for each point using calibrations for these surface conditions. Using this data, the thermal gradient and solid-liquid interface velocity were approximated and correlated to experimentally observed microstructural variation within the part. This work shows that by using a method of process monitoring, repeatability of a build could be monitored specifically in relation to microstructure control. PMID:28256595

Microeconomics of process control in semiconductor manufacturing

NASA Astrophysics Data System (ADS)

Monahan, Kevin M.

2003-06-01

Process window control enables accelerated design-rule shrinks for both logic and memory manufacturers, but simple microeconomic models that directly link the effects of process window control to maximum profitability are rare. In this work, we derive these links using a simplified model for the maximum rate of profit generated by the semiconductor manufacturing process. We show that the ability of process window control to achieve these economic objectives may be limited by variability in the larger manufacturing context, including measurement delays and process variation at the lot, wafer, x-wafer, x-field, and x-chip levels. We conclude that x-wafer and x-field CD control strategies will be critical enablers of density, performance and optimum profitability at the 90 and 65nm technology nodes. These analyses correlate well with actual factory data and often identify millions of dollars in potential incremental revenue and cost savings. As an example, we show that a scatterometry-based CD Process Window Monitor is an economically justified, enabling technology for the 65nm node.

40 CFR 63.605 - Monitoring requirements.

Code of Federal Regulations, 2014 CFR

2014-07-01

... (CONTINUED) NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS FOR SOURCE CATEGORIES (CONTINUED) National Emission Standards for Hazardous Air Pollutants From Phosphoric Acid Manufacturing Plants § 63.605... the mass flow of phosphorus-bearing feed material to the process. The monitoring system shall have an...

Evaluating Process Sustainability Using Flowsheet Monitoring

EPA Science Inventory

Environmental metric software can be used to evaluate the sustainability of a chemical based on data from the chemical process that is used to manufacture it. One problem in developing environmental metric software is that chemical process simulation packages typically do not rea...

Portable Positron Measurement System (PPMS)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Akers, Doug

Portable Positron Measurement System (PPMS) is an automated, non-destructive inspection system based on positron annihilation, which characterizes a material's in situatomic-level properties during the manufacturing processes of formation, solidification, and heat treatment. Simultaneous manufacturing and quality monitoring now are possible. Learn more about the lab's project on our facebook site http://www.facebook.com/idahonationallaboratory.

Portable Positron Measurement System (PPMS)

ScienceCinema

None

2017-12-09

Portable Positron Measurement System (PPMS) is an automated, non-destructive inspection system based on positron annihilation, which characterizes a material's in situatomic-level properties during the manufacturing processes of formation, solidification, and heat treatment. Simultaneous manufacturing and quality monitoring now are possible. Learn more about the lab's project on our facebook site http://www.facebook.com/idahonationallaboratory.

Monitoring of staphylococcal starters in two French processing plants manufacturing dry fermented sausages.

PubMed

Corbiere Morot-Bizot, S; Leroy, S; Talon, R

2007-01-01

The growth and survival of Staphylococcus xylosus and Staphylococcus carnosus were monitored during sausage manufacture in two processing plants. The gram-positive, catalase-positive cocci isolated from the processing plants F10 and F11 were identified by Staphylococcus-specific PCR and species-specific oligonucleotide array. In the inoculated products with starter cultures, 90% of staphylococcal strains isolated in F10 were identified as S. xylosus and 10% as S. carnosus. In F11, 77% were identified as S. xylosus and 20% as S. carnosus. Staphylococcus xylosus dominated the staphylococcal microbiota while S. carnosus survived during the process. The pulse-field gel electrophoresis analysis revealed that all S. xylosus and S. carnosus strains isolated corresponded to the starter strains inoculated. The two starter strains of S. xylosus co-dominated in the isolates from sausages of F11, whereas the strain with pattern A1 was dominant in the isolates from sausages of F10. In the environments, no S. carnosus and S. xylosus were found, whereas Staphylococcus equorum and Staphylococcus saprophyticus were the main species isolated. This work highlighted the domination of S. xylosus starter strains, which showed a strong capacity to grow during sausage process, while S. carnosus survived during the process. Successful implantation of starter cultures is obviously a prerequisite for their contribution to sensorial qualities. Thus, the monitoring of the growth and the survival of S. xylosus and S. carnosus are required to guarantee a well-adapted starter culture. This study revealed that the two Staphylococcus species are suitable for manufacturing sausages in processing plants with very different capacities of production.

Managing unexpected events in the manufacturing of biologic medicines.

PubMed

Grampp, Gustavo; Ramanan, Sundar

2013-08-01

The manufacturing of biologic medicines (biologics) requires robust process and facility design, rigorous regulatory compliance, and a well-trained workforce. Because of the complex attributes of biologics and their sensitivity to production and handling conditions, manufacturing of these medicines also requires a high-reliability manufacturing organization. As required by regulators, such an organization must monitor the state-of-control for the manufacturing process. A high-reliability organization also invests in an experienced and fully engaged technical support staff and fosters a management culture that rewards in-depth analysis of unexpected results, robust risk assessments, and timely and effective implementation of mitigation measures. Such a combination of infrastructure, technology, human capital, management, and a science-based operations culture does not occur without a strong organizational and financial commitment. These attributes of a high-reliability biologics manufacturer are difficult to achieve and may be differentiating factors as the supply of biologics diversifies in future years.

[Construction of NIRS-based process analytical system for production of salvianolic acid for injection and relative discussion].

PubMed

Zhang, Lei; Yue, Hong-Shui; Ju, Ai-Chun; Ye, Zheng-Liang

2016-10-01

Currently, near infrared spectroscopy (NIRS) has been considered as an efficient tool for achieving process analytical technology(PAT) in the manufacture of traditional Chinese medicine (TCM) products. In this article, the NIRS based process analytical system for the production of salvianolic acid for injection was introduced. The design of the process analytical system was described in detail, including the selection of monitored processes and testing mode, and potential risks that should be avoided. Moreover, the development of relative technologies was also presented, which contained the establishment of the monitoring methods for the elution of polyamide resin and macroporous resin chromatography processes, as well as the rapid analysis method for finished products. Based on author's experience of research and work, several issues in the application of NIRS to the process monitoring and control in TCM production were then raised, and some potential solutions were also discussed. The issues include building the technical team for process analytical system, the design of the process analytical system in the manufacture of TCM products, standardization of the NIRS-based analytical methods, and improving the management of process analytical system. Finally, the prospect for the application of NIRS in the TCM industry was put forward. Copyright© by the Chinese Pharmaceutical Association.

Evaluating Process Sustainability Using Flowsheet Monitoring (Abstract)

EPA Science Inventory

Environmental metric software can be used to evaluate the sustainability of a chemical based upon data from the chemical process that is used to manufacture it. One problem in developing environmental metric software is that chemical process simulation packages typically do not p...

Monitoring cure properties of out-of-autoclave BMI composites using IFPI sensor

NASA Astrophysics Data System (ADS)

Kaur, Amardeep; Anandan, Sudharshan; Yuan, Lei; Watkins, Steve E.; Chandrashekhara, K.; Xiao, Hai; Phan, Nam

2016-04-01

A non-destructive technique for inspection of a Bismaleimide (BMI) composite is presented using an optical fiber sensor. High performance BMI composites are used for Aerospace application for their mechanical strength. They are also used as an alternative to toughened epoxy resins. A femtosecond-laser-inscribed Intrinsic Fabry-Perot Interferometer (IFPI) sensor is used to perform real time cure monitoring of a BMI composite. The composite is cured using the out-of-autoclave (OOA) process. The IFPI sensor was used for in-situ monitoring; different curing stages are analyzed throughout the curing process. Temperature-induced-strain was measured to analyze the cure properties. The IFPI structure comprises of two reflecting mirrors inscribed on the core of the fiber using a femtosecond-laser manufacturing process. The manufacturing process makes the sensor thermally stable and robust for embedded applications. The sensor can withstand very high temperatures of up to 850 °C. The temperature and strain sensitivities of embedded IFPI sensor were measured to be 1.4 pm/μepsilon and 0.6 pm/μepsilon respectively.

Low cost composite manufacturing utilizing intelligent pultrusion and resin transfer molding (IPRTM)

NASA Astrophysics Data System (ADS)

Bradley, James E.; Wysocki, Tadeusz S., Jr.

1993-02-01

This article describes an innovative method for the economical manufacturing of large, intricately-shaped tubular composite parts. Proprietary intelligent process control techniques are combined with standard pultrusion and RTM methodologies to provide high part throughput, performance, and quality while substantially reducing scrap, rework costs, and labor requirements. On-line process monitoring and control is achieved through a smart tooling interface consisting of modular zone tiles installed on part-specific die assemblies. Real-time archiving of process run parameters provides enhanced SPC and SQC capabilities.

Process and control systems for composites manufacturing

NASA Technical Reports Server (NTRS)

Tsiang, T. H.; Wanamaker, John L.

1992-01-01

A precise control of composite material processing would not only improve part quality, but it would also directly reduce the overall manufacturing cost. The development and incorporation of sensors will help to generate real-time information for material processing relationships and equipment characteristics. In the present work, the thermocouple, pressure transducer, and dielectrometer technologies were investigated. The monitoring sensors were integrated with the computerized control system in three non-autoclave fabrication techniques: hot-press, self contained tool (self heating and pressurizing), and pressure vessel). The sensors were implemented in the parts and tools.

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

NASA Astrophysics Data System (ADS)

Babu, S. S.; Raghavan, N.; Raplee, J.; Foster, S. J.; Frederick, C.; Haines, M.; Dinwiddie, R.; Kirka, M. K.; Plotkowski, A.; Lee, Y.; Dehoff, R. R.

2018-06-01

Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.

Spectral imaging applications: Remote sensing, environmental monitoring, medicine, military operations, factory automation and manufacturing

NASA Technical Reports Server (NTRS)

Gat, N.; Subramanian, S.; Barhen, J.; Toomarian, N.

1996-01-01

This paper reviews the activities at OKSI related to imaging spectroscopy presenting current and future applications of the technology. The authors discuss the development of several systems including hardware, signal processing, data classification algorithms and benchmarking techniques to determine algorithm performance. Signal processing for each application is tailored by incorporating the phenomenology appropriate to the process, into the algorithms. Pixel signatures are classified using techniques such as principal component analyses, generalized eigenvalue analysis and novel very fast neural network methods. The major hyperspectral imaging systems developed at OKSI include the Intelligent Missile Seeker (IMS) demonstration project for real-time target/decoy discrimination, and the Thermal InfraRed Imaging Spectrometer (TIRIS) for detection and tracking of toxic plumes and gases. In addition, systems for applications in medical photodiagnosis, manufacturing technology, and for crop monitoring are also under development.

At-line validation of a process analytical technology approach for quality control of melamine-urea-formaldehyde resin in composite wood-panel production using near infrared spectroscopy.

PubMed

Meder, Roger; Stahl, Wolfgang; Warburton, Paul; Woolley, Sam; Earnshaw, Scott; Haselhofer, Klaus; van Langenberg, Ken; Ebdon, Nick; Mulder, Roger

2017-01-01

The reactivity of melamine-urea-formaldehyde resins is of key importance in the manufacture of engineered wood products such as medium density fibreboard (MDF) and other wood composite products. Often the MDF manufacturing plant has little available information on the resin reactivity other than details of the resin specification at the time of batch manufacture, which often occurs off-site at a third-party resin plant. Often too, fresh resin on delivery at the MDF plant is mixed with variable volume of aged resin in storage tanks, thereby rendering any specification of the fresh resin batch obsolete. It is therefore highly desirable to develop a real-time, at-line or on-line, process analytical technology to monitor the quality of the resin prior to MDF panel manufacture. Near infrared (NIR) spectroscopy has been calibrated against standard quality methods and against 13 C nuclear magnetic resonance (NMR) measures of molecular composition in order to provide at-line process analytical technology (PAT), to monitor the resin quality, particularly the formaldehyde content of the resin. At-line determination of formaldehyde content in the resin was made possible using a six-factor calibration with an R 2 (cal) value of 0.973, and R 2 (CV) value of 0.929 and a root-mean-square error of cross-validation of 0.01. This calibration was then used to generate control charts of formaldehyde content at regular four-hourly periods during MDF panel manufacture in a commercial MDF manufacturing plant.

Quality-by-design III: application of near-infrared spectroscopy to monitor roller compaction in-process and product quality attributes of immediate release tablets.

PubMed

Kona, Ravikanth; Fahmy, Raafat M; Claycamp, Gregg; Polli, James E; Martinez, Marilyn; Hoag, Stephen W

2015-02-01

The objective of this study is to use near-infrared spectroscopy (NIRS) coupled with multivariate chemometric models to monitor granule and tablet quality attributes in the formulation development and manufacturing of ciprofloxacin hydrochloride (CIP) immediate release tablets. Critical roller compaction process parameters, compression force (CFt), and formulation variables identified from our earlier studies were evaluated in more detail. Multivariate principal component analysis (PCA) and partial least square (PLS) models were developed during the development stage and used as a control tool to predict the quality of granules and tablets. Validated models were used to monitor and control batches manufactured at different sites to assess their robustness to change. The results showed that roll pressure (RP) and CFt played a critical role in the quality of the granules and the finished product within the range tested. Replacing binder source did not statistically influence the quality attributes of the granules and tablets. However, lubricant type has significantly impacted the granule size. Blend uniformity, crushing force, disintegration time during the manufacturing was predicted using validated PLS regression models with acceptable standard error of prediction (SEP) values, whereas the models resulted in higher SEP for batches obtained from different manufacturing site. From this study, we were able to identify critical factors which could impact the quality attributes of the CIP IR tablets. In summary, we demonstrated the ability of near-infrared spectroscopy coupled with chemometrics as a powerful tool to monitor critical quality attributes (CQA) identified during formulation development.

Direct analysis in real time mass spectrometry, a process analytical technology tool for real-time process monitoring in botanical drug manufacturing.

PubMed

Wang, Lu; Zeng, Shanshan; Chen, Teng; Qu, Haibin

2014-03-01

A promising process analytical technology (PAT) tool has been introduced for batch processes monitoring. Direct analysis in real time mass spectrometry (DART-MS), a means of rapid fingerprint analysis, was applied to a percolation process with multi-constituent substances for an anti-cancer botanical preparation. Fifteen batches were carried out, including ten normal operations and five abnormal batches with artificial variations. The obtained multivariate data were analyzed by a multi-way partial least squares (MPLS) model. Control trajectories were derived from eight normal batches, and the qualification was tested by R(2) and Q(2). Accuracy and diagnosis capability of the batch model were then validated by the remaining batches. Assisted with high performance liquid chromatography (HPLC) determination, process faults were explained by corresponding variable contributions. Furthermore, a batch level model was developed to compare and assess the model performance. The present study has demonstrated that DART-MS is very promising in process monitoring in botanical manufacturing. Compared with general PAT tools, DART-MS offers a particular account on effective compositions and can be potentially used to improve batch quality and process consistency of samples in complex matrices. Copyright © 2014 Elsevier B.V. All rights reserved.

Design of intelligent composites with life-cycle health management capabilities

NASA Astrophysics Data System (ADS)

Rosania, Colleen L.; Larrosa, Cecilia C.; Chang, Fu-Kuo

2015-03-01

Use of carbon fiber reinforced polymers (CFRPs) presents challenges because of their complex manufacturing processes and different damage mechanics in relation to legacy metal materials. New monitoring methods for manufacturing, quality verification, damage estimation, and prognosis are needed to use CFRPs safely and efficiently. This work evaluates the development of intelligent composite materials using integrated piezoelectric sensors to monitor the material during cure and throughout service life. These sensors are used to propagate ultrasonic waves through the structure for health monitoring. During manufacturing, data is collected at different stages during the cure cycle, detecting the changing material properties during cure and verifying quality and degree of cure. The same sensors can then be used with previously developed techniques to perform damage detection, such as impact detection and matrix crack density estimation. Real-time damage estimation can be combined with prognostic models to predict future propagation of damage in the material. In this work experimental results will be presented from composite coupons with embedded piezoelectric sensors. Cure monitoring and damage detection results derived from analysis of the ultrasonic sensor signal will be shown. Sensitive signal parameters to the different stimuli in both the time and frequency domains will be explored for this analysis. From these results, use of the same sensor networks from manufacturing throughout the life of the composite material will demonstrate the full life-cycle monitoring capability of these intelligent materials.

A novel spatter detection algorithm based on typical cellular neural network operations for laser beam welding processes

NASA Astrophysics Data System (ADS)

Nicolosi, L.; Abt, F.; Blug, A.; Heider, A.; Tetzlaff, R.; Höfler, H.

2012-01-01

Real-time monitoring of laser beam welding (LBW) has increasingly gained importance in several manufacturing processes ranging from automobile production to precision mechanics. In the latter, a novel algorithm for the real-time detection of spatters was implemented in a camera based on cellular neural networks. The latter can be connected to the optics of commercially available laser machines leading to real-time monitoring of LBW processes at rates up to 15 kHz. Such high monitoring rates allow the integration of other image evaluation tasks such as the detection of the full penetration hole for real-time control of process parameters.

Vacuum mechatronics

NASA Technical Reports Server (NTRS)

Hackwood, Susan; Belinski, Steven E.; Beni, Gerardo

1989-01-01

The discipline of vacuum mechatronics is defined as the design and development of vacuum-compatible computer-controlled mechanisms for manipulating, sensing and testing in a vacuum environment. The importance of vacuum mechatronics is growing with an increased application of vacuum in space studies and in manufacturing for material processing, medicine, microelectronics, emission studies, lyophylisation, freeze drying and packaging. The quickly developing field of vacuum mechatronics will also be the driving force for the realization of an advanced era of totally enclosed clean manufacturing cells. High technology manufacturing has increasingly demanding requirements for precision manipulation, in situ process monitoring and contamination-free environments. To remove the contamination problems associated with human workers, the tendency in many manufacturing processes is to move towards total automation. This will become a requirement in the near future for e.g., microelectronics manufacturing. Automation in ultra-clean manufacturing environments is evolving into the concept of self-contained and fully enclosed manufacturing. A Self Contained Automated Robotic Factory (SCARF) is being developed as a flexible research facility for totally enclosed manufacturing. The construction and successful operation of a SCARF will provide a novel, flexible, self-contained, clean, vacuum manufacturing environment. SCARF also requires very high reliability and intelligent control. The trends in vacuum mechatronics and some of the key research issues are reviewed.

40 CFR 439.2 - General monitoring requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

... chemistry, products and by-products resulting from each of the manufacturing processes. This determination... the permitting authority, reconfirmed by an annual chemical analysis of wastewater from each...

40 CFR 439.2 - General monitoring requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

... chemistry, products and by-products resulting from each of the manufacturing processes. This determination... the permitting authority, reconfirmed by an annual chemical analysis of wastewater from each...

Computer-aided video exposure monitoring.

PubMed

Walsh, P T; Clark, R D; Flaherty, S; Gentry, S J

2000-01-01

A computer-aided video exposure monitoring system was used to record exposure information. The system comprised a handheld camcorder, portable video cassette recorder, radio-telemetry transmitter/receiver, and handheld or notebook computers for remote data logging, photoionization gas/vapor detectors (PIDs), and a personal aerosol monitor. The following workplaces were surveyed using the system: dry cleaning establishments--monitoring tetrachoroethylene in the air and in breath; printing works--monitoring white spirit type solvent; tire manufacturing factory--monitoring rubber fume; and a slate quarry--monitoring respirable dust and quartz. The system based on the handheld computer, in particular, simplified the data acquisition process compared with earlier systems in use by our laboratory. The equipment is more compact and easier to operate, and allows more accurate calibration of the instrument reading on the video image. Although a variety of data display formats are possible, the best format for videos intended for educational and training purposes was the review-preview chart superimposed on the video image of the work process. Recommendations for reducing exposure by engineering or by modifying work practice were possible through use of the video exposure system in the dry cleaning and tire manufacturing applications. The slate quarry work illustrated how the technique can be used to test ventilation configurations quickly to see their effect on the worker's personal exposure.

Process monitoring of additive manufacturing by using optical tomography

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zenzinger, Guenter, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de; Bamberg, Joachim, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de; Ladewig, Alexander, E-mail: guenter.zenzinger@mtu.de, E-mail: alexander.ladewig@mtu.de

2015-03-31

Parts fabricated by means of additive manufacturing are usually of complex shape and owing to the fabrication procedure by using selective laser melting (SLM), potential defects and inaccuracies are often very small in lateral size. Therefore, an adequate quality inspection of such parts is rather challenging, while non-destructive-techniques (NDT) are difficult to realize, but considerable efforts are necessary in order to ensure the quality of SLM-parts especially used for aerospace components. Thus, MTU Aero Engines is currently focusing on the development of an Online Process Control system which monitors and documents the complete welding process during the SLM fabrication procedure.more » A high-resolution camera system is used to obtain images, from which tomographic data for a 3dim analysis of SLM-parts are processed. From the analysis, structural irregularities and structural disorder resulting from any possible erroneous melting process become visible and may be allocated anywhere within the 3dim structure. Results of our optical tomography (OT) method as obtained on real defects are presented.« less

A practical approach for exploration and modeling of the design space of a bacterial vaccine cultivation process.

PubMed

Streefland, M; Van Herpen, P F G; Van de Waterbeemd, B; Van der Pol, L A; Beuvery, E C; Tramper, J; Martens, D E; Toft, M

2009-10-15

A licensed pharmaceutical process is required to be executed within the validated ranges throughout the lifetime of product manufacturing. Changes to the process, especially for processes involving biological products, usually require the manufacturer to demonstrate that the safety and efficacy of the product remains unchanged by new or additional clinical testing. Recent changes in the regulations for pharmaceutical processing allow broader ranges of process settings to be submitted for regulatory approval, the so-called process design space, which means that a manufacturer can optimize his process within the submitted ranges after the product has entered the market, which allows flexible processes. In this article, the applicability of this concept of the process design space is investigated for the cultivation process step for a vaccine against whooping cough disease. An experimental design (DoE) is applied to investigate the ranges of critical process parameters that still result in a product that meets specifications. The on-line process data, including near infrared spectroscopy, are used to build a descriptive model of the processes used in the experimental design. Finally, the data of all processes are integrated in a multivariate batch monitoring model that represents the investigated process design space. This article demonstrates how the general principles of PAT and process design space can be applied for an undefined biological product such as a whole cell vaccine. The approach chosen for model development described here, allows on line monitoring and control of cultivation batches in order to assure in real time that a process is running within the process design space.

Exposure monitoring of graphene nanoplatelets manufacturing workplaces.

PubMed

Lee, Ji Hyun; Han, Jong Hun; Kim, Jae Hyun; Kim, Boowook; Bello, Dhimiter; Kim, Jin Kwon; Lee, Gun Ho; Sohn, Eun Kyung; Lee, Kyungmin; Ahn, Kangho; Faustman, Elaine M; Yu, Il Je

2016-01-01

Graphenes have emerged as a highly promising, two-dimensional engineered nanomaterial that can possibly substitute carbon nanotubes. They are being explored in numerous R&D and industrial applications in laboratories across the globe, leading to possible human and environmental exposures to them. Yet, there are no published data on graphene exposures in occupational settings and no readily available methods for their detection and quantitation exist. This study investigates for the first time the potential exposure of workers and research personnel to graphenes in two research facilities and evaluates the status of the control measures. One facility manufactures graphene using graphite exfoliation and chemical vapor deposition (CVD), while the other facility grows graphene on a copper plate using CVD, which is then transferred to a polyethylene terephthalate (PET) sheet. Graphene exposures and process emissions were investigated for three tasks - CVD growth, exfoliation, and transfer - using a multi-metric approach, which utilizes several direct reading instruments, integrated sampling, and chemical and morphological analysis. Real-time instruments included a dust monitor, condensation particle counter (CPC), nanoparticle surface area monitor, scanning mobility particle sizer, and an aethalometer. Morphologically, graphenes and other nanostructures released from the work process were investigated using a transmission electron microscope (TEM). Graphenes were quantified in airborne respirable samples as elemental carbon via thermo-optical analysis. The mass concentrations of total suspended particulate at Workplaces A and B were very low, and elemental carbon concentrations were mostly below the detection limit, indicating very low exposure to graphene or any other particles. The real-time monitoring, especially the aethalometer, showed a good response to the released black carbon, providing a signature of the graphene released during the opening of the CVD reactor at Workplace A. The TEM observation of the samples obtained from Workplaces A and B showed graphene-like structures and aggregated/agglomerated carbon structures. Taken together, the current findings on common scenarios (exfoliation, CVD growth, and transfer), while not inclusive of all graphene manufacturing processes, indicate very minimal graphene or particle exposure at facilities manufacturing graphenes with good manufacturing practices.

Network-based production quality control

NASA Astrophysics Data System (ADS)

Kwon, Yongjin; Tseng, Bill; Chiou, Richard

2007-09-01

This study investigates the feasibility of remote quality control using a host of advanced automation equipment with Internet accessibility. Recent emphasis on product quality and reduction of waste stems from the dynamic, globalized and customer-driven market, which brings opportunities and threats to companies, depending on the response speed and production strategies. The current trends in industry also include a wide spread of distributed manufacturing systems, where design, production, and management facilities are geographically dispersed. This situation mandates not only the accessibility to remotely located production equipment for monitoring and control, but efficient means of responding to changing environment to counter process variations and diverse customer demands. To compete under such an environment, companies are striving to achieve 100%, sensor-based, automated inspection for zero-defect manufacturing. In this study, the Internet-based quality control scheme is referred to as "E-Quality for Manufacturing" or "EQM" for short. By its definition, EQM refers to a holistic approach to design and to embed efficient quality control functions in the context of network integrated manufacturing systems. Such system let designers located far away from the production facility to monitor, control and adjust the quality inspection processes as production design evolves.

Graphite nanoplatelet enabled embeddable fiber sensor for in situ curing monitoring and structural health monitoring of polymeric composites.

PubMed

Luo, Sida; Liu, Tao

2014-06-25

A graphite nanoplatelet (GNP) thin film enabled 1D fiber sensor (GNP-FibSen) was fabricated by a continuous roll-to-roll spray coating process, characterized by scanning electron microscopy and Raman spectroscopy and evaluated by coupled electrical-mechanical tensile testing. The neat GNP-FibSen sensor shows very high gauge sensitivity with a gauge factor of ∼17. By embedding the sensor in fiberglass prepreg laminate parts, the dual functionalities of the GNP-FibSen sensor were demonstrated. In the manufacturing process, the resistance change of the embedded sensor provides valuable local resin curing information. After the manufacturing process, the same sensor is able to map the strain/stress states and detect the failure of the host composite. The superior durability of the embedded GNP-FibSen sensor has been demonstrated through 10,000 cycles of coupled electromechanical tests.

System for monitoring an industrial or biological process

DOEpatents

Gross, Kenneth C.; Wegerich, Stephan W.; Vilim, Rick B.; White, Andrew M.

1998-01-01

A method and apparatus for monitoring and responding to conditions of an industrial process. Industrial process signals, such as repetitive manufacturing, testing and operational machine signals, are generated by a system. Sensor signals characteristic of the process are generated over a time length and compared to reference signals over the time length. The industrial signals are adjusted over the time length relative to the reference signals, the phase shift of the industrial signals is optimized to the reference signals and the resulting signals output for analysis by systems such as SPRT.

System for monitoring an industrial or biological process

DOEpatents

Gross, K.C.; Wegerich, S.W.; Vilim, R.B.; White, A.M.

1998-06-30

A method and apparatus are disclosed for monitoring and responding to conditions of an industrial process. Industrial process signals, such as repetitive manufacturing, testing and operational machine signals, are generated by a system. Sensor signals characteristic of the process are generated over a time length and compared to reference signals over the time length. The industrial signals are adjusted over the time length relative to the reference signals, the phase shift of the industrial signals is optimized to the reference signals and the resulting signals output for analysis by systems such as SPRT. 49 figs.

Utilizing dynamic light scattering as a process analytical technology for protein folding and aggregation monitoring in vaccine manufacturing.

PubMed

Yu, Zhou; Reid, Jennifer C; Yang, Yan-Ping

2013-12-01

Protein aggregation is a common challenge in the manufacturing of biological products. It is possible to minimize the extent of aggregation through timely measurement and in-depth characterization of aggregation. In this study, we demonstrated the use of dynamic light scattering (DLS) to monitor inclusion body (IB) solubilization, protein refolding, and aggregation near the production line of a recombinant protein-based vaccine candidate. Our results were in good agreement with those measured by size-exclusion chromatography. DLS was also used to characterize the mechanism of aggregation. As DLS is a quick, nonperturbing technology, it can potentially be used as an at-line process analytical technology to ensure complete IB solubilization and aggregate-free refolding. © 2013 Wiley Periodicals, Inc. and the American Pharmacists Association.

NREL Patents Method for Continuous Monitoring of Materials During

Science.gov Websites

Manufacturing | News | NREL NREL Patents Method for Continuous Monitoring of Materials During Manufacturing News Release: NREL Patents Method for Continuous Monitoring of Materials During Manufacturing patent for a novel method that rapidly characterizes specialized materials during the manufacturing

Mining manufacturing data for discovery of high productivity process characteristics.

PubMed

Charaniya, Salim; Le, Huong; Rangwala, Huzefa; Mills, Keri; Johnson, Kevin; Karypis, George; Hu, Wei-Shou

2010-06-01

Modern manufacturing facilities for bioproducts are highly automated with advanced process monitoring and data archiving systems. The time dynamics of hundreds of process parameters and outcome variables over a large number of production runs are archived in the data warehouse. This vast amount of data is a vital resource to comprehend the complex characteristics of bioprocesses and enhance production robustness. Cell culture process data from 108 'trains' comprising production as well as inoculum bioreactors from Genentech's manufacturing facility were investigated. Each run constitutes over one-hundred on-line and off-line temporal parameters. A kernel-based approach combined with a maximum margin-based support vector regression algorithm was used to integrate all the process parameters and develop predictive models for a key cell culture performance parameter. The model was also used to identify and rank process parameters according to their relevance in predicting process outcome. Evaluation of cell culture stage-specific models indicates that production performance can be reliably predicted days prior to harvest. Strong associations between several temporal parameters at various manufacturing stages and final process outcome were uncovered. This model-based data mining represents an important step forward in establishing a process data-driven knowledge discovery in bioprocesses. Implementation of this methodology on the manufacturing floor can facilitate a real-time decision making process and thereby improve the robustness of large scale bioprocesses. 2010 Elsevier B.V. All rights reserved.

Additive manufacturing in production: challenges and opportunities

NASA Astrophysics Data System (ADS)

Ahuja, Bhrigu; Karg, Michael; Schmidt, Michael

2015-03-01

Additive manufacturing, characterized by its inherent layer by layer fabrication methodology has been coined by many as the latest revolution in the manufacturing industry. Due to its diversification of Materials, processes, system technology and applications, Additive Manufacturing has been synonymized with terminology such as Rapid prototyping, 3D printing, free-form fabrication, Additive Layer Manufacturing, etc. A huge media and public interest in the technology has led to an innovative attempt of exploring the technology for applications beyond the scope of the traditional engineering industry. Nevertheless, it is believed that a critical factor for the long-term success of Additive Manufacturing would be its ability to fulfill the requirements defined by the traditional manufacturing industry. A parallel development in market trends and product requirements has also lead to a wider scope of opportunities for Additive Manufacturing. The presented paper discusses some of the key challenges which are critical to ensure that Additive Manufacturing is truly accepted as a mainstream production technology in the industry. These challenges would highlight on various aspects of production such as product requirements, process management, data management, intellectual property, work flow management, quality assurance, resource planning, etc. In Addition, changing market trends such as product life cycle, mass customization, sustainability, environmental impact and localized production will form the foundation for the follow up discussion on the current limitations and the corresponding research opportunities. A discussion on ongoing research to address these challenges would include topics like process monitoring, design complexity, process standardization, multi-material and hybrid fabrication, new material development, etc.

Additively Manufactured IN718 Components with Wirelessly Powered and Interrogated Embedded Sensing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Attridge, Paul; Bajekal, Sanjay; Klecka, Michael

A methodology is described for embedding commercial-off-the-shelf sensors together with wireless communication and power circuit elements using direct laser metal sintered additively manufactured components. Physics based models of the additive manufacturing processes and sensor/wireless level performance models guided the design and embedment processes. A combination of cold spray deposition and laser engineered net shaping was used to fashion the transmitter/receiving elements and embed the sensors, thereby providing environmental protection and component robustness/survivability for harsh conditions. By design, this complement of analog and digital sensors were wirelessly powered and interrogated using a health and utilization monitoring system; enabling real-time, in situmore » prognostics and diagnostics.« less

The Use of Multidimensional Image-Based Analysis to Accurately Monitor Cell Growth in 3D Bioreactor Culture

PubMed Central

Baradez, Marc-Olivier; Marshall, Damian

2011-01-01

The transition from traditional culture methods towards bioreactor based bioprocessing to produce cells in commercially viable quantities for cell therapy applications requires the development of robust methods to ensure the quality of the cells produced. Standard methods for measuring cell quality parameters such as viability provide only limited information making process monitoring and optimisation difficult. Here we describe a 3D image-based approach to develop cell distribution maps which can be used to simultaneously measure the number, confluency and morphology of cells attached to microcarriers in a stirred tank bioreactor. The accuracy of the cell distribution measurements is validated using in silico modelling of synthetic image datasets and is shown to have an accuracy >90%. Using the cell distribution mapping process and principal component analysis we show how cell growth can be quantitatively monitored over a 13 day bioreactor culture period and how changes to manufacture processes such as initial cell seeding density can significantly influence cell morphology and the rate at which cells are produced. Taken together, these results demonstrate how image-based analysis can be incorporated in cell quality control processes facilitating the transition towards bioreactor based manufacture for clinical grade cells. PMID:22028809

The use of multidimensional image-based analysis to accurately monitor cell growth in 3D bioreactor culture.

PubMed

Baradez, Marc-Olivier; Marshall, Damian

2011-01-01

The transition from traditional culture methods towards bioreactor based bioprocessing to produce cells in commercially viable quantities for cell therapy applications requires the development of robust methods to ensure the quality of the cells produced. Standard methods for measuring cell quality parameters such as viability provide only limited information making process monitoring and optimisation difficult. Here we describe a 3D image-based approach to develop cell distribution maps which can be used to simultaneously measure the number, confluency and morphology of cells attached to microcarriers in a stirred tank bioreactor. The accuracy of the cell distribution measurements is validated using in silico modelling of synthetic image datasets and is shown to have an accuracy >90%. Using the cell distribution mapping process and principal component analysis we show how cell growth can be quantitatively monitored over a 13 day bioreactor culture period and how changes to manufacture processes such as initial cell seeding density can significantly influence cell morphology and the rate at which cells are produced. Taken together, these results demonstrate how image-based analysis can be incorporated in cell quality control processes facilitating the transition towards bioreactor based manufacture for clinical grade cells.

40 CFR 439.2 - General monitoring requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

... assessment of the process chemistry, products and by-products resulting from each of the manufacturing... applications for approval by the permitting authority, reconfirmed by an annual chemical analysis of wastewater...

40 CFR 439.2 - General monitoring requirements.

Code of Federal Regulations, 2014 CFR

2014-07-01

... assessment of the process chemistry, products and by-products resulting from each of the manufacturing... applications for approval by the permitting authority, reconfirmed by an annual chemical analysis of wastewater...

40 CFR 439.2 - General monitoring requirements.

Code of Federal Regulations, 2012 CFR

2012-07-01

... assessment of the process chemistry, products and by-products resulting from each of the manufacturing... applications for approval by the permitting authority, reconfirmed by an annual chemical analysis of wastewater...

Continuous processing and the applications of online tools in pharmaceutical product manufacture: developments and examples.

PubMed

Ooi, Shing Ming; Sarkar, Srimanta; van Varenbergh, Griet; Schoeters, Kris; Heng, Paul Wan Sia

2013-04-01

Continuous processing and production in pharmaceutical manufacturing has received increased attention in recent years mainly due to the industries' pressing needs for more efficient, cost-effective processes and production, as well as regulatory facilitation. To achieve optimum product quality, the traditional trial-and-error method for the optimization of different process and formulation parameters is expensive and time consuming. Real-time evaluation and the control of product quality using an online process analyzer in continuous processing can provide high-quality production with very high-throughput at low unit cost. This review focuses on continuous processing and the application of different real-time monitoring tools used in the pharmaceutical industry for continuous processing from powder to tablets.

Technology for Manufacturing Efficiency

NASA Technical Reports Server (NTRS)

1995-01-01

The Ground Processing Scheduling System (GPSS) was developed by Ames Research Center, Kennedy Space Center and divisions of the Lockheed Company to maintain the scheduling for preparing a Space Shuttle Orbiter for a mission. Red Pepper Software Company, now part of PeopleSoft, Inc., commercialized the software as their ResponseAgent product line. The software enables users to monitor manufacturing variables, report issues and develop solutions to existing problems.

Application of biospeckle phenomenon on monitoring of leavening process in breadmaking

NASA Astrophysics Data System (ADS)

da Silva, Emerson Rodrigo; da Silva Junior, Elieste; Júnior, Mauro Favoretto; da Silva Lannes, Suzana Caetano; Muramatsu, Mikiya

2008-04-01

Since the sixties, dynamic speckles have found a wide number of applications, covering fields from engineering to biomedicine. However, despite of this potential, its utilisation in food manufacture control is still incipient. In this work, our objective was to use the biospeckle phenomenon to monitoring the expansion of the dough during the leavening process. Our experiments consisted in the temporal evolution observation of speckle patterns scattered by samples prepared from two formulations: by yoghurt addition and without it. Every two minutes, it was constructed a 2-D image, recording the Time History Speckle Pattern (THSP). The full monitoring time was 50 minutes. A new estimator of activity index, proposed by some of the authors, was used in data analysis. This estimator is based on contrast of successive correlations of intensities recorded in THSP. It was found a strong correlation between the activities on the samples and the type of fermentative agents. These results reveal an interesting potential of the biospeckle to control in bread manufacture industries.

High throughput wafer defect monitor for integrated metrology applications in photolithography

NASA Astrophysics Data System (ADS)

Rao, Nagaraja; Kinney, Patrick; Gupta, Anand

2008-03-01

The traditional approach to semiconductor wafer inspection is based on the use of stand-alone metrology tools, which while highly sensitive, are large, expensive and slow, requiring inspection to be performed off-line and on a lot sampling basis. Due to the long cycle times and sparse sampling, the current wafer inspection approach is not suited to rapid detection of process excursions that affect yield. The semiconductor industry is gradually moving towards deploying integrated metrology tools for real-time "monitoring" of product wafers during the manufacturing process. Integrated metrology aims to provide end-users with rapid feedback of problems during the manufacturing process, and the benefit of increased yield, and reduced rework and scrap. The approach of monitoring 100% of the wafers being processed requires some trade-off in sensitivity compared to traditional standalone metrology tools, but not by much. This paper describes a compact, low-cost wafer defect monitor suitable for integrated metrology applications and capable of detecting submicron defects on semiconductor wafers at an inspection rate of about 10 seconds per wafer (or 360 wafers per hour). The wafer monitor uses a whole wafer imaging approach to detect defects on both un-patterned and patterned wafers. Laboratory tests with a prototype system have demonstrated sensitivity down to 0.3 µm on un-patterned wafers and down to 1 µm on patterned wafers, at inspection rates of 10 seconds per wafer. An ideal application for this technology is preventing photolithography defects such as "hot spots" by implementing a wafer backside monitoring step prior to exposing wafers in the lithography step.

Inhibiting the Physiological Stress Effects of a Sustained Attention Task on Shoulder Muscle Activity.

PubMed

Wixted, Fiona; O'Riordan, Cliona; O'Sullivan, Leonard

2018-01-11

The objective of this study was to investigate if a breathing technique could counteract the effects of hyperventilation due to a sustained attention task on shoulder muscle activity. The trend towards higher levels of automation in industry is increasing. Consequently, manufacturing operators often monitor automated process for long periods of their work shift. Prolonged monitoring work requires sustained attention, which is a cognitive process that humans are typically poor at and find stressful. As sustained attention becomes an increasing requirement of manufacturing operators' job content, the resulting stress experienced could contribute to the onset of many health problems, including work related musculoskeletal disorders (WRMSDs). The SART attention test was completed by a group of participants before and after a breathing intervention exercise. The effects of the abdominal breathing intervention on breathing rate, upper trapezius muscle activity and end-tidal CO₂ were evaluated. The breathing intervention reduced the moderation effect of end-tidal CO₂ on upper trapezius muscle activity. Abdominal breathing could be a useful technique in reducing the effects of sustained attention work on muscular activity. This research can be applied to highly-automated manufacturing industries, where prolonged monitoring of work is widespread and could, in its role as a stressor, be a potential contributor to WRMSDs.

AE Monitoring of Diamond Turned Rapidly Soldified Aluminium 443

NASA Astrophysics Data System (ADS)

Onwuka, G.; Abou-El-Hossein, K.; Mkoko, Z.

2017-05-01

The fast replacement of conventional aluminium with rapidly solidified aluminium alloys has become a noticeable trend in the current manufacturing industries involved in the production of optics and optical molding inserts. This is as a result of the improved performance and durability of rapidly solidified aluminium alloys when compared to conventional aluminium. Melt spinning process is vital for manufacturing rapidly solidified aluminium alloys like RSA 905, RSA 6061 and RSA 443 which are common in the industries today. RSA 443 is a newly developed alloy with few research findings and huge research potential. There is no available literature focused on monitoring the machining of RSA 443 alloys. In this research, Acoustic Emission sensing technique was applied to monitor the single point diamond turning of RSA 443 on an ultrahigh precision lathe machine. The machining process was carried out after careful selection of feed, speed and depths of cut. The monitoring process was achieved with a high sampling data acquisition system using different tools while concurrent measurement of the surface roughness and tool wear were initiated after covering a total feed distance of 13km. An increasing trend of raw AE spikes and peak to peak signal were observed with an increase in the surface roughness and tool wear values. Hence, acoustic emission sensing technique proves to be an effective monitoring method for the machining of RSA 443 alloy.

New Whole-House Solutions Case Study: Northwest Energy Efficient Manufactured Housing Program High-Performance Test Homes - Pacific Northwest

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

2015-05-01

This project represents the third phase of a multi-year effort to develop and bring to market a High Performance Manufactured Home (HPMH). In this project, the Northwest Energy Efficient Manufactured Housing Program worked with Building America Partnership for Improved Residential Construction and Bonneville Power Administration to help four factory homebuilders build prototype zero energy ready manufactured homes, resulting in what is expected to be a 30% savings relative to the Building America Benchmark. (The actual % savings varies depending on choice of heating equipment and climate zone). Previous phases of this project created a HPMH specification and prototyped individual measuresmore » from the package to obtain engineering approvals and develop preliminary factory construction processes. This case study describes the project team's work during 2014 to build prototype homes to the HPMH specifications and to monitor the homes for energy performance and durability. Monitoring is expected to continue into 2016.« less

Vision Systems Illuminate Industrial Processes

NASA Technical Reports Server (NTRS)

2013-01-01

When NASA designs a spacecraft to undertake a new mission, innovation does not stop after the design phase. In many cases, these spacecraft are firsts of their kind, requiring not only remarkable imagination and expertise in their conception but new technologies and methods for their manufacture. In the realm of manufacturing, NASA has from necessity worked on the cutting-edge, seeking new techniques and materials for creating unprecedented structures, as well as capabilities for reducing the cost and increasing the efficiency of existing manufacturing technologies. From friction stir welding enhancements (Spinoff 2009) to thermoset composites (Spinoff 2011), NASA s innovations in manufacturing have often transferred to the public in ways that enable the expansion of the Nation s industrial productivity. NASA has long pursued ways of improving upon and ensuring quality results from manufacturing processes ranging from arc welding to thermal coating applications. But many of these processes generate blinding light (hence the need for special eyewear during welding) that obscures the process while it is happening, making it difficult to monitor and evaluate. In the 1980s, NASA partnered with a company to develop technology to address this issue. Today, that collaboration has spawned multiple commercial products that not only support effective manufacturing for private industry but also may support NASA in the use of an exciting, rapidly growing field of manufacturing ideal for long-duration space missions.

Information flow analysis and Petri-net-based modeling for welding flexible manufacturing cell

NASA Astrophysics Data System (ADS)

Qiu, T.; Chen, Shanben; Wang, Y. T.; Wu, Lin

2000-10-01

Due to the development of advanced manufacturing technology and the introduction of Smart-Manufacturing notion in the field of modern industrial production, welding flexible manufacturing system (WFMS) using robot technology has become the inevitable developing direction on welding automation. In WFMS process, the flexibility for different welding products and the realizing on corresponding welding parameters control are the guarantees for welding quality. Based on a new intelligent arc-welding flexible manufacturing cell (WFMC), the system structure and control policies are studied in this paper. Aiming at the different information flows among every subsystem and central monitoring computer in this WFMC, Petri net theory is introduced into the process of welding manufacturing. With its help, a discrete control model of WFMC has been constructed, in which the system status is regarded as place and the control process is regarded as transition. Moreover, grounded on automation Petri net principle, the judging and utilizing of information obtained from welding sensors are imported into net structure, which extends the traditional Petri net concepts. The control model and policies researched in this paper have established foundation for further intelligent real-time control on WFMC and WFMS.

On the lower bound of monitor solutions of maximally permissive supervisors for a subclass α-S3PR of flexible manufacturing systems

NASA Astrophysics Data System (ADS)

Chao, Daniel Yuh

2015-01-01

Recently, a novel and computationally efficient method - based on a vector covering approach - to design optimal control places and an iteration approach that computes the reachability graph to obtain a maximally permissive liveness enforcing supervisor for FMS (flexible manufacturing systems) have been reported. However, it is unclear as to the relationship between the structure of the net and the minimal number of monitors required. This paper develops a theory to show that the minimal number of monitors required cannot be less than that of basic siphons in α-S3PR (systems of simple sequential processes with resources). This confirms that two of the three controlled systems by Chen et al. are of a minimal monitor configuration since they belong to α-S3PR and their number in each example equals that of basic siphons.

Design of overload vehicle monitoring and response system based on DSP

NASA Astrophysics Data System (ADS)

Yu, Yan; Liu, Yiheng; Zhao, Xuefeng

2014-03-01

The overload vehicles are making much more damage to the road surface than the regular ones. Many roads and bridges are equipped with structural health monitoring system (SHM) to provide early-warning to these damage and evaluate the safety of road and bridge. However, because of the complex nature of SHM system, it's expensive to manufacture, difficult to install and not well-suited for the regular bridges and roads. Based on this application background, this paper designs a compact structural health monitoring system based on DSP, which is highly integrated, low-power, easy to install and inexpensive to manufacture. The designed system is made up of sensor arrays, the charge amplifier module, the DSP processing unit, the alarm system for overload, and the estimate for damage of the road and bridge structure. The signals coming from sensor arrays go through the charge amplifier. DSP processing unit will receive the amplified signals, estimate whether it is an overload signal or not, and convert analog variables into digital ones so that they are compatible with the back-end digital circuit for further processing. The system will also restrict certain vehicles that are overweight, by taking image of the car brand, sending the alarm, and transferring the collected pressure data to remote data center for further monitoring analysis by rain-flow counting method.

Using PAT to accelerate the transition to continuous API manufacturing.

PubMed

Gouveia, Francisca F; Rahbek, Jesper P; Mortensen, Asmus R; Pedersen, Mette T; Felizardo, Pedro M; Bro, Rasmus; Mealy, Michael J

2017-01-01

Significant improvements can be realized by converting conventional batch processes into continuous ones. The main drivers include reduction of cost and waste, increased safety, and simpler scale-up and tech transfer activities. Re-designing the process layout offers the opportunity to incorporate a set of process analytical technologies (PAT) embraced in the Quality-by-Design (QbD) framework. These tools are used for process state estimation, providing enhanced understanding of the underlying variability in the process impacting quality and yield. This work describes a road map for identifying the best technology to speed-up the development of continuous processes while providing the basis for developing analytical methods for monitoring and controlling the continuous full-scale reaction. The suitability of in-line Raman, FT-infrared (FT-IR), and near-infrared (NIR) spectroscopy for real-time process monitoring was investigated in the production of 1-bromo-2-iodobenzene. The synthesis consists of three consecutive reaction steps including the formation of an unstable diazonium salt intermediate, which is critical to secure high yield and avoid formation of by-products. All spectroscopic methods were able to capture critical information related to the accumulation of the intermediate with very similar accuracy. NIR spectroscopy proved to be satisfactory in terms of performance, ease of installation, full-scale transferability, and stability to very adverse process conditions. As such, in-line NIR was selected to monitor the continuous full-scale production. The quantitative method was developed against theoretical concentration values of the intermediate since representative sampling for off-line reference analysis cannot be achieved. The rapid and reliable analytical system allowed the following: speeding up the design of the continuous process and a better understanding of the manufacturing requirements to ensure optimal yield and avoid unreacted raw materials and by-products in the continuous reactor effluent. Graphical Abstract Using PAT to accelerate the transition to continuous API manufacturing.

Calibrating IR Cameras for In-Situ Temperature Measurement During the Electron Beam Melting Process using Inconel 718 and Ti-Al6-V4

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dinwiddie, Ralph Barton; Lloyd, Peter D; Dehoff, Ryan R

2016-01-01

The Department of Energy s (DOE) Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) provides world-leading capabilities in advanced manufacturing (AM) facilities which leverage previous, on-going government investments in materials science research and characterization. MDF contains systems for fabricating components with complex geometries using AM techniques (i.e. 3D-Printing). Various metal alloy printers, for example, use electron beam melting (EBM) systems for creating these components which are otherwise extremely difficult- if not impossible- to machine. ORNL has partnered with manufacturers on improving the final part quality of components and developing new materials for further advancing these devices. One methodmore » being used to study (AM) processes in more depth relies on the advanced imaging capabilities at ORNL. High performance mid-wave infrared (IR) cameras are used for in-situ process monitoring and temperature measurements. However, standard factory calibrations are insufficient due to very low transmissions of the leaded glass window required for X-ray absorption. Two techniques for temperature calibrations will be presented and compared. In-situ measurement of emittance will also be discussed. Ample information can be learned from in-situ IR process monitoring of the EBM process. Ultimately, these imaging systems have the potential for routine use for online quality assurance and feedback control.« less

Portable System for Monitoring the Microclimate in the Footwear-Foot Interface

PubMed Central

Sandoval-Palomares, José de Jesús; Yáñez-Mendiola, Javier; Gómez-Espinosa, Alfonso; López-Vela, José Martin

2016-01-01

A new, continuously-monitoring portable device that monitors the diabetic foot has shown to help in reduction of diabetic foot complications. Persons affected by diabetic foot have shown to be particularly sensitive in the plantar surface; this sensitivity coupled with certain ambient conditions may cause dry skin. This dry skin leads to the formation of fissures that may eventually result in a foot ulceration and subsequent hospitalization. This new device monitors the micro-climate temperature and humidity areas between the insole and sole of the footwear. The monitoring system consists of an array of ten sensors that take readings of relative humidity within the range of 100% ± 2% and temperature within the range of −40 °C to 123.8 ± 0.3 °C. Continuous data is collected using embedded C software and the recorded data is processed in Matlab. This allows for the display of data; the implementation of the iterative Gauss-Newton algorithm method was used to display an exponential response curve. Therefore, the aim of our system is to obtain feedback data and provide the critical information to various footwear manufacturers. The footwear manufactures will utilize this critical information to design and manufacture diabetic footwear that reduce the risk of ulcers in diabetic feet. PMID:27399718

In-situ measurement of processing properties during fabrication in a production tool

NASA Technical Reports Server (NTRS)

Kranbuehl, D. E.; Haverty, P.; Hoff, M.; Loos, A. C.

1988-01-01

Progress is reported on the use of frequency-dependent electromagnetic measurements (FDEMs) as a single, convenient technique for continuous in situ monitoring of polyester cure during fabrication in a laboratory and manufacturing environment. Preliminary FDEM sensor and modeling work using the Loss-Springer model in order to develop an intelligent closed-loop, sensor-controlled cure process is described. FDEMs using impedance bridges in the Hz to MHz region is found to be ideal for automatically monitoring polyester processing properties continuously throughout the cure cycle.

Applications of open-path Fourier transform infrared for identification of volatile organic compound pollution sources and characterization of source emission behaviors.

PubMed

Lin, Chitsan; Liou, Naiwei; Sun, Endy

2008-06-01

An open-path Fourier transform infrared spectroscopy (OP-FTIR) system was set up for 3-day continuous line-averaged volatile organic compound (VOC) monitoring in a paint manufacturing plant. Seven VOCs (toluene, m-xylene, p-xylene, styrene, methanol, acetone, and 2-butanone) were identified in the ambient environment. Daytime-only batch operation mode was well explained by the time-series concentration plots. Major sources of methanol, m-xylene, acetone, and 2-butanone were identified in the southeast direction where paint solvent manufacturing processes are located. However, an attempt to uncover sources of styrene was not successful because the method detection limit (MDL) of the OP-FTIR system was not sensitive enough to produce conclusive data. In the second scenario, the OP-FTIR system was set up in an industrial complex to distinguish the origins of several VOCs. Eight major VOCs were identified in the ambient environment. The pollutant detected wind-rose percentage plots that clearly showed that ethylene, propylene, 2-butanone, and toluene mainly originated from the tank storage area, whereas the source of n-butane was mainly from the butadiene manufacturing processes of the refinery plant, and ammonia was identified as an accompanying reduction product in the gasoline desulfuration process. Advantages of OP-FTIR include its ability to simultaneously and continuously analyze many compounds, and its long path length monitoring has also shown advantages in obtaining more comprehensive data than the traditional multiple, single-point monitoring methods.

Quality-by-Design approach to monitor the operation of a batch bioreactor in an industrial avian vaccine manufacturing process.

PubMed

Largoni, Martina; Facco, Pierantonio; Bernini, Donatella; Bezzo, Fabrizio; Barolo, Massimiliano

2015-10-10

Monitoring batch bioreactors is a complex task, due to the fact that several sources of variability can affect a running batch and impact on the final product quality. Additionally, the product quality itself may not be measurable on line, but requires sampling and lab analysis taking several days to be completed. In this study we show that, by using appropriate process analytical technology tools, the operation of an industrial batch bioreactor used in avian vaccine manufacturing can be effectively monitored as the batch progresses. Multivariate statistical models are built from historical databases of batches already completed, and they are used to enable the real time identification of the variability sources, to reliably predict the final product quality, and to improve process understanding, paving the way to a reduction of final product rejections, as well as to a reduction of the product cycle time. It is also shown that the product quality "builds up" mainly during the first half of a batch, suggesting on the one side that reducing the variability during this period is crucial, and on the other side that the batch length can possibly be shortened. Overall, the study demonstrates that, by using a Quality-by-Design approach centered on the appropriate use of mathematical modeling, quality can indeed be built "by design" into the final product, whereas the role of end-point product testing can progressively reduce its importance in product manufacturing. Copyright © 2015 Elsevier B.V. All rights reserved.

Devices for monitoring content of microparticles and bacterium in injection solutions in pharmaceutical production

NASA Astrophysics Data System (ADS)

Bilyi, Olexander I.; Getman, Vasyl B.; Konyev, Fedir A.; Sapunkov, Olexander; Sapunkov, Pavlo G.

2001-06-01

The devices for monitoring of parameters of efficiency of water solutions filtration, which are based on the analysis of scattered light by microparticles are considered in this article. The efficiency of using of devices in pharmaceutics in technological processes of manufacturing medical injection solutions is shown. The examples of monitoring of contents of bacterial cultures Pseudomonas aeruginosa, Escherichia coli, and Micrococcus luteus in water solutions of glucose are indicated.

Intelligent Extruder

DOE Office of Scientific and Technical Information (OSTI.GOV)

AlperEker; Mark Giammattia; Paul Houpt

''Intelligent Extruder'' described in this report is a software system and associated support services for monitoring and control of compounding extruders to improve material quality, reduce waste and energy use, with minimal addition of new sensors or changes to the factory floor system components. Emphasis is on process improvements to the mixing, melting and de-volatilization of base resins, fillers, pigments, fire retardants and other additives in the :finishing'' stage of high value added engineering polymer materials. While GE Plastics materials were used for experimental studies throughout the program, the concepts and principles are broadly applicable to other manufacturers materials. Themore » project involved a joint collaboration among GE Global Research, GE Industrial Systems and Coperion Werner & Pleiderer, USA, a major manufacturer of compounding equipment. Scope of the program included development of a algorithms for monitoring process material viscosity without rheological sensors or generating waste streams, a novel detection scheme for rapid detection of process upsets and an adaptive feedback control system to compensate for process upsets where at line adjustments are feasible. Software algorithms were implemented and tested on a laboratory scale extruder (50 lb/hr) at GE Global Research and data from a production scale system (2000 lb/hr) at GE Plastics was used to validate the monitoring and detection software. Although not evaluated experimentally, a new concept for extruder process monitoring through estimation of high frequency drive torque without strain gauges is developed and demonstrated in simulation. A plan to commercialize the software system is outlined, but commercialization has not been completed.« less

Defect recognition in CFRP components using various NDT methods within a smart manufacturing process

NASA Astrophysics Data System (ADS)

Schumacher, David; Meyendorf, Norbert; Hakim, Issa; Ewert, Uwe

2018-04-01

The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of defective volume. Besides ultrasound, thermography and eddy current, different X-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the concepts of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized.

Implementation of Non-Destructive Evaluation and Process Monitoring in DLP-based Additive Manufacturing

NASA Astrophysics Data System (ADS)

Kovalenko, Iaroslav; Verron, Sylvain; Garan, Maryna; Šafka, Jiří; Moučka, Michal

2017-04-01

This article describes a method of in-situ process monitoring in the digital light processing (DLP) 3D printer. It is based on the continuous measurement of the adhesion force between printing surface and bottom of a liquid resin bath. This method is suitable only for the bottom-up DPL printers. Control system compares the force at the moment of unsticking of printed layer from the bottom of the tank, when it has the largest value in printing cycle, with theoretical value. Implementation of suggested algorithm can make detection of faults during the printing process possible.

Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

NASA Technical Reports Server (NTRS)

Agapakis, John E.; Bolstad, Jon

1993-01-01

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

Statistical Process Control in the Practice of Program Evaluation.

ERIC Educational Resources Information Center

Posavac, Emil J.

1995-01-01

A technique developed to monitor the quality of manufactured products, statistical process control (SPC), incorporates several features that may prove attractive to evaluators. This paper reviews the history of SPC, suggests how the approach can enrich program evaluation, and illustrates its use in a hospital-based example. (SLD)

In-line verification of linewidth uniformity for 0.18 and below: design rule reticles

NASA Astrophysics Data System (ADS)

Tan, TaiSheng; Kuo, Shen C.; Wu, Clare; Falah, Reuven; Hemar, Shirley; Sade, Amikam; Gottlib, Gidon

2000-07-01

Mask making process development and control is addressed using a reticle inspection tool equipped with the new revolutionized application called LBM-Linewidth Bias Monitoring. In order to use the LBM for mask-making process control, procedures and corresponding test plates are a developed, such that routine monitoring of the manufacturing process discloses process variation and machine variation. At the same time systematic variation are studied and either taken care of or taken into consideration to allow successful production line work. In this paper the contribution of the LBM for mask quality monitoring is studied with respect to dense layers, e.g. DRAM. Another aspect of this application - the detection of very small CD mis-uniformity areas is discussed.

Using the surface charge profiler for in-line monitoring of doping concentration in silicon epitaxial wafer manufacturing

NASA Astrophysics Data System (ADS)

Tower, Joshua P.; Kamieniecki, Emil; Nguyen, M. C.; Danel, Adrien

1999-08-01

The Surface Charge Profiler (SCP) has been introduced for monitoring and development of silicon epitaxial processes. The SCP measures the near-surface doping concentration and offers advantages that lead to yield enhancement in several ways. First, non-destructive measurement technology enables in-line process monitoring, eliminating the need to sacrifice production wafers for resistivity measurements. Additionally, the full-wafer mapping capability helps in development of improved epitaxial growth processes and early detection of reactor problems. As examples, we present the use of SCP to study the effects of susceptor degradation in barrel reactors and to study autodoping for development of improved dopant uniformity.

[Near infrared spectroscopy based process trajectory technology and its application in monitoring and controlling of traditional Chinese medicine manufacturing process].

PubMed

Li, Wen-Long; Qu, Hai-Bin

2016-10-01

In this paper, the principle of NIRS (near infrared spectroscopy)-based process trajectory technology was introduced.The main steps of the technique include:① in-line collection of the processes spectra of different technics; ② unfolding of the 3-D process spectra;③ determination of the process trajectories and their normal limits;④ monitoring of the new batches with the established MSPC (multivariate statistical process control) models.Applications of the technology in the chemical and biological medicines were reviewed briefly. By a comprehensive introduction of our feasibility research on the monitoring of traditional Chinese medicine technical process using NIRS-based multivariate process trajectories, several important problems of the practical applications which need urgent solutions are proposed, and also the application prospect of the NIRS-based process trajectory technology is fully discussed and put forward in the end. Copyright© by the Chinese Pharmaceutical Association.

Sampling the food processing environment: taking up the cudgel for preventive quality management in food processing environments.

PubMed

Wagner, Martin; Stessl, Beatrix

2014-01-01

The Listeria monitoring program for Austrian cheese factories was established in 1988. The basic idea is to control the introduction of L. monocytogenes into the food processing environment, preventing the pathogen from contaminating the food under processing. The Austrian Listeria monitoring program comprises four levels of investigation, dealing with routine monitoring of samples and consequences of finding a positive sample. Preventive quality control concepts attempt to detect a foodborne hazard along the food processing chain, prior to food delivery, retailing, and consumption. The implementation of a preventive food safety concept provokes a deepened insight by the manufacturers into problems concerning food safety. The development of preventive quality assurance strategies contributes to the national food safety status and protects public health.

Monitoring the progression of calcium and protein solubilisation as affected by calcium chelators during small-scale manufacture of casein-based food matrices.

PubMed

McIntyre, Irene; O'Sullivan, Michael; O'Riordan, Dolores

2017-12-15

Calcium and protein solubilisation during small-scale manufacture of semi-solid casein-based food matrices was investigated and found to be very different in the presence or absence of calcium chelating salts. Calcium concentrations in the dispersed phase increased and calcium-ion activity (A Ca ++ ) decreased during manufacture of the matrices containing calcium chelating salts; with ∼23% of total calcium solubilised by the end of manufacture. In the absence of calcium chelating salts, these concentrations were significantly lower at equivalent processing times and remained unchanged as did A Ca ++ , throughout manufacture. The protein content of the dispersed phase was low (≤3% of total protein), but was significantly higher for matrices containing calcium chelating salts. This study elucidates the critical role of calcium chelating salts in modulating casein hydration and dispersion and gives an indication of the levels of soluble calcium and protein required to allow matrix formation during manufacture of casein-based food structures e.g. processed and analogue cheese. Copyright © 2017 Elsevier Ltd. All rights reserved.

Demonstration of array eddy current technology for real-time monitoring of laser powder bed fusion additive manufacturing process

NASA Astrophysics Data System (ADS)

Todorov, Evgueni; Boulware, Paul; Gaah, Kingsley

2018-03-01

Nondestructive evaluation (NDE) at various fabrication stages is required to assure quality of feedstock and solid builds. Industry efforts are shifting towards solutions that can provide real-time monitoring of additive manufacturing (AM) fabrication process layer-by-layer while the component is being built to reduce or eliminate dependence on post-process inspection. Array eddy current (AEC), electromagnetic NDE technique was developed and implemented to directly scan the component without physical contact with the powder and fused layer surfaces at elevated temperatures inside a LPBF chamber. The technique can detect discontinuities, surface irregularities, and undesirable metallurgical phase transformations in magnetic and nonmagnetic conductive materials used for laser fusion. The AEC hardware and software were integrated with the L-PBF test bed. Two layer-by-layer tests of Inconel 625 coupons with AM built discontinuities and lack of fusion were conducted inside the L-PBF chamber. The AEC technology demonstrated excellent sensitivity to seeded, natural surface, and near-surface-embedded discontinuities, while also detecting surface topography. The data was acquired and imaged in a layer-by-layer sequence demonstrating the real-time monitoring capabilities of this new technology.

Cyber physical systems role in manufacturing technologies

NASA Astrophysics Data System (ADS)

Al-Ali, A. R.; Gupta, Ragini; Nabulsi, Ahmad Al

2018-04-01

Empowered by the recent development in single System-on-Chip, Internet of Things, and cloud computing technologies, cyber physical systems are evolving as a major controller during and post the manufacturing products process. In additional to their real physical space, cyber products nowadays have a virtual space. A product virtual space is a digital twin that is attached to it to enable manufacturers and their clients to better manufacture, monitor, maintain and operate it throughout its life time cycles, i.e. from the product manufacturing date, through operation and to the end of its lifespan. Each product is equipped with a tiny microcontroller that has a unique identification number, access code and WiFi conductivity to access it anytime and anywhere during its life cycle. This paper presents the cyber physical systems architecture and its role in manufacturing. Also, it highlights the role of Internet of Things and cloud computing in industrial manufacturing and factory automation.

Evaluation of an artificial intelligence program for estimating occupational exposures.

PubMed

Johnston, Karen L; Phillips, Margaret L; Esmen, Nurtan A; Hall, Thomas A

2005-03-01

Estimation and Assessment of Substance Exposure (EASE) is an artificial intelligence program developed by UK's Health and Safety Executive to assess exposure. EASE computes estimated airborne concentrations based on a substance's vapor pressure and the types of controls in the work area. Though EASE is intended only to make broad predictions of exposure from occupational environments, some occupational hygienists might attempt to use EASE for individual exposure characterizations. This study investigated whether EASE would accurately predict actual sampling results from a chemical manufacturing process. Personal breathing zone time-weighted average (TWA) monitoring data for two volatile organic chemicals--a common solvent (toluene) and a specialty monomer (chloroprene)--present in this manufacturing process were compared to EASE-generated estimates. EASE-estimated concentrations for specific tasks were weighted by task durations reported in the monitoring record to yield TWA estimates from EASE that could be directly compared to the measured TWA data. Two hundred and six chloroprene and toluene full-shift personal samples were selected from eight areas of this manufacturing process. The Spearman correlation between EASE TWA estimates and measured TWA values was 0.55 for chloroprene and 0.44 for toluene, indicating moderate predictive values for both compounds. For toluene, the interquartile range of EASE estimates at least partially overlapped the interquartile range of the measured data distributions in all process areas. The interquartile range of EASE estimates for chloroprene fell above the interquartile range of the measured data distributions in one process area, partially overlapped the third quartile of the measured data in five process areas and fell within the interquartile range in two process areas. EASE is not a substitute for actual exposure monitoring. However, EASE can be used in conditions that cannot otherwise be sampled and in preliminary exposure assessment if it is recognized that the actual interquartile range could be much wider and/or offset by a factor of 10 or more.

Process analytical technology in continuous manufacturing of a commercial pharmaceutical product.

PubMed

Vargas, Jenny M; Nielsen, Sarah; Cárdenas, Vanessa; Gonzalez, Anthony; Aymat, Efrain Y; Almodovar, Elvin; Classe, Gustavo; Colón, Yleana; Sanchez, Eric; Romañach, Rodolfo J

2018-03-01

The implementation of process analytical technology and continuous manufacturing at an FDA approved commercial manufacturing site is described. In this direct compaction process the blends produced were monitored with a Near Infrared (NIR) spectroscopic calibration model developed with partial least squares (PLS) regression. The authors understand that this is the first study where the continuous manufacturing (CM) equipment was used as a gravimetric reference method for the calibration model. A principal component analysis (PCA) model was also developed to identify the powder blend, and determine whether it was similar to the calibration blends. An air diagnostic test was developed to assure that powder was present within the interface when the NIR spectra were obtained. The air diagnostic test as well the PCA and PLS calibration model were integrated into an industrial software platform that collects the real time NIR spectra and applies the calibration models. The PCA test successfully detected an equipment malfunction. Variographic analysis was also performed to estimate the sampling analytical errors that affect the results from the NIR spectroscopic method during commercial production. The system was used to monitor and control a 28 h continuous manufacturing run, where the average drug concentration determined by the NIR method was 101.17% of label claim with a standard deviation of 2.17%, based on 12,633 spectra collected. The average drug concentration for the tablets produced from these blends was 100.86% of label claim with a standard deviation of 0.4%, for 500 tablets analyzed by Fourier Transform Near Infrared (FT-NIR) transmission spectroscopy. The excellent agreement between the mean drug concentration values in the blends and tablets produced provides further evidence of the suitability of the validation strategy that was followed. Copyright © 2018 Elsevier B.V. All rights reserved.

[Monitoring method for macroporous resin column chromatography process of salvianolic acids based on near infrared spectroscopy].

PubMed

Hou, Xiang-Mei; Zhang, Lei; Yue, Hong-Shui; Ju, Ai-Chun; Ye, Zheng-Liang

2016-07-01

To study and establish a monitoring method for macroporous resin column chromatography process of salvianolic acids by using near infrared spectroscopy (NIR) as a process analytical technology (PAT).The multivariate statistical process control (MSPC) model was developed based on 7 normal operation batches, and 2 test batches (including one normal operation batch and one abnormal operation batch) were used to verify the monitoring performance of this model. The results showed that MSPC model had a good monitoring ability for the column chromatography process. Meanwhile, NIR quantitative calibration model was established for three key quality indexes (rosmarinic acid, lithospermic acid and salvianolic acid B) by using partial least squares (PLS) algorithm. The verification results demonstrated that this model had satisfactory prediction performance. The combined application of the above two models could effectively achieve real-time monitoring for macroporous resin column chromatography process of salvianolic acids, and can be used to conduct on-line analysis of key quality indexes. This established process monitoring method could provide reference for the development of process analytical technology for traditional Chinese medicines manufacturing. Copyright© by the Chinese Pharmaceutical Association.

Optimizing process and equipment efficiency using integrated methods

NASA Astrophysics Data System (ADS)

D'Elia, Michael J.; Alfonso, Ted F.

1996-09-01

The semiconductor manufacturing industry is continually riding the edge of technology as it tries to push toward higher design limits. Mature fabs must cut operating costs while increasing productivity to remain profitable and cannot justify large capital expenditures to improve productivity. Thus, they must push current tool production capabilities to cut manufacturing costs and remain viable. Working to continuously improve mature production methods requires innovation. Furthermore, testing and successful implementation of these ideas into modern production environments require both supporting technical data and commitment from those working with the process daily. At AMD, natural work groups (NWGs) composed of operators, technicians, engineers, and supervisors collaborate to foster innovative thinking and secure commitment. Recently, an AMD NWG improved equipment cycle time on the Genus tungsten silicide (WSi) deposition system. The team used total productive manufacturing (TPM) to identify areas for process improvement. Improved in-line equipment monitoring was achieved by constructing a real time overall equipment effectiveness (OEE) calculator which tracked equipment down, idle, qualification, and production times. In-line monitoring results indicated that qualification time associated with slow Inspex turn-around time and machine downtime associated with manual cleans contributed greatly to reduced availability. Qualification time was reduced by 75% by implementing a new Inspex monitor pre-staging technique. Downtime associated with manual cleans was reduced by implementing an in-situ plasma etch back to extend the time between manual cleans. A designed experiment was used to optimize the process. Time between 18 hour manual cleans has been improved from every 250 to every 1500 cycles. Moreover defect density realized a 3X improvement. Overall, the team achieved a 35% increase in tool availability. This paper details the above strategies and accomplishments.

Monitoring techniques for the manufacture of tapered optical fibers.

PubMed

Mullaney, Kevin; Correia, Ricardo; Staines, Stephen E; James, Stephen W; Tatam, Ralph P

2015-10-01

The use of a range of optical techniques to monitor the process of fabricating optical fiber tapers is investigated. Thermal imaging was used to optimize the alignment of the optical system; the transmission spectrum of the fiber was monitored to confirm that the tapers had the required optical properties and the strain induced in the fiber during tapering was monitored using in-line optical fiber Bragg gratings. Tapers were fabricated with diameters down to 5 μm and with waist lengths of 20 mm using single-mode SMF-28 fiber.

Quality control troubleshooting tools for the mill floor

Treesearch

John Dramm

2000-01-01

Statistical Process Control (SPC) provides effective tools for improving process quality in the forest products industry resulting in reduced costs and improved productivity. Implementing SPC helps identify and locate problems that occur in wood products manufacturing. SPC tools achieve their real value when applied on the mill floor for monitoring and troubleshooting...

Factory-Calibrated Continuous Glucose Sensors: The Science Behind the Technology.

PubMed

Hoss, Udo; Budiman, Erwin Satrya

2017-05-01

The use of commercially available continuous glucose monitors for diabetes management requires sensor calibrations, which until recently are exclusively performed by the patient. A new development is the implementation of factory calibration for subcutaneous glucose sensors, which eliminates the need for user calibrations and the associated blood glucose tests. Factory calibration means that the calibration process is part of the sensor manufacturing process and performed under controlled laboratory conditions. The ability to move from a user calibration to factory calibration is based on several technical requirements related to sensor stability and the robustness of the sensor manufacturing process. The main advantages of factory calibration over the conventional user calibration are: (a) more convenience for the user, since no more fingersticks are required for calibration and (b) elimination of use errors related to the execution of the calibration process, which can lead to sensor inaccuracies. The FreeStyle Libre ™ and FreeStyle Libre Pro ™ flash continuous glucose monitoring systems are the first commercially available sensor systems using factory-calibrated sensors. For these sensor systems, no user calibrations are required throughout the sensor wear duration.

Factory-Calibrated Continuous Glucose Sensors: The Science Behind the Technology

PubMed Central

Budiman, Erwin Satrya

2017-01-01

Abstract The use of commercially available continuous glucose monitors for diabetes management requires sensor calibrations, which until recently are exclusively performed by the patient. A new development is the implementation of factory calibration for subcutaneous glucose sensors, which eliminates the need for user calibrations and the associated blood glucose tests. Factory calibration means that the calibration process is part of the sensor manufacturing process and performed under controlled laboratory conditions. The ability to move from a user calibration to factory calibration is based on several technical requirements related to sensor stability and the robustness of the sensor manufacturing process. The main advantages of factory calibration over the conventional user calibration are: (a) more convenience for the user, since no more fingersticks are required for calibration and (b) elimination of use errors related to the execution of the calibration process, which can lead to sensor inaccuracies. The FreeStyle Libre™ and FreeStyle Libre Pro™ flash continuous glucose monitoring systems are the first commercially available sensor systems using factory-calibrated sensors. For these sensor systems, no user calibrations are required throughout the sensor wear duration. PMID:28541139

In-situ quality monitoring during laser brazing

NASA Astrophysics Data System (ADS)

Ungers, Michael; Fecker, Daniel; Frank, Sascha; Donst, Dmitri; Märgner, Volker; Abels, Peter; Kaierle, Stefan

Laser brazing of zinc coated steel is a widely established manufacturing process in the automotive sector, where high quality requirements must be fulfilled. The strength, impermeablitiy and surface appearance of the joint are particularly important for judging its quality. The development of an on-line quality control system is highly desired by the industry. This paper presents recent works on the development of such a system, which consists of two cameras operating in different spectral ranges. For the evaluation of the system, seam imperfections are created artificially during experiments. Finally image processing algorithms for monitoring process parameters based the captured images are presented.

Mesenchymal Stem Cells as Therapeutics Agents: Quality and Environmental Regulatory Aspects

PubMed Central

Sabata, Roger; Verges, Josep; Zugaza, José L.; Ruiz, Adolfina; Clares, Beatriz

2016-01-01

Mesenchymal stem cells (MSCs) are one of the main stem cells that have been used for advanced therapies and regenerative medicine. To carry out the translational clinical application of MSCs, their manufacturing and administration in human must be controlled; therefore they should be considered as medicine: stem cell-based medicinal products (SCMPs). The development of MSCs as SCMPs represents complicated therapeutics due to their extreme complex nature and rigorous regulatory oversights. The manufacturing process of MSCs needs to be addressed in clean environments in compliance with requirements of Good Manufacturing Practice (GMP). Facilities should maintain these GMP conditions according to international and national medicinal regulatory frameworks that introduce a number of specifications in order to produce MSCs as safe SCMPs. One of these important and complex requirements is the environmental monitoring. Although a number of environmental requirements are clearly defined, some others are provided as recommendations. In this review we aim to outline the current issues with regard to international guidelines which impact environmental monitoring in cleanrooms and clean areas for the manufacturing of MSCs. PMID:27999600

Intelligent system of coordination and control for manufacturing

NASA Astrophysics Data System (ADS)

Ciortea, E. M.

2016-08-01

This paper wants shaping an intelligent system monitoring and control, which leads to optimizing material and information flows of the company. The paper presents a model for tracking and control system using intelligent real. Production system proposed for simulation analysis provides the ability to track and control the process in real time. Using simulation models be understood: the influence of changes in system structure, commands influence on the general condition of the manufacturing process conditions influence the behavior of some system parameters. Practical character consists of tracking and real-time control of the technological process. It is based on modular systems analyzed using mathematical models, graphic-analytical sizing, configuration, optimization and simulation.

40 CFR Table 2 to Subpart Mmm of... - Standards for New and Existing PAI Sources

Code of Federal Regulations, 2012 CFR

2012-07-01

... a HAP Particulate matter concentration not to exceed 0.01 gr/dscf. Heat exchange systems Each heat exchange system used to cool process equipment in PAI manufacturing operations Monitoring and leak repair...

40 CFR Table 2 to Subpart Mmm of... - Standards for New and Existing PAI Sources

Code of Federal Regulations, 2011 CFR

2011-07-01

... a HAP Particulate matter concentration not to exceed 0.01 gr/dscf. Heat exchange systems Each heat exchange system used to cool process equipment in PAI manufacturing operations Monitoring and leak repair...

Knowledge Reasoning with Semantic Data for Real-Time Data Processing in Smart Factory

PubMed Central

Wang, Shiyong; Li, Di; Liu, Chengliang

2018-01-01

The application of high-bandwidth networks and cloud computing in manufacturing systems will be followed by mass data. Industrial data analysis plays important roles in condition monitoring, performance optimization, flexibility, and transparency of the manufacturing system. However, the currently existing architectures are mainly for offline data analysis, not suitable for real-time data processing. In this paper, we first define the smart factory as a cloud-assisted and self-organized manufacturing system in which physical entities such as machines, conveyors, and products organize production through intelligent negotiation and the cloud supervises this self-organized process for fault detection and troubleshooting based on data analysis. Then, we propose a scheme to integrate knowledge reasoning and semantic data where the reasoning engine processes the ontology model with real time semantic data coming from the production process. Based on these ideas, we build a benchmarking system for smart candy packing application that supports direct consumer customization and flexible hybrid production, and the data are collected and processed in real time for fault diagnosis and statistical analysis. PMID:29415444

Hyperspectral imaging using near infrared spectroscopy to monitor coat thickness uniformity in the manufacture of a transdermal drug delivery system.

PubMed

Pavurala, Naresh; Xu, Xiaoming; Krishnaiah, Yellela S R

2017-05-15

Hyperspectral imaging using near infrared spectroscopy (NIRS) integrates spectroscopy and conventional imaging to obtain both spectral and spatial information of materials. The non-invasive and rapid nature of hyperspectral imaging using NIRS makes it a valuable process analytical technology (PAT) tool for in-process monitoring and control of the manufacturing process for transdermal drug delivery systems (TDS). The focus of this investigation was to develop and validate the use of Near Infra-red (NIR) hyperspectral imaging to monitor coat thickness uniformity, a critical quality attribute (CQA) for TDS. Chemometric analysis was used to process the hyperspectral image and a partial least square (PLS) model was developed to predict the coat thickness of the TDS. The goodness of model fit and prediction were 0.9933 and 0.9933, respectively, indicating an excellent fit to the training data and also good predictability. The % Prediction Error (%PE) for internal and external validation samples was less than 5% confirming the accuracy of the PLS model developed in the present study. The feasibility of the hyperspectral imaging as a real-time process analytical tool for continuous processing was also investigated. When the PLS model was applied to detect deliberate variation in coating thickness, it was able to predict both the small and large variations as well as identify coating defects such as non-uniform regions and presence of air bubbles. Published by Elsevier B.V.

Implant Monitoring Measurements On Ultra Shallow Implants Before And After Anneal Using Photomodulated Reflection And Junction Photovoltage Measurement Techniques

NASA Astrophysics Data System (ADS)

Tallian, M.; Pap, A.; Mocsar, K.; Somogyi, A.; Nadudvari, Gy.; Kosztka, D.; Pavelka, T.

2011-01-01

Ultra shallow junctions are becoming widely used in the micro- and nanoelectronic devices, and novel measurement methods are needed to monitor the manufacturing processes. Photomodulated Reflection measurements before anneal and Junction Photovoltage-based sheet resistance measurements after anneal are non-contact, nondestructive techniques suitable for characterizing both the implantation and the annealing process. Tests verify that these methods are consistent with each other and by using them together, defects originating in the implantation and anneal steps can be separated.

Toward Higher QA: From Parametric Release of Sterile Parenteral Products to PAT for Other Pharmaceutical Dosage Forms.

PubMed

Hock, Sia Chong; Constance, Neo Xue Rui; Wah, Chan Lai

2012-01-01

Pharmaceutical products are generally subjected to end-product batch testing as a means of quality control. Due to the inherent limitations of conventional batch testing, this is not the most ideal approach for determining the pharmaceutical quality of the finished dosage form. In the case of terminally sterilized parenteral products, the limitations of conventional batch testing have been successfully addressed with the application of parametric release (the release of a product based on control of process parameters instead of batch sterility testing at the end of the manufacturing process). Consequently, there has been an increasing interest in applying parametric release to other pharmaceutical dosage forms, beyond terminally sterilized parenteral products. For parametric release to be possible, manufacturers must be capable of designing quality into the product, monitoring the manufacturing processes, and controlling the quality of intermediates and finished products in real-time. Process analytical technology (PAT) has been thought to be capable of contributing to these prerequisites. It is believed that the appropriate use of PAT tools can eventually lead to the possibility of real-time release of other pharmaceutical dosage forms, by-passing the need for end-product batch testing. Hence, this literature review attempts to present the basic principles of PAT, introduce the various PAT tools that are currently available, present their recent applications to pharmaceutical processing, and explain the potential benefits that PAT can bring to conventional ways of processing and quality assurance of pharmaceutical products. Last but not least, current regulations governing the use of PAT and the manufacturing challenges associated with PAT implementation are also discussed. Pharmaceutical products are generally subjected to end-product batch testing as a means of quality control. Due to the inherent limitations of conventional batch testing, this is not the most ideal approach. In the case of terminally sterilized parenteral products, these limitations have been successfully addressed with the application of parametric release (the release of a product based on control of process parameters instead of batch sterility testing at the end of the manufacturing process). Consequently, there has been an increasing interest in applying parametric release to other pharmaceutical dosage forms. With the advancement of process analytical technology (PAT), it is possible to monitor the manufacturing processes closely. This will eventually enable quality control of the intermediates and finished products, and thus their release in real-time. Hence, this literature review attempts to present the basic principles of PAT, introduce the various PAT tools that are currently available, present their recent applications to pharmaceutical processing, and explain the potential benefits that PAT can bring to conventional ways of processing and quality assurance of pharmaceutical products. It will also discuss the current regulations governing the use of PAT and the manufacturing challenges associated with the implementation of PAT.

78 FR 2657 - Foreign-Trade Zone 141-Rochester, NY, Application for Manufacturing Authority, Firth Rixson, Inc...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-01-14

... monitoring of the actual impact of Firth Rixson's FTZ use. If there were to be evidence of negative effects... competitors' plants abroad) through unrestricted FTZ benefits on its processing of foreign-origin titanium...

40 CFR Table 1 to Subpart Hhhh of... - Minimum Requirements for Monitoring and Recordkeeping

Code of Federal Regulations, 2010 CFR

2010-07-01

...-hour block averages. 2. Other process or control device parameters specified in your OMM b plan. As... value for each product manufactured during the operating day. 6. UF-to-latex ratio in the binder c For... Required if a thermal oxidizer is used to control formaldehyde emissions. b Required if process...

Some Inspection Methods for Quality Control and In-service Inspection of GLARE

NASA Astrophysics Data System (ADS)

Sinke, J.

2003-07-01

Quality control of materials and structures is an important issue, also for GLARE. During the manufacturing stage the processes and materials should be monitored and checked frequently in order to obtain a qualified product. During the operation of the aircraft, frequent monitoring and inspections are performed to maintain the quality at a prescribed level. Therefore, in-service inspection methods are applied, and when necessary repair activities are conducted. For the quality control of the GLARE panels and components during manufacturing, the C-scan method proves to be an effective tool. For in-service inspection the Eddy Current Method is one of the suitable options. In this paper a brief overview is presented of both methods and their application on GLARE products.

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

PubMed Central

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-01-01

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing. PMID:27854322

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining.

PubMed

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-11-16

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

Particle monitoring and control in vacuum processing equipment

NASA Astrophysics Data System (ADS)

Borden, Peter G., Dr.; Gregg, John

1989-10-01

Particle contamination during vacuum processes has emerged as the largest single source of yield loss in VLSI manufacturing. While a number of tools have been available to help understand the sources and nature of this contamination, only recently has it been possible to monitor free particle levels within vacuum equipment in real-time. As a result, a better picture is available of how particle contamination can affect a variety of processes. This paper reviews some of the work that has been done to monitor particles in vacuum loadlocks and in processes such as etching, sputtering and ion implantation. The aim has been to make free particles in vacuum equipment a measurable process parameter. Achieving this allows particles to be controlled using statistical process control. It will be shown that free particle levels in load locks correlate to wafer surface counts, device yield and process conditions, but that these levels are considerable higher during production than when dummy wafers are run to qualify a system. It will also be shown how real-time free particle monitoring can be used to monitor and control cleaning cycles, how major episodic events can be detected, and how data can be gathered in a format suitable for statistical process control.

Pattern centric design based sensitive patterns and process monitor in manufacturing

NASA Astrophysics Data System (ADS)

Hsiang, Chingyun; Cheng, Guojie; Wu, Kechih

2017-03-01

When design rule is mitigating to smaller dimension, process variation requirement is tighter than ever and challenges the limits of device yield. Masks, lithography, etching and other processes have to meet very tight specifications in order to keep defect and CD within the margins of the process window. Conventionally, Inspection and metrology equipments are utilized to monitor and control wafer quality in-line. In high throughput optical inspection, nuisance and review-classification become a tedious labor intensive job in manufacturing. Certain high-resolution SEM images are taken to validate defects after optical inspection. These high resolution SEM images catch not only optical inspection highlighted point, also its surrounding patterns. However, this pattern information is not well utilized in conventional quality control method. Using this complementary design based pattern monitor not only monitors and analyzes the variation of patterns sensitivity but also reduce nuisance and highlight defective patterns or killer defects. After grouping in either single or multiple layers, systematic defects can be identified quickly in this flow. In this paper, we applied design based pattern monitor in different layers to monitor process variation impacts on all kinds of patterns. First, the contour of high resolutions SEM image is extracted and aligned to design with offset adjustment and fine alignment [1]. Second, specified pattern rules can be applied on design clip area, the same size as SEM image, and form POI (pattern of interest) areas. Third, the discrepancy of contour and design measurement at different pattern types in measurement blocks. Fourth, defective patterns are reported by discrepancy detection criteria and pattern grouping [4]. Meanwhile, reported pattern defects are ranked by number and severity by discrepancy. In this step, process sensitive high repeatable systematic defects can be identified quickly Through this design based process pattern monitor method, most of optical inspection nuisances can be filtered out at contour to design discrepancy measurement. Daily analysis results are stored at database as reference to compare with incoming data. Defective pattern library contains existing and known systematic defect patterns which help to catch and identify new pattern defects or process impacts. On the other hand, this defect pattern library provides extra valuable information for mask, pattern and defects verification, inspection care area generation, further OPC fix and process enhancement and investigation.

Computers in manufacturing

NASA Astrophysics Data System (ADS)

Hudson, C. A.

1982-02-01

CAD/CAM advances and applications for enhancing productivity in industry are explored. Wide-spread use of CAD/CAM devices are projected to occur by the time period 1992-1997, resulting in a higher percentage of technicians in the manufacturing process, while the cost of computers and software will continue to fall and become more widely available. Computer aided design is becoming a commercially viable system for design and geometric modeling, engineering analysis, kinematics, and drafting, and efforts to bridge the gap between CAD and CAM are indicated, with particular attention given to layering, wherein individual monitoring of different parts of the manufacturing process can be effected without crossover of unnecessary information. The potentials and barriers to the use of robotics are described, with the added optimism that displaced workers to date have moved up to jobs of higher skill and interest.

A preliminary investigation of the Environmental Control and Life Support Subsystem (EC/LSS) for the space construction base manufacturing modules

NASA Technical Reports Server (NTRS)

Wells, H. B.

1977-01-01

The preliminary data of the environmental control and life support subsystem for a space construction base manufacturing module was reported. A space processing module, which is capable of performing production biological experiments, was chosen as a baseline configuration. The primary assemblies and components considered for use were humidity and temperature control, ventilation fan, cabin fan, water separator, condensate storage, overboard dumping, distribution system, contaminant monitoring, cabin sensors, and fire and smoke detection.

Sodium monitoring in commercially processed and restaurant foods.

PubMed

Ahuja, Jaspreet K C; Pehrsson, Pamela R; Haytowitz, David B; Wasswa-Kintu, Shirley; Nickle, Melissa; Showell, Bethany; Thomas, Robin; Roseland, Janet; Williams, Juhi; Khan, Mona; Nguyen, Quynhanh; Hoy, Kathy; Martin, Carrie; Rhodes, Donna; Moshfegh, Alanna; Gillespie, Cathleen; Gunn, Janelle; Merritt, Robert; Cogswell, Mary

2015-03-01

Most sodium in the US diet comes from commercially processed and restaurant foods. Sodium reduction in these foods is key to several recent public health efforts. The objective was to provide an overview of a program led by the USDA, in partnership with other government agencies, to monitor sodium contents in commercially processed and restaurant foods in the United States. We also present comparisons of nutrients generated under the program to older data. We track ∼125 commercially processed and restaurant food items ("sentinel foods") annually using information from food manufacturers and periodically by nationwide sampling and laboratory analyses. In addition, we monitor >1100 other commercially processed and restaurant food items, termed "priority-2 foods" (P2Fs) biennially by using information from food manufacturers. These foods serve as indicators for assessing changes in the sodium content of commercially processed and restaurant foods in the United States. We sampled all sentinel foods nationwide and reviewed all P2Fs in 2010-2013 to determine baseline sodium concentrations. We updated sodium values for 73 sentinel foods and 551 P2Fs in the USDA's National Nutrient Database for Standard Reference (releases 23-26). Sodium values changed by at least 10% for 43 of the sentinel foods, which, for 31 foods, including commonly consumed foods such as bread, tomato catsup, and potato chips, the newer sodium values were lower. Changes in the concentrations of related nutrients (total and saturated fat, total sugar, potassium, or dietary fiber) that were recommended by the 2010 Dietary Guidelines for Americans for reduced or increased consumption accompanied sodium reduction. The results of sodium reduction efforts, based on resampling of the sentinel foods or re-review of P2Fs, will become available beginning in 2015. This monitoring program tracks sodium reduction efforts, improves food composition databases, and strengthens national nutrition monitoring. © 2015 American Society for Nutrition.

Sodium monitoring in commercially processed and restaurant foods

PubMed Central

Ahuja, Jaspreet KC; Pehrsson, Pamela R; Haytowitz, David B; Wasswa-Kintu, Shirley; Nickle, Melissa; Showell, Bethany; Thomas, Robin; Roseland, Janet; Williams, Juhi; Khan, Mona; Nguyen, Quynhanh; Hoy, Kathy; Martin, Carrie; Rhodes, Donna; Moshfegh, Alanna; Gillespie, Cathleen; Gunn, Janelle; Merritt, Robert; Cogswell, Mary

2015-01-01

Background Most sodium in the US diet comes from commercially processed and restaurant foods. Sodium reduction in these foods is key to several recent public health efforts. Objective The objective was to provide an overview of a program led by the USDA, in partnership with other government agencies, to monitor sodium contents in commercially processed and restaurant foods in the United States. We also present comparisons of nutrients generated under the program to older data. Design We track ∼125 commercially processed and restaurant food items (“sentinel foods”) annually using information from food manufacturers and periodically by nationwide sampling and laboratory analyses. In addition, we monitor >1100 other commercially processed and restaurant food items, termed “priority-2 foods” (P2Fs) biennially by using information from food manufacturers. These foods serve as indicators for assessing changes in the sodium content of commercially processed and restaurant foods in the United States. We sampled all sentinel foods nationwide and reviewed all P2Fs in 2010–2013 to determine baseline sodium concentrations. Results We updated sodium values for 73 sentinel foods and 551 P2Fs in the USDA’s National Nutrient Database for Standard Reference (releases 23–26). Sodium values changed by at least 10% for 43 of the sentinel foods, which, for 31 foods, including commonly consumed foods such as bread, tomato catsup, and potato chips, the newer sodium values were lower. Changes in the concentrations of related nutrients (total and saturated fat, total sugar, potassium, or dietary fiber) that were recommended by the 2010 Dietary Guidelines for Americans for reduced or increased consumption accompanied sodium reduction. The results of sodium reduction efforts, based on resampling of the sentinel foods or re-review of P2Fs, will become available beginning in 2015. Conclusion This monitoring program tracks sodium reduction efforts, improves food composition databases, and strengthens national nutrition monitoring. PMID:25733648

Integrated Process Modeling-A Process Validation Life Cycle Companion.

PubMed

Zahel, Thomas; Hauer, Stefan; Mueller, Eric M; Murphy, Patrick; Abad, Sandra; Vasilieva, Elena; Maurer, Daniel; Brocard, Cécile; Reinisch, Daniela; Sagmeister, Patrick; Herwig, Christoph

2017-10-17

During the regulatory requested process validation of pharmaceutical manufacturing processes, companies aim to identify, control, and continuously monitor process variation and its impact on critical quality attributes (CQAs) of the final product. It is difficult to directly connect the impact of single process parameters (PPs) to final product CQAs, especially in biopharmaceutical process development and production, where multiple unit operations are stacked together and interact with each other. Therefore, we want to present the application of Monte Carlo (MC) simulation using an integrated process model (IPM) that enables estimation of process capability even in early stages of process validation. Once the IPM is established, its capability in risk and criticality assessment is furthermore demonstrated. IPMs can be used to enable holistic production control strategies that take interactions of process parameters of multiple unit operations into account. Moreover, IPMs can be trained with development data, refined with qualification runs, and maintained with routine manufacturing data which underlines the lifecycle concept. These applications will be shown by means of a process characterization study recently conducted at a world-leading contract manufacturing organization (CMO). The new IPM methodology therefore allows anticipation of out of specification (OOS) events, identify critical process parameters, and take risk-based decisions on counteractions that increase process robustness and decrease the likelihood of OOS events.

Quality control of inkjet technology for DNA microarray fabrication.

PubMed

Pierik, Anke; Dijksman, Frits; Raaijmakers, Adrie; Wismans, Ton; Stapert, Henk

2008-12-01

A robust manufacturing process is essential to make high-quality DNA microarrays, especially for use in diagnostic tests. We investigated different failure modes of the inkjet printing process used to manufacture low-density microarrays. A single nozzle inkjet spotter was provided with two optical imaging systems, monitoring in real time the flight path of every droplet. If a droplet emission failure is detected, the printing process is automatically stopped. We analyzed over 1.3 million droplets. This information was used to investigate the performance of the inkjet system and to obtain detailed insight into the frequency and causes of jetting failures. Of all the substrates investigated, 96.2% were produced without any system or jetting failures. In 1.6% of the substrates, droplet emission failed and was correctly identified. Appropriate measures could then be taken to get the process back on track. In 2.2%, the imaging systems failed while droplet emission occurred correctly. In 0.1% of the substrates, droplet emission failure that was not timely detected occurred. Thus, the overall yield of the microarray manufacturing process was 99.9%, which is highly acceptable for prototyping.

Near Infrared Spectroscopy for On-line Monitoring of Alkali- Free Cloth/Phenolic Resin Prepreg During Manufacture

PubMed Central

Jiang, Bo; Huang, Yu Dong

2007-01-01

A NIR method was developed for the on-line monitoring of alkali-free cloth/phenolic resin prepreg during its manufacturing process. First, the sizing content of the alkali-free cloth was analyzed, and then the resin, soluble resin and volatiles content of the prepreg was analyzed simultaneously using the FT-NIR spectrometer. Partial least square (PLS) regression was used to develop the calibration models, which for the sizing content was preprocessed by 1stDER +MSC, for the volatile content by 1stDER +VN, for the soluble resin content by 1stDER +MSC and for the resin content by the VN spectral data preprocessing method. RMSEP of the prediction model for the sizing content was 0.732 %, for the resin content it was 0.605, for the soluble resin content it was 0.101 and for volatiles content it was 0.127. The results of the paired t-test revealed that there was no significant difference between the NIR method and the standard method. The NIR spectroscopy method could be used to predict the resin, soluble resin and the volatiles content of the prepreg simultaneously, as well as sizing content of alkali-free cloth. The processing parameters of the prepreg during manufacture could be adjusted quickly with the help of the NIR analysis results. The results indicated that the NIR spectroscopy method was sufficiently accurate and effective for the on-line monitoring of alkali-free cloth/phenolic resin prepreg.

Expert system and process optimization techniques for real-time monitoring and control of plasma processes

NASA Astrophysics Data System (ADS)

Cheng, Jie; Qian, Zhaogang; Irani, Keki B.; Etemad, Hossein; Elta, Michael E.

1991-03-01

To meet the ever-increasing demand of the rapidly-growing semiconductor manufacturing industry it is critical to have a comprehensive methodology integrating techniques for process optimization real-time monitoring and adaptive process control. To this end we have accomplished an integrated knowledge-based approach combining latest expert system technology machine learning method and traditional statistical process control (SPC) techniques. This knowledge-based approach is advantageous in that it makes it possible for the task of process optimization and adaptive control to be performed consistently and predictably. Furthermore this approach can be used to construct high-level and qualitative description of processes and thus make the process behavior easy to monitor predict and control. Two software packages RIST (Rule Induction and Statistical Testing) and KARSM (Knowledge Acquisition from Response Surface Methodology) have been developed and incorporated with two commercially available packages G2 (real-time expert system) and ULTRAMAX (a tool for sequential process optimization).

Near-infrared spectroscopy monitoring and control of the fluidized bed granulation and coating processes-A review.

PubMed

Liu, Ronghua; Li, Lian; Yin, Wenping; Xu, Dongbo; Zang, Hengchang

2017-09-15

The fluidized bed granulation and pellets coating technologies are widely used in pharmaceutical industry, because the particles made in a fluidized bed have good flowability, compressibility, and the coating thickness of pellets are homogeneous. With the popularization of process analytical technology (PAT), real-time analysis for critical quality attributes (CQA) was getting more attention. Near-infrared (NIR) spectroscopy, as a PAT tool, could realize the real-time monitoring and control during the granulating and coating processes, which could optimize the manufacturing processes. This article reviewed the application of NIR spectroscopy in CQA (moisture content, particle size and tablet/pellet thickness) monitoring during fluidized bed granulation and coating processes. Through this review, we would like to provide references for realizing automated control and intelligent production in fluidized bed granulation and pellets coating of pharmaceutical industry. Copyright © 2017 Elsevier B.V. All rights reserved.

Biomanufacturing process analytical technology (PAT) application for downstream processing: Using dissolved oxygen as an indicator of product quality for a protein refolding reaction.

PubMed

Pizarro, Shelly A; Dinges, Rachel; Adams, Rachel; Sanchez, Ailen; Winter, Charles

2009-10-01

Process analytical technology (PAT) is an initiative from the US FDA combining analytical and statistical tools to improve manufacturing operations and ensure regulatory compliance. This work describes the use of a continuous monitoring system for a protein refolding reaction to provide consistency in product quality and process performance across batches. A small-scale bioreactor (3 L) is used to understand the impact of aeration for refolding recombinant human vascular endothelial growth factor (rhVEGF) in a reducing environment. A reverse-phase HPLC assay is used to assess product quality. The goal in understanding the oxygen needs of the reaction and its impact to quality, is to make a product that is efficiently refolded to its native and active form with minimum oxidative degradation from batch to batch. Because this refolding process is heavily dependent on oxygen, the % dissolved oxygen (DO) profile is explored as a PAT tool to regulate process performance at commercial manufacturing scale. A dynamic gassing out approach using constant mass transfer (k(L)a) is used for scale-up of the aeration parameters to manufacturing scale tanks (2,000 L, 15,000 L). The resulting DO profiles of the refolding reaction show similar trends across scales and these are analyzed using rpHPLC. The desired product quality attributes are then achieved through alternating air and nitrogen sparging triggered by changes in the monitored DO profile. This approach mitigates the impact of differences in equipment or feedstock components between runs, and is directly inline with the key goal of PAT to "actively manage process variability using a knowledge-based approach." (c) 2009 Wiley Periodicals, Inc.

Occupational exposure to styrene in the fibreglass reinforced plastic industry: comparison between two different manufacturing processes.

PubMed

Tranfo, Giovanna; Gherardi, Monica; Paci, E; Gatto, Mariapia; Gordiani, A; Caporossi, Lidia; Capanna, Silvia; Sisto, Renata; Papaleo, B; Fiumalbi, Carla; Garofani, Patrizia

2012-01-01

Styrene is used in manufacturing fiberglass reinforced plastics: and occupational exposure was related to neurotoxicology and genotoxicity. The sum of the metabolites mandelic and phenylglyoxylic acids is the ACGIH biomarker for occupational exposure with a BEI of 400 mg/g of creatinine in end shift urine corresponding to a airborne styrene concentration of 85 mg/m3. There are two main molding processes, open and closed, the last more effective at controlling worker's styrene exposure. To compare the open molding process to the compression of fiber reinforced resin foils, a kind of closed molding, monitoring the styrene exposure of workers in two production sites (A and B). Environmental Monitoring was carried out by Radiello samplers and Biological Monitoring by means of the determination of MA and PGA with HPLC/MS/MS in 10 workers at Site A and 14 at Site B. The median values for styrene exposure resulted 31.1 mg/m3 for Site A and 24.4 mg/m for Site B, while the medians for the sum of the two metabolites in the end shift urine were 86.7 e 33.8 mg/g creatinine respectively. There is a significant linear correlation between personal styrene exposure and the excretion of styrene metabolites (R = 0.74). As expected the exposure markers of the workers of the two production sites resulted higher in the open process. The analytical results of both environmental and biological monitoring were all below the occupational exposure limits, confirming the efficacy of the protective devices.

Data-driven multi-scale multi-physics models to derive process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Lian, Yanping; Yu, Cheng; Liu, Zeliang; Yan, Jinhui; Wolff, Sarah; Wu, Hao; Ndip-Agbor, Ebot; Mozaffar, Mojtaba; Ehmann, Kornel; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-05-01

Additive manufacturing (AM) possesses appealing potential for manipulating material compositions, structures and properties in end-use products with arbitrary shapes without the need for specialized tooling. Since the physical process is difficult to experimentally measure, numerical modeling is a powerful tool to understand the underlying physical mechanisms. This paper presents our latest work in this regard based on comprehensive material modeling of process-structure-property relationships for AM materials. The numerous influencing factors that emerge from the AM process motivate the need for novel rapid design and optimization approaches. For this, we propose data-mining as an effective solution. Such methods—used in the process-structure, structure-properties and the design phase that connects them—would allow for a design loop for AM processing and materials. We hope this article will provide a road map to enable AM fundamental understanding for the monitoring and advanced diagnostics of AM processing.

Data-driven multi-scale multi-physics models to derive process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Lian, Yanping; Yu, Cheng; Liu, Zeliang; Yan, Jinhui; Wolff, Sarah; Wu, Hao; Ndip-Agbor, Ebot; Mozaffar, Mojtaba; Ehmann, Kornel; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-01-01

Additive manufacturing (AM) possesses appealing potential for manipulating material compositions, structures and properties in end-use products with arbitrary shapes without the need for specialized tooling. Since the physical process is difficult to experimentally measure, numerical modeling is a powerful tool to understand the underlying physical mechanisms. This paper presents our latest work in this regard based on comprehensive material modeling of process-structure-property relationships for AM materials. The numerous influencing factors that emerge from the AM process motivate the need for novel rapid design and optimization approaches. For this, we propose data-mining as an effective solution. Such methods—used in the process-structure, structure-properties and the design phase that connects them—would allow for a design loop for AM processing and materials. We hope this article will provide a road map to enable AM fundamental understanding for the monitoring and advanced diagnostics of AM processing.

PAT: From Western solid dosage forms to Chinese materia medica preparations using NIR-CI.

PubMed

Zhou, Luwei; Xu, Manfei; Wu, Zhisheng; Shi, Xinyuan; Qiao, Yanjiang

2016-01-01

Near-infrared chemical imaging (NIR-CI) is an emerging technology that combines traditional near-infrared spectroscopy with chemical imaging. Therefore, NIR-CI can extract spectral information from pharmaceutical products and simultaneously visualize the spatial distribution of chemical components. The rapid and non-destructive features of NIR-CI make it an attractive process analytical technology (PAT) for identifying and monitoring critical control parameters during the pharmaceutical manufacturing process. This review mainly focuses on the pharmaceutical applications of NIR-CI in each unit operation during the manufacturing processes, from the Western solid dosage forms to the Chinese materia medica preparations. Finally, future applications of chemical imaging in the pharmaceutical industry are discussed. Copyright © 2015 John Wiley & Sons, Ltd.

Phase-I monitoring of standard deviations in multistage linear profiles

NASA Astrophysics Data System (ADS)

Kalaei, Mahdiyeh; Soleimani, Paria; Niaki, Seyed Taghi Akhavan; Atashgar, Karim

2018-03-01

In most modern manufacturing systems, products are often the output of some multistage processes. In these processes, the stages are dependent on each other, where the output quality of each stage depends also on the output quality of the previous stages. This property is called the cascade property. Although there are many studies in multistage process monitoring, there are fewer works on profile monitoring in multistage processes, especially on the variability monitoring of a multistage profile in Phase-I for which no research is found in the literature. In this paper, a new methodology is proposed to monitor the standard deviation involved in a simple linear profile designed in Phase I to monitor multistage processes with the cascade property. To this aim, an autoregressive correlation model between the stages is considered first. Then, the effect of the cascade property on the performances of three types of T 2 control charts in Phase I with shifts in standard deviation is investigated. As we show that this effect is significant, a U statistic is next used to remove the cascade effect, based on which the investigated control charts are modified. Simulation studies reveal good performances of the modified control charts.

40 CFR Table 1 to Subpart Uuuu of... - Emission Limits and Work Practice Standards

Code of Federal Regulations, 2014 CFR

2014-07-01

... least once per month as specified in § 63.148(f)(2)). 12. heat exchanger system that cools process equipment or materials in the process unit each existing or new affected source monitor and repair the heat exchanger system according to § 63.104(a) through (e), except that references to “chemical manufacturing...

40 CFR Table 1 to Subpart Uuuu of... - Emission Limits and Work Practice Standards

Code of Federal Regulations, 2012 CFR

2012-07-01

... least once per month as specified in § 63.148(f)(2)). 12. heat exchanger system that cools process equipment or materials in the process unit each existing or new affected source monitor and repair the heat exchanger system according to § 63.104(a) through (e), except that references to “chemical manufacturing...

40 CFR Table 1 to Subpart Uuuu of... - Emission Limits and Work Practice Standards

Code of Federal Regulations, 2013 CFR

2013-07-01

... least once per month as specified in § 63.148(f)(2)). 12. heat exchanger system that cools process equipment or materials in the process unit each existing or new affected source monitor and repair the heat exchanger system according to § 63.104(a) through (e), except that references to “chemical manufacturing...

40 CFR Table 1 to Subpart Uuuu of... - Emission Limits and Work Practice Standards

Code of Federal Regulations, 2011 CFR

2011-07-01

... least once per month as specified in § 63.148(f)(2)). 12. heat exchanger system that cools process equipment or materials in the process unit each existing or new affected source monitor and repair the heat exchanger system according to § 63.104(a) through (e), except that references to “chemical manufacturing...

Energy intensity of computer manufacturing: hybrid assessment combining process and economic input-output methods.

PubMed

Williams, Eric

2004-11-15

The total energy and fossil fuels used in producing a desktop computer with 17-in. CRT monitor are estimated at 6400 megajoules (MJ) and 260 kg, respectively. This indicates that computer manufacturing is energy intensive: the ratio of fossil fuel use to product weight is 11, an order of magnitude larger than the factor of 1-2 for many other manufactured goods. This high energy intensity of manufacturing, combined with rapid turnover in computers, results in an annual life cycle energy burden that is surprisingly high: about 2600 MJ per year, 1.3 times that of a refrigerator. In contrast with many home appliances, life cycle energy use of a computer is dominated by production (81%) as opposed to operation (19%). Extension of usable lifespan (e.g. by reselling or upgrading) is thus a promising approach to mitigating energy impacts as well as other environmental burdens associated with manufacturing and disposal.

The Internet in the Workplace: Issues of Implementation and Impact.

ERIC Educational Resources Information Center

Anderson, Byron

1996-01-01

As the Internet (with pluses and minuses) creeps forward, many work environments, business practices, and consumer processes will change significantly. Manufacturing, electronic commerce, health care, education, environmental monitoring, libraries, and government services will be profoundly affected. Fully implementing the Internet will take…

Biomarkers of early genotoxicity and oxidative stress for occupational risk assessment of exposure to styrene in the fibreglass reinforced plastic industry.

PubMed

Cavallo, Delia; Tranfo, Giovanna; Ursini, Cinzia Lucia; Fresegna, Anna Maria; Ciervo, Aureliano; Maiello, Raffaele; Paci, Enrico; Pigini, Daniela; Gherardi, Monica; Gatto, Maria Pia; Buresti, Giuliana; Iavicoli, Sergio

2018-06-10

This study aimed to identify sensitive and not-invasive biomarkers of early genotoxic/oxidative effect for exposure to styrene in the fibreglass reinforced plastic manufacture. We studied 11 workers of a plastic manufacture using open molding process (A), 16 workers of a manufacture using closed process (B) and 12 controls. We evaluated geno/cytotoxic effects on buccal cells by Buccal Micronucleus Cytome (BMCyt) assay and genotoxic/oxidative effects on lymphocytes by Fpg-comet test. On A workers we also evaluated urinary 8oxoGua, 8oxodGuo and 8oxoGuo to investigate oxidative stress. Personal inhalation exposure to styrene was monitored by passive air sampling and GC/MS. Biological monitoring included urinary metabolites mandelic acid (MA) and phenylglyoxylic acid (PGA). The findings show higher styrene exposure, urinary MA + PGA levels and micronucleus frequency in manufacture A. Higher buccal karyolytic cell frequency vs controls were found in both exposed populations. We found in exposed workers, no induction of direct DNA damage but oxidative DNA damage. Fpg-comet assay and urinary oxidized guanine seem to be sensitive biomarkers of oxidative stress and BMCyt assay a good-not invasive biomarker of cyto-genotoxicity at target organ. The study, although limited by the small number of studied subjects, shows the usefulness of used biomarkers in risk assessment of styrene-exposed workers. Copyright © 2018 Elsevier B.V. All rights reserved.

Application of Raman Spectroscopy and Univariate Modelling As a Process Analytical Technology for Cell Therapy Bioprocessing

PubMed Central

Baradez, Marc-Olivier; Biziato, Daniela; Hassan, Enas; Marshall, Damian

2018-01-01

Cell therapies offer unquestionable promises for the treatment, and in some cases even the cure, of complex diseases. As we start to see more of these therapies gaining market authorization, attention is turning to the bioprocesses used for their manufacture, in particular the challenge of gaining higher levels of process control to help regulate cell behavior, manage process variability, and deliver product of a consistent quality. Many processes already incorporate the measurement of key markers such as nutrient consumption, metabolite production, and cell concentration, but these are often performed off-line and only at set time points in the process. Having the ability to monitor these markers in real-time using in-line sensors would offer significant advantages, allowing faster decision-making and a finer level of process control. In this study, we use Raman spectroscopy as an in-line optical sensor for bioprocess monitoring of an autologous T-cell immunotherapy model produced in a stirred tank bioreactor system. Using reference datasets generated on a standard bioanalyzer, we develop chemometric models from the Raman spectra for glucose, glutamine, lactate, and ammonia. These chemometric models can accurately monitor donor-specific increases in nutrient consumption and metabolite production as the primary T-cell transition from a recovery phase and begin proliferating. Using a univariate modeling approach, we then show how changes in peak intensity within the Raman spectra can be correlated with cell concentration and viability. These models, which act as surrogate markers, can be used to monitor cell behavior including cell proliferation rates, proliferative capacity, and transition of the cells to a quiescent phenotype. Finally, using the univariate models, we also demonstrate how Raman spectroscopy can be applied for real-time monitoring. The ability to measure these key parameters using an in-line Raman optical sensor makes it possible to have immediate feedback on process performance. This could help significantly improve cell therapy bioprocessing by allowing proactive decision-making based on real-time process data. Going forward, these types of in-line sensors also open up opportunities to improve bioprocesses further through concepts such as adaptive manufacturing. PMID:29556497

Application of Raman Spectroscopy and Univariate Modelling As a Process Analytical Technology for Cell Therapy Bioprocessing.

PubMed

Baradez, Marc-Olivier; Biziato, Daniela; Hassan, Enas; Marshall, Damian

2018-01-01

Cell therapies offer unquestionable promises for the treatment, and in some cases even the cure, of complex diseases. As we start to see more of these therapies gaining market authorization, attention is turning to the bioprocesses used for their manufacture, in particular the challenge of gaining higher levels of process control to help regulate cell behavior, manage process variability, and deliver product of a consistent quality. Many processes already incorporate the measurement of key markers such as nutrient consumption, metabolite production, and cell concentration, but these are often performed off-line and only at set time points in the process. Having the ability to monitor these markers in real-time using in-line sensors would offer significant advantages, allowing faster decision-making and a finer level of process control. In this study, we use Raman spectroscopy as an in-line optical sensor for bioprocess monitoring of an autologous T-cell immunotherapy model produced in a stirred tank bioreactor system. Using reference datasets generated on a standard bioanalyzer, we develop chemometric models from the Raman spectra for glucose, glutamine, lactate, and ammonia. These chemometric models can accurately monitor donor-specific increases in nutrient consumption and metabolite production as the primary T-cell transition from a recovery phase and begin proliferating. Using a univariate modeling approach, we then show how changes in peak intensity within the Raman spectra can be correlated with cell concentration and viability. These models, which act as surrogate markers, can be used to monitor cell behavior including cell proliferation rates, proliferative capacity, and transition of the cells to a quiescent phenotype. Finally, using the univariate models, we also demonstrate how Raman spectroscopy can be applied for real-time monitoring. The ability to measure these key parameters using an in-line Raman optical sensor makes it possible to have immediate feedback on process performance. This could help significantly improve cell therapy bioprocessing by allowing proactive decision-making based on real-time process data. Going forward, these types of in-line sensors also open up opportunities to improve bioprocesses further through concepts such as adaptive manufacturing.

Additive manufacturing of materials: Opportunities and challenges

DOE Office of Scientific and Technical Information (OSTI.GOV)

Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performancemore » computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.« less

Additive manufacturing of materials: Opportunities and challenges

DOE PAGES

Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.; ...

2015-11-01

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performancemore » computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.« less

Monitoring of the microbial communities involved in the soy sauce manufacturing process by PCR-denaturing gradient gel electrophoresis.

PubMed

Tanaka, Yasushi; Watanabe, Jun; Mogi, Yoshinobu

2012-08-01

Soy sauce is a traditional seasoning produced through the fermentation of soybeans and wheat using microbes. In this study, the microbial communities involved in the soy sauce manufacturing process were analyzed by PCR-Denaturing Gradient Gel Electrophoresis (PCR-DGGE). The bacterial DGGE profile indicated that the bacterial microbes in the koji were Weissella cibaria (Weissella confusa, Weissella kimchii, Weissella salipiscis, Lactobacillus fermentum, Lactobacillus plantarum, Lactobacillus iners, or Streptococcus thermophilus), Staphylococcus gallinarum (or Staphylococcus xylosus), and Staphylococcus kloosii. In addition to these bacteria, Tetragenococcus halophilus was also detected in the mash during lactic acid fermentation. The fungal DGGE profile indicated that the fungal microbes in the koji were not only Aspergillus oryzae but also several yeasts. In the mash, Zygosaccharomyces rouxii appeared in the early fermentation stage, Candida etchellsii (or Candida nodaensis) and Candida versatilis were detected at the middle fermentation stage, and Candida etchellsii was detected at the mature fermentation stage. These results suggest that the microbial communities present during the soy sauce manufacturing process change drastically throughout its production. This is the first report to reveal the microbial communities involved in the soy sauce manufacturing process using a culture-independent method. Crown Copyright © 2012. Published by Elsevier Ltd. All rights reserved.

76 FR 36339 - Mandatory Reporting of Greenhouse Gases: Additional Sources of Fluorinated GHGs: Extension of...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-06-22

... Monitoring Provisions for Electronics Manufacturing AGENCY: Environmental Protection Agency (EPA). ACTION... monitoring methods in Subpart I: Electronics Manufacturing of the Mandatory Greenhouse Gas Reporting Rule...: Electronics Manufacturing of the Greenhouse Gas Reporting Rule on December 1, 2010 (75 FR 74774). This subpart...

On-line tool breakage monitoring of vibration tapping using spindle motor current

NASA Astrophysics Data System (ADS)

Li, Guangjun; Lu, Huimin; Liu, Gang

2008-10-01

Input current of driving motor has been employed successfully as monitoring the cutting state in manufacturing processes for more than a decade. In vibration tapping, however, the method of on-line monitoring motor electric current has not been reported. In this paper, a tap failure prediction method is proposed to monitor the vibration tapping process using the electrical current signal of the spindle motor. The process of vibration tapping is firstly described. Then the relationship between the torque of vibration tapping and the electric current of motor is investigated by theoretic deducing and experimental measurement. According to those results, a monitoring method of tool's breakage is proposed through monitoring the ratio of the current amplitudes during adjacent vibration tapping periods. Finally, a low frequency vibration tapping system with motor current monitoring is built up using a servo motor B-106B and its driver CR06. The proposed method has been demonstrated with experiment data of vibration tapping in titanic alloys. The result of experiments shows that the method, which can avoid the tool breakage and giving a few error alarms when the threshold of amplitude ratio is 1.2 and there is at least 2 times overrun among 50 adjacent periods, is feasible for tool breakage monitoring in the process of vibration tapping small thread holes.

Decision support tool for diagnosing the source of variation

NASA Astrophysics Data System (ADS)

Masood, Ibrahim; Azrul Azhad Haizan, Mohamad; Norbaya Jumali, Siti; Ghazali, Farah Najihah Mohd; Razali, Hazlin Syafinaz Md; Shahir Yahya, Mohd; Azlan, Mohd Azwir bin

2017-08-01

Identifying the source of unnatural variation (SOV) in manufacturing process is essential for quality control. The Shewhart control chart patterns (CCPs) are commonly used to monitor the SOV. However, a proper interpretation of CCPs associated to its SOV requires a high skill industrial practitioner. Lack of knowledge in process engineering will lead to erroneous corrective action. The objective of this study is to design the operating procedures of computerized decision support tool (DST) for process diagnosis. The DST is an embedded tool in CCPs recognition scheme. Design methodology involves analysis of relationship between geometrical features, manufacturing process and CCPs. The DST contents information about CCPs and its possible root cause error and description on SOV phenomenon such as process deterioration in tool bluntness, offsetting tool, loading error, and changes in materials hardness. The DST will be useful for an industrial practitioner in making effective troubleshooting.

Near infrared spectroscopy based monitoring of extraction processes of raw material with the help of dynamic predictive modeling

NASA Astrophysics Data System (ADS)

Wang, Haixia; Suo, Tongchuan; Wu, Xiaolin; Zhang, Yue; Wang, Chunhua; Yu, Heshui; Li, Zheng

2018-03-01

The control of batch-to-batch quality variations remains a challenging task for pharmaceutical industries, e.g., traditional Chinese medicine (TCM) manufacturing. One difficult problem is to produce pharmaceutical products with consistent quality from raw material of large quality variations. In this paper, an integrated methodology combining the near infrared spectroscopy (NIRS) and dynamic predictive modeling is developed for the monitoring and control of the batch extraction process of licorice. With the spectra data in hand, the initial state of the process is firstly estimated with a state-space model to construct a process monitoring strategy for the early detection of variations induced by the initial process inputs such as raw materials. Secondly, the quality property of the end product is predicted at the mid-course during the extraction process with a partial least squares (PLS) model. The batch-end-time (BET) is then adjusted accordingly to minimize the quality variations. In conclusion, our study shows that with the help of the dynamic predictive modeling, NIRS can offer the past and future information of the process, which enables more accurate monitoring and control of process performance and product quality.

Using the scanning electron microscope on the production line to assure quality semiconductors

NASA Technical Reports Server (NTRS)

Adolphsen, J. W.; Anstead, R. J.

1972-01-01

The use of the scanning electron microscope to detect metallization defects introduced during batch processing of semiconductor devices is discussed. A method of determining metallization integrity was developed which culminates in a procurement specification using the scanning microscope on the production line as a quality control tool. Batch process control of the metallization operation is monitored early in the manufacturing cycle.

Manufacturing technology methodology for propulsion system parts

NASA Astrophysics Data System (ADS)

McRae, M. M.

1992-07-01

A development history and a current status evaluation are presented for lost-wax casting of such gas turbine engine components as turbine vanes and blades. The most advanced such systems employ computer-integrated manufacturing methods for high process repeatability, reprogramming versatility, and feedback monitoring. Stereolithography-based plastic model 3D prototyping has also been incorporated for the wax part of the investment casting; it may ultimately be possible to produce the 3D prototype in wax directly, or even to create a ceramic mold directly. Nonintrusive inspections are conducted by X-radiography and neutron radiography.

Controlling high-throughput manufacturing at the nano-scale

NASA Astrophysics Data System (ADS)

Cooper, Khershed P.

2013-09-01

Interest in nano-scale manufacturing research and development is growing. The reason is to accelerate the translation of discoveries and inventions of nanoscience and nanotechnology into products that would benefit industry, economy and society. Ongoing research in nanomanufacturing is focused primarily on developing novel nanofabrication techniques for a variety of applications—materials, energy, electronics, photonics, biomedical, etc. Our goal is to foster the development of high-throughput methods of fabricating nano-enabled products. Large-area parallel processing and highspeed continuous processing are high-throughput means for mass production. An example of large-area processing is step-and-repeat nanoimprinting, by which nanostructures are reproduced again and again over a large area, such as a 12 in wafer. Roll-to-roll processing is an example of continuous processing, by which it is possible to print and imprint multi-level nanostructures and nanodevices on a moving flexible substrate. The big pay-off is high-volume production and low unit cost. However, the anticipated cost benefits can only be realized if the increased production rate is accompanied by high yields of high quality products. To ensure product quality, we need to design and construct manufacturing systems such that the processes can be closely monitored and controlled. One approach is to bring cyber-physical systems (CPS) concepts to nanomanufacturing. CPS involves the control of a physical system such as manufacturing through modeling, computation, communication and control. Such a closely coupled system will involve in-situ metrology and closed-loop control of the physical processes guided by physics-based models and driven by appropriate instrumentation, sensing and actuation. This paper will discuss these ideas in the context of controlling high-throughput manufacturing at the nano-scale.

High temperature polymerization monitoring of an epoxy resin using ultrasound

NASA Astrophysics Data System (ADS)

Maréchal, P.; Ghodhbani, N.; Duflo, H.

2018-05-01

In this study, the real time ultrasonic monitoring is investigated to quantify changes in physical and mechanical properties during the manufacture of composite structures. In this context, an experimental transmission was developed with the aim of characterizing a high temperature polymerization reaction and post-curing properties using an ultrasonic method. First, the monitoring of ultrasonic parameters of a thermosetting resin is carried out in a device reproducing the experimental conditions for manufacturing a composite material with a process known as RTM, that is to say an isothermal polymerization at T = 160°C. During this curing, the resin is changing from its initial viscous liquid state to its final viscous solid state. Between those states, a glassy transition stage is observed, during which the physical properties are strongly changing, i.e. an increase of the ultrasonic velocity up to its steady value and a transient increase of the ultrasonic attenuation. Second, the ultrasonic inspection of the thermosetting resin is performed during a heating and cooling process to study the temperature sensitivity after curing. This type of characterization leads to identifying the ultrasonic properties dependence before, during and after the glassy transition temperature Tg . Eventually, this study is composed of two complementary parts: the first is useful for the curing optimization, while the second one is fruitful for the post-processing characterization in a temperature range including the glassy transition temperature Tg .

Simulation based energy-resource efficient manufacturing integrated with in-process virtual management

NASA Astrophysics Data System (ADS)

Katchasuwanmanee, Kanet; Cheng, Kai; Bateman, Richard

2016-09-01

As energy efficiency is one of the key essentials towards sustainability, the development of an energy-resource efficient manufacturing system is among the great challenges facing the current industry. Meanwhile, the availability of advanced technological innovation has created more complex manufacturing systems that involve a large variety of processes and machines serving different functions. To extend the limited knowledge on energy-efficient scheduling, the research presented in this paper attempts to model the production schedule at an operation process by considering the balance of energy consumption reduction in production, production work flow (productivity) and quality. An innovative systematic approach to manufacturing energy-resource efficiency is proposed with the virtual simulation as a predictive modelling enabler, which provides real-time manufacturing monitoring, virtual displays and decision-makings and consequentially an analytical and multidimensional correlation analysis on interdependent relationships among energy consumption, work flow and quality errors. The regression analysis results demonstrate positive relationships between the work flow and quality errors and the work flow and energy consumption. When production scheduling is controlled through optimization of work flow, quality errors and overall energy consumption, the energy-resource efficiency can be achieved in the production. Together, this proposed multidimensional modelling and analysis approach provides optimal conditions for the production scheduling at the manufacturing system by taking account of production quality, energy consumption and resource efficiency, which can lead to the key competitive advantages and sustainability of the system operations in the industry.

Structural Health Monitoring with Fiber Bragg Grating and Piezo Arrays

NASA Technical Reports Server (NTRS)

Black, Richard J.; Faridian, Ferey; Moslehi, Behzad; Sotoudeh, Vahid

2012-01-01

Structural health monitoring (SHM) is one of the most important tools available for the maintenance, safety, and integrity of aerospace structural systems. Lightweight, electromagnetic-interference- immune, fiber-optic sensor-based SHM will play an increasing role in more secure air transportation systems. Manufacturers and maintenance personnel have pressing needs for significantly improving safety and reliability while providing for lower inspection and maintenance costs. Undetected or untreated damage may grow and lead to catastrophic structural failure. Damage can originate from the strain/stress history of the material, imperfections of domain boundaries in metals, delamination in multi-layer materials, or the impact of machine tools in the manufacturing process. Damage can likewise develop during service life from wear and tear, or under extraordinary circumstances such as with unusual forces, temperature cycling, or impact of flying objects. Monitoring and early detection are key to preventing a catastrophic failure of structures, especially when these are expected to perform near their limit conditions.

Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System

PubMed Central

Hinderdael, Michaël; Strantza, Maria; De Baere, Dieter; Devesse, Wim; De Graeve, Iris; Terryn, Herman; Guillaume, Patrick

2017-01-01

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored. PMID:28841186

Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hinderdael, Michaël; Strantza, Maria; De Baere, Dieter

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the referencemore » specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.« less

Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System

DOE PAGES

Hinderdael, Michaël; Strantza, Maria; De Baere, Dieter; ...

2017-08-25

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the referencemore » specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.« less

Fatigue Performance of Ti-6Al-4V Additively Manufactured Specimens with Integrated Capillaries of an Embedded Structural Health Monitoring System.

PubMed

Hinderdael, Michaël; Strantza, Maria; De Baere, Dieter; Devesse, Wim; De Graeve, Iris; Terryn, Herman; Guillaume, Patrick

2017-08-25

Additive manufacturing (AM) of metals offers new possibilities for the production of complex structures. Up to now, investigations on the mechanical response of AM metallic parts show a significant spread and unexpected failures cannot be excluded. In this work, we focus on the detection of fatigue cracks through the integration of a Structural Health Monitoring (SHM) system in Ti-6Al-4V specimens. The working principle of the presented system is based on the integration of small capillaries that are capable of detecting fatigue cracks. Four-point bending fatigue tests have been performed on Ti-6Al-4V specimens with integrated capillaries and compared to the reference specimenswithout capillaries. Specimens were produced by conventional subtractive manufacturing of wrought material and AM, using the laser based Directed Energy Deposition (DED) process. In this study, we investigated the effect of the presence of the capillary on the fatigue strength and fatigue initiation location. Finite element (FEM) simulations were performed to validate the experimental test results. The presence of a drilled capillary in the specimens did not alter the fatigue initiation location. However, the laser based DED production process introduced roughness on the capillary surface that altered the fatigue initiation location to the capillary surface. The fatigue performance was greatly reduced when considering a printed capillary. It is concluded that the surface quality of the integrated capillary is of primary importance in order not to influence the structural integrity of the component to be monitored.

21 CFR 600.11 - Physical establishment, equipment, animals, and care.

Code of Federal Regulations, 2013 CFR

2013-04-01

... of 170 °C maintained for 2 hours with dry heat. Processing and storage containers, filters, filling... “Caution: microbial spores. See directions for storage, use and disposition.”, and (v) the container of... or product dedicated items from the manufacturing area. Environmental monitoring specific for the...

21 CFR 111.123 - What quality control operations are required for the master manufacturing record, the batch...

Code of Federal Regulations, 2010 CFR

2010-04-01

... monitoring required under subpart E; (4) Conducting any required material review and making any required disposition decision; (5) Approving or rejecting any reprocessing; (6) Determining whether all in-process... and to determine that the product is consistent with your purchase order. ...

Increased Reliability of Gas Turbine Components by Robust Coatings Manufacturing

NASA Astrophysics Data System (ADS)

Sharma, A.; Dudykevych, T.; Sansom, D.; Subramanian, R.

2017-08-01

The expanding operational windows of the advanced gas turbine components demand increasing performance capability from protective coating systems. This demand has led to the development of novel multi-functional, multi-materials coating system architectures over the last years. In addition, the increasing dependency of components exposed to extreme environment on protective coatings results in more severe penalties, in case of a coating system failure. This emphasizes that reliability and consistency of protective coating systems are equally important to their superior performance. By means of examples, this paper describes the effects of scatter in the material properties resulting from manufacturing variations on coating life predictions. A strong foundation in process-property-performance correlations as well as regular monitoring and control of the coating process is essential for robust and well-controlled coating process. Proprietary and/or commercially available diagnostic tools can help in achieving these goals, but their usage in industrial setting is still limited. Various key contributors to process variability are briefly discussed along with the limitations of existing process and product control methods. Other aspects that are important for product reliability and consistency in serial manufacturing as well as advanced testing methodologies to simplify and enhance product inspection and improve objectivity are briefly described.

Study of Out-Time on the Processing and Properties of IM7/977-3 Composites

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Sutter, James K.; Scheiman, Daniel A.; Maryanski, Michael; Schlea, Michelle

2010-01-01

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-life limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-life limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The neat resin was evaluated by differential scanning calorimetry, DSC, to characterize cure behavior of the aged material, as well as any change in activation energy. The rise in the modulus of the uncured prepreg was monitored throughout the 60 days by dynamic mechanical analysis, DMA. Composite panels made of the fresh and aged prepreg material were also characterized by DMA. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Multivariate statistical monitoring as applied to clean-in-place (CIP) and steam-in-place (SIP) operations in biopharmaceutical manufacturing.

PubMed

Roy, Kevin; Undey, Cenk; Mistretta, Thomas; Naugle, Gregory; Sodhi, Manbir

2014-01-01

Multivariate statistical process monitoring (MSPM) is becoming increasingly utilized to further enhance process monitoring in the biopharmaceutical industry. MSPM can play a critical role when there are many measurements and these measurements are highly correlated, as is typical for many biopharmaceutical operations. Specifically, for processes such as cleaning-in-place (CIP) and steaming-in-place (SIP, also known as sterilization-in-place), control systems typically oversee the execution of the cycles, and verification of the outcome is based on offline assays. These offline assays add to delays and corrective actions may require additional setup times. Moreover, this conventional approach does not take interactive effects of process variables into account and cycle optimization opportunities as well as salient trends in the process may be missed. Therefore, more proactive and holistic online continued verification approaches are desirable. This article demonstrates the application of real-time MSPM to processes such as CIP and SIP with industrial examples. The proposed approach has significant potential for facilitating enhanced continuous verification, improved process understanding, abnormal situation detection, and predictive monitoring, as applied to CIP and SIP operations. © 2014 American Institute of Chemical Engineers.

Monitoring of laser material processing using machine integrated low-coherence interferometry

NASA Astrophysics Data System (ADS)

Kunze, Rouwen; König, Niels; Schmitt, Robert

2017-06-01

Laser material processing has become an indispensable tool in modern production. With the availability of high power pico- and femtosecond laser sources, laser material processing is advancing into applications, which demand for highest accuracies such as laser micro milling or laser drilling. In order to enable narrow tolerance windows, a closedloop monitoring of the geometrical properties of the processed work piece is essential for achieving a robust manufacturing process. Low coherence interferometry (LCI) is a high-precision measuring principle well-known from surface metrology. In recent years, we demonstrated successful integrations of LCI into several different laser material processing methods. Within this paper, we give an overview about the different machine integration strategies, that always aim at a complete and ideally telecentric integration of the measurement device into the existing beam path of the processing laser. Thus, highly accurate depth measurements within machine coordinates and a subsequent process control and quality assurance are possible. First products using this principle have already found its way to the market, which underlines the potential of this technology for the monitoring of laser material processing.

24 CFR 3282.7 - Definitions.

Code of Federal Regulations, 2012 CFR

2012-04-01

... or appliance which is built in as an integral part of the manufactured home during the manufacturing... (paragraph ff). (q) Joint monitoring team means a monitoring inspection team composed of personnel provided...

24 CFR 3282.7 - Definitions.

Code of Federal Regulations, 2011 CFR

2011-04-01

... or appliance which is built in as an integral part of the manufactured home during the manufacturing... (paragraph ff). (q) Joint monitoring team means a monitoring inspection team composed of personnel provided...

24 CFR 3282.7 - Definitions.

Code of Federal Regulations, 2013 CFR

2013-04-01

... or appliance which is built in as an integral part of the manufactured home during the manufacturing... (paragraph ff). (q) Joint monitoring team means a monitoring inspection team composed of personnel provided...

24 CFR 3282.7 - Definitions.

Code of Federal Regulations, 2014 CFR

2014-04-01

... or appliance which is built in as an integral part of the manufactured home during the manufacturing... monitoring team means a monitoring inspection team composed of personnel provided by the various State...

Toward determining melt pool quality metrics via coaxial monitoring in laser powder bed fusion.

PubMed

Fisher, Brian A; Lane, Brandon; Yeung, Ho; Beuth, Jack

2018-01-01

The current industry trend in metal additive manufacturing is towards greater real time process monitoring capabilities during builds to ensure high quality parts. While the hardware implementations that allow for real time monitoring of the melt pool have advanced significantly, the knowledge required to correlate the generated data to useful metrics of interest are still lacking. This research presents promising results that aim to bridge this knowledge gap by determining a novel means to correlate easily obtainable sensor data (thermal emission) to key melt pool size metrics (e.g., melt pool cross sectional area).

40 CFR 60.423 - Monitoring of operations.

Code of Federal Regulations, 2014 CFR

2014-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Ammonium Sulfate Manufacture § 60.423 Monitoring of operations. (a) The owner or operator of any ammonium sulfate manufacturing... monitoring devices which can be used to determine the mass flow of ammonium sulfate feed material streams to...

40 CFR 60.423 - Monitoring of operations.

Code of Federal Regulations, 2010 CFR

2010-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Ammonium Sulfate Manufacture § 60.423 Monitoring of operations. (a) The owner or operator of any ammonium sulfate manufacturing... monitoring devices which can be used to determine the mass flow of ammonium sulfate feed material streams to...

40 CFR 60.423 - Monitoring of operations.

Code of Federal Regulations, 2011 CFR

2011-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Ammonium Sulfate Manufacture § 60.423 Monitoring of operations. (a) The owner or operator of any ammonium sulfate manufacturing... monitoring devices which can be used to determine the mass flow of ammonium sulfate feed material streams to...

40 CFR 60.423 - Monitoring of operations.

Code of Federal Regulations, 2012 CFR

2012-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Ammonium Sulfate Manufacture § 60.423 Monitoring of operations. (a) The owner or operator of any ammonium sulfate manufacturing... monitoring devices which can be used to determine the mass flow of ammonium sulfate feed material streams to...

40 CFR 60.423 - Monitoring of operations.

Code of Federal Regulations, 2013 CFR

2013-07-01

... (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Ammonium Sulfate Manufacture § 60.423 Monitoring of operations. (a) The owner or operator of any ammonium sulfate manufacturing... monitoring devices which can be used to determine the mass flow of ammonium sulfate feed material streams to...

Pharmacovigilance in China: current situation, successes and challenges.

PubMed

Zhang, Li; Wong, Lisa Y L; He, Ying; Wong, Ian C K

2014-10-01

With the integration of the global pharmaceutical economy and the gradual transformation of the healthcare insurance system in China, the legislative framework for a comprehensive regulatory system monitoring the whole process including drug development, manufacture, distribution and use has been established by the China Food and Drug Administration (CFDA) to ensure the safety and effectiveness of medication use. China has established a relatively comprehensive pharmacovigilance system covering regulation, organisation and technology from 1989 to 2014. As of 2013, one national centre, 34 provincial centres and more than 400 municipal centres for adverse drug reaction (ADR) monitoring were included in the four-level pharmacovigilance network (national, provincial, municipal and county) with more than 200,000 grassroot organisation users. The China Adverse Drug Reaction Monitoring System (CADRMS) is an online spontaneous reporting system which connects the four-level pharmacovigilance network. By 2013, CADRMS had received over 6.6 million ADR case reports. After integrating and analysing pharmacovigilance data, the National Centre for ADR Monitoring (NCADRM) publishes medication safety information by releasing ADR bulletins, National ADR Annual Reports and International Pharmacovigilance Newsletters. The NCADRM also routinely provides CADRMS data feedback to manufacturers. The CFDA implemented risk management through several approaches, including arranging 'manufacturer communication meetings', modification of medication package inserts, and restriction, suspension or withdrawal of marketing authorisations. Seamless information exchange with overseas regulatory authorities and organisations remains an area for improvement. Further development of the China pharmacovigilance system in terms of signal generation, post-marketing pharmacoepidemiology research and education is also needed.

High-frequency ultrasonic imaging of growth and development in manufactured engineered oral mucosal tissue surfaces.

PubMed

Winterroth, Frank; Kato, Hiroko; Kuo, Shiuhyang; Feinberg, Stephen E; Hollister, Scott J; Fowlkes, J Brian; Hollman, Kyle W

2014-09-01

This study uses high-resolution ultrasound to examine the growth and development of engineered oral mucosal tissues manufactured under aseptic conditions. The specimens are a commercially available natural tissue scaffold, AlloDerm, and oral keratinocytes seeded onto AlloDerm to form an ex vivo-produced oral mucosal equivalent (EVPOME) suitable for intra-oral grafting. The seeded cells produce a keratinized protective upper layer that smooths out any remaining surface irregularities on the underlying AlloDerm. Two-dimensional acoustic imaging of unseeded AlloDerm and developing EVPOMEs was performed on each day of their growth and development, each tissue specimen being imaged under aseptic conditions (total time from seeding to maturation: 11 d). Ultrasonic monitoring offers us the ability to determine the constituents of the EVPOME that are responsible for changes in its mechanical behavior during the manufacturing process. Ultrasonic monitoring affords us an opportunity to non-invasively assess, in real time, tissue-engineered constructs before release for use in patient care. Copyright © 2014 World Federation for Ultrasound in Medicine & Biology. Published by Elsevier Inc. All rights reserved.

Qualification of computerized monitoring systems in a cell therapy facility compliant with the good manufacturing practices.

PubMed

Del Mazo-Barbara, Anna; Mirabel, Clémentine; Nieto, Valentín; Reyes, Blanca; García-López, Joan; Oliver-Vila, Irene; Vives, Joaquim

2016-09-01

Computerized systems (CS) are essential in the development and manufacture of cell-based medicines and must comply with good manufacturing practice, thus pushing academic developers to implement methods that are typically found within pharmaceutical industry environments. Qualitative and quantitative risk analyses were performed by Ishikawa and Failure Mode and Effects Analysis, respectively. A process for qualification of a CS that keeps track of environmental conditions was designed and executed. The simplicity of the Ishikawa analysis permitted to identify critical parameters that were subsequently quantified by Failure Mode Effects Analysis, resulting in a list of test included in the qualification protocols. The approach presented here contributes to simplify and streamline the qualification of CS in compliance with pharmaceutical quality standards.

Interoperability for Space Mission Monitor and Control: Applying Technologies from Manufacturing Automation and Process Control Industries

NASA Technical Reports Server (NTRS)

Jones, Michael K.

1998-01-01

Various issues associated with interoperability for space mission monitor and control are presented in viewgraph form. Specific topics include: 1) Space Project Mission Operations Control Architecture (SuperMOCA) goals and methods for achieving them; 2) Specifics on the architecture: open standards ad layering, enhancing interoperability, and promoting commercialization; 3) An advertisement; 4) Status of the task - government/industry cooperation and architecture and technology demonstrations; and 5) Key features of messaging services and virtual devices.

A quick method for AlCu interconnect electromigration performance predicting and monitoring

NASA Astrophysics Data System (ADS)

Zhang, Wenjie; Yi, Leeward; Tao, Kai; Ma, Yue; Chang, Pingyi; Mao, Duli; Wu, Jin; Zou, S. C.

2006-05-01

The film properties and microstructures of (bottom)Si/SiO2/Ti(top) and (bottom)Si/SiO2/Ti/TiN/AlCu(top) stacks deposited by different processes were characterized. The resistivities of thin Ti films and the reflectivities of AlCu alloy films were found to correlate with the microstructure as well as the mean time to failure (MTTF) in the electromigration (EM) test. A quick-turn monitor for AlCu interconnect reliability in the semiconductor manufacturing industry was established.

Application of optical broadband monitoring to quasi-rugate filters by ion-beam sputtering

NASA Astrophysics Data System (ADS)

Lappschies, Marc; Görtz, Björn; Ristau, Detlev

2006-03-01

Methods for the manufacture of rugate filters by the ion-beam-sputtering process are presented. The first approach gives an example of a digitized version of a continuous-layer notch filter. This method allows the comparison of the basic theory of interference coatings containing thin layers with practical results. For the other methods, a movable zone target is employed to fabricate graded and gradual rugate filters. The examples demonstrate the potential of broadband optical monitoring in conjunction with the ion-beam-sputtering process. First-characterization results indicate that these types of filter may exhibit higher laser-induced damage-threshold values than those of classical filters.

Fault detection in heavy duty wheels by advanced vibration processing techniques and lumped parameter modeling

NASA Astrophysics Data System (ADS)

Malago`, M.; Mucchi, E.; Dalpiaz, G.

2016-03-01

Heavy duty wheels are used in applications such as automatic vehicles and are mainly composed of a polyurethane tread glued to a cast iron hub. In the manufacturing process, the adhesive application between tread and hub is a critical assembly phase, since it is completely made by an operator and a contamination of the bond area may happen. Furthermore, the presence of rust on the hub surface can contribute to worsen the adherence interface, reducing the operating life. In this scenario, a quality control procedure for fault detection to be used at the end of the manufacturing process has been developed. This procedure is based on vibration processing techniques and takes advantages of the results of a lumped parameter model. Indicators based on cyclostationarity can be considered as key parameters to be adopted in a monitoring test station at the end of the production line due to their not deterministic characteristics.

Manufacturing Research: Self-Directed Control

DTIC Science & Technology

1991-01-01

reduce this sensitivity. SDO is performing Taguchi’s parameter design . 1-13 Statistical Process Control SPC techniques will be used to monitor the process...Florida,R.E. Krieger Pub. Co., 1988. Dehnad, Khowrow, Quality Control . Robust Design . and the Taguchi Method, Pacific Grove, California, Wadsworth... control system. This turns out to be a non -trivial exercise. A human operator can see an event occur (such as the vessel pressurizing above its setpoint

Generic Raman-based calibration models enabling real-time monitoring of cell culture bioreactors.

PubMed

Mehdizadeh, Hamidreza; Lauri, David; Karry, Krizia M; Moshgbar, Mojgan; Procopio-Melino, Renee; Drapeau, Denis

2015-01-01

Raman-based multivariate calibration models have been developed for real-time in situ monitoring of multiple process parameters within cell culture bioreactors. Developed models are generic, in the sense that they are applicable to various products, media, and cell lines based on Chinese Hamster Ovarian (CHO) host cells, and are scalable to large pilot and manufacturing scales. Several batches using different CHO-based cell lines and corresponding proprietary media and process conditions have been used to generate calibration datasets, and models have been validated using independent datasets from separate batch runs. All models have been validated to be generic and capable of predicting process parameters with acceptable accuracy. The developed models allow monitoring multiple key bioprocess metabolic variables, and hence can be utilized as an important enabling tool for Quality by Design approaches which are strongly supported by the U.S. Food and Drug Administration. © 2015 American Institute of Chemical Engineers.

The implementation of a Hazard Analysis and Critical Control Point management system in a peanut butter ice cream plant.

PubMed

Hung, Yu-Ting; Liu, Chi-Te; Peng, I-Chen; Hsu, Chin; Yu, Roch-Chui; Cheng, Kuan-Chen

2015-09-01

To ensure the safety of the peanut butter ice cream manufacture, a Hazard Analysis and Critical Control Point (HACCP) plan has been designed and applied to the production process. Potential biological, chemical, and physical hazards in each manufacturing procedure were identified. Critical control points for the peanut butter ice cream were then determined as the pasteurization and freezing process. The establishment of a monitoring system, corrective actions, verification procedures, and documentation and record keeping were followed to complete the HACCP program. The results of this study indicate that implementing the HACCP system in food industries can effectively enhance food safety and quality while improving the production management. Copyright © 2015. Published by Elsevier B.V.

An Optical Interferometric Triaxial Displacement Sensor for Structural Health Monitoring: Characterization of Sliding and Debonding for a Delamination Process

PubMed Central

Chen, Yizheng; Zhuang, Yiyang; Du, Yang; Gerald, Rex E.; Tang, Yan

2017-01-01

This paper presents an extrinsic Fabry–Perot interferometer-based optical fiber sensor (EFPI) for measuring three-dimensional (3D) displacements, including interfacial sliding and debonding during delamination. The idea employs three spatially arranged EFPIs as the sensing elements. In our sensor, the three EFPIs are formed by three endfaces of three optical fibers and their corresponding inclined mirrors. Two coincident roof-like metallic structures are used to support the three fibers and the three mirrors, respectively. Our sensor was calibrated and then used to monitor interfacial sliding and debonding between a long square brick of mortar and its support structure (i.e., a steel base plate) during the drying/curing process. This robust and easy-to-manufacture triaxial EFPI-based 3D displacement sensor has great potential in structural health monitoring, the construction industry, oil well monitoring, and geotechnology. PMID:29165351

An Optical Interferometric Triaxial Displacement Sensor for Structural Health Monitoring: Characterization of Sliding and Debonding for a Delamination Process.

PubMed

Zhu, Chen; Chen, Yizheng; Zhuang, Yiyang; Du, Yang; Gerald, Rex E; Tang, Yan; Huang, Jie

2017-11-22

This paper presents an extrinsic Fabry-Perot interferometer-based optical fiber sensor (EFPI) for measuring three-dimensional (3D) displacements, including interfacial sliding and debonding during delamination. The idea employs three spatially arranged EFPIs as the sensing elements. In our sensor, the three EFPIs are formed by three endfaces of three optical fibers and their corresponding inclined mirrors. Two coincident roof-like metallic structures are used to support the three fibers and the three mirrors, respectively. Our sensor was calibrated and then used to monitor interfacial sliding and debonding between a long square brick of mortar and its support structure (i.e., a steel base plate) during the drying/curing process. This robust and easy-to-manufacture triaxial EFPI-based 3D displacement sensor has great potential in structural health monitoring, the construction industry, oil well monitoring, and geotechnology.

[Monitoring of methyl methacrylate monomer released from autopolymerized denture base polymers during processing using time-of-flight mass spectrometer].

PubMed

Ma, Yu-juan; Cui, Hua-peng; Li, Hai-yang

2011-04-01

To analyze the amount and tendency of methyl methacrylate (MMA) released from autopolymerized denture base polymer (self-curing resin) during processing using time-of-flight mass spectrometer (TOF-MS). Self-curing resin was mixed in the container using a ratio of 2 g of powder to 1 g of liquid in accordance with the manufacturer's instructions for 40 s as a specimen. The amount of MMA released from the specimen was continuously monitored and simultaneously recorded every minute by TOF-MS since immediately after mixing. A total of five specimens were monitored. The amount of MMA increased dramatically at 11 min [(45.2 ± 3.5) mg/L] after mixing, and reached the highest level at 13 min [(228.9 ± 22.6) mg/L], then become stable at 23 min [(8.8 ± 2.3) mg/L] after mixing. The releasing tendency of MMA could be analyzed accurately with continuously monitoring during processing. The amount of MMA released from self-curing resin changed rapidly and the processing was complicated and changeful.

System theory in industrial patient monitoring: an overview.

PubMed

Baura, G D

2004-01-01

Patient monitoring refers to the continuous observation of repeating events of physiologic function to guide therapy or to monitor the effectiveness of interventions, and is used primarily in the intensive care unit and operating room. Commonly processed signals are the electrocardiogram, intraarterial blood pressure, arterial saturation of oxygen, and cardiac output. To this day, the majority of physiologic waveform processing in patient monitors is conducted using heuristic curve fitting. However in the early 1990s, a few enterprising engineers and physicians began using system theory to improve their core processing. Applications included improvement of signal-to-noise ratio, either due to low signal levels or motion artifact, and improvement in feature detection. The goal of this mini-symposium is to review the early work in this emerging field, which has led to technologic breakthroughs. In this overview talk, the process of system theory algorithm research and development is discussed. Research for industrial monitors involves substantial data collection, with some data used for algorithm training and the remainder used for validation. Once the algorithms are validated, they are translated into detailed specifications. Development then translates these specifications into DSP code. The DSP code is verified and validated per the Good Manufacturing Practices mandated by FDA.

Process defects and in situ monitoring methods in metal powder bed fusion: a review

NASA Astrophysics Data System (ADS)

Grasso, Marco; Colosimo, Bianca Maria

2017-04-01

Despite continuous technological enhancements of metal Additive Manufacturing (AM) systems, the lack of process repeatability and stability still represents a barrier for the industrial breakthrough. The most relevant metal AM applications currently involve industrial sectors (e.g. aerospace and bio-medical) where defects avoidance is fundamental. Because of this, there is the need to develop novel in situ monitoring tools able to keep under control the stability of the process on a layer-by-layer basis, and to detect the onset of defects as soon as possible. On the one hand, AM systems must be equipped with in situ sensing devices able to measure relevant quantities during the process, a.k.a. process signatures. On the other hand, in-process data analytics and statistical monitoring techniques are required to detect and localize the defects in an automated way. This paper reviews the literature and the commercial tools for in situ monitoring of powder bed fusion (PBF) processes. It explores the different categories of defects and their main causes, the most relevant process signatures and the in situ sensing approaches proposed so far. Particular attention is devoted to the development of automated defect detection rules and the study of process control strategies, which represent two critical fields for the development of future smart PBF systems.

40 CFR 60.256 - Continuous monitoring requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

... device is to be certified by the manufacturer to be accurate within ±1 inch water gauge. (B) A monitoring device for the continuous measurement of the water supply pressure to the control equipment. The monitoring device is to be certified by the manufacturer to be accurate within ±5 percent of design water...

Laser micromachining of biofactory-on-a-chip devices

NASA Astrophysics Data System (ADS)

Burt, Julian P.; Goater, Andrew D.; Hayden, Christopher J.; Tame, John A.

2002-06-01

Excimer laser micromachining provides a flexible means for the manufacture and rapid prototyping of miniaturized systems such as Biofactory-on-a-Chip devices. Biofactories are miniaturized diagnostic devices capable of characterizing, manipulating, separating and sorting suspension of particles such as biological cells. Such systems operate by exploiting the electrical properties of microparticles and controlling particle movement in AC non- uniform stationary and moving electric fields. Applications of Biofactory devices are diverse and include, among others, the healthcare, pharmaceutical, chemical processing, environmental monitoring and food diagnostic markets. To achieve such characterization and separation, Biofactory devices employ laboratory-on-a-chip type components such as complex multilayer microelectrode arrays, microfluidic channels, manifold systems and on-chip detection systems. Here we discuss the manufacturing requirements of Biofactory devices and describe the use of different excimer laser micromachined methods both in stand-alone processes and also in conjunction with conventional fabrication processes such as photolithography and thermal molding. Particular attention is given to the production of large area multilayer microelectrode arrays and the manufacture of complex cross-section microfluidic channel systems for use in simple distribution and device interfacing.

In Situ Fringe Projection Profilometry for Laser Power Bed Fusion Process

NASA Astrophysics Data System (ADS)

Zhang, Bin

Additive manufacturing (AM) offers an industrial solution to produce parts with complex geometries and internal structures that conventional manufacturing techniques cannot produce. However, current metal additive process, particularly the laser powder bed fusion (LPBF) process, suffers from poor surface finish and various material defects which hinder its wide applications. One way to solve this problem is by adding in situ metrology sensor onto the machine chamber. Matured manufacturing processes are tightly monitored and controlled, and instrumentation advances are needed to realize this same advantage for metal additive process. This encourages us to develop an in situ fringe projection system for the LPBF process. The development of such a system and the measurement capability are demonstrated in this dissertation. We show that this system can measure various powder bed signatures including powder layer variations, the average height drop between fused metal and unfused powder, and the height variations on the fused surfaces. The ability to measure textured surface is also evaluated through the instrument transfer function (ITF). We analyze the mathematical model of the proposed fringe projection system, and prove the linearity of the system through simulations. A practical ITF measurement technique using a stepped surface is also demonstrated. The measurement results are compared with theoretical predictions generated through the ITF simulations.

21 CFR 26.15 - Monitoring continued equivalence.

Code of Federal Regulations, 2010 CFR

2010-04-01

... MUTUAL RECOGNITION OF PHARMACEUTICAL GOOD MANUFACTURING PRACTICE REPORTS, MEDICAL DEVICE QUALITY SYSTEM... COMMUNITY Specific Sector Provisions for Pharmaceutical Good Manufacturing Practices § 26.15 Monitoring... number of joint inspections; and the conduct of common training sessions. ...

21 CFR 26.15 - Monitoring continued equivalence.

Code of Federal Regulations, 2011 CFR

2011-04-01

... MUTUAL RECOGNITION OF PHARMACEUTICAL GOOD MANUFACTURING PRACTICE REPORTS, MEDICAL DEVICE QUALITY SYSTEM... COMMUNITY Specific Sector Provisions for Pharmaceutical Good Manufacturing Practices § 26.15 Monitoring... number of joint inspections; and the conduct of common training sessions. ...

Using Laser Ultrasound to Detect Subsurface Defects in Metal Laser Powder Bed Fusion Components

NASA Astrophysics Data System (ADS)

Everton, Sarah; Dickens, Phill; Tuck, Chris; Dutton, Ben

2018-03-01

Laser powder bed fusion offers many advantages over conventional manufacturing methods, such as the integration of multiple parts that can result in significant weight-savings. The increased design freedom that layer-wise manufacture allows has also been seen to enhance component performance at little or no added cost. For such benefits to be realized, however, the material quality must first be assured. Laser ultrasonic testing is a noncontact inspection technique that has been proposed as suitable for in situ monitoring of metal additive manufacturing processes. This article explores the current capability of this technique to detect manufactured, subsurface defects in Ti-6Al-4V samples, ex situ. The results are compared with x-ray computed tomography reconstructions and focus variation microscopy. Although laser ultrasound has been used to identify material discontinuities, further work is required before this technique could be implemented in situ.

40 CFR 421.3 - Monitoring and reporting requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

... for cyanide are not required for a facility in the primary beryllium subcategory (subpart O of this... calandar year has been analyzed and found to contain less than 0.07 mg/1 cyanide. (2) The owner or operator... issuing authority that cyanide is neither generated nor used in the beryllium manufacturing process...

46 CFR 162.050-5 - Contents of application.

Code of Federal Regulations, 2014 CFR

2014-10-01

... control procedures, in-process and final inspections and tests followed in manufacturing the item, and..., and maintenance of the item. (7) For each monitor and bilge alarm and each control on a separator, the vibration test report described in § 162.050-37. (8) For each oil content meter, a statement of whether it...

46 CFR 162.050-5 - Contents of application.

Code of Federal Regulations, 2011 CFR

2011-10-01

... control procedures, in-process and final inspections and tests followed in manufacturing the item, and..., and maintenance of the item. (7) For each monitor and bilge alarm and each control on a separator, the vibration test report described in § 162.050-37. (8) For each oil content meter, a statement of whether it...

46 CFR 162.050-5 - Contents of application.

Code of Federal Regulations, 2013 CFR

2013-10-01

... control procedures, in-process and final inspections and tests followed in manufacturing the item, and..., and maintenance of the item. (7) For each monitor and bilge alarm and each control on a separator, the vibration test report described in § 162.050-37. (8) For each oil content meter, a statement of whether it...

Optical microsystem for analyzing engine lubricants

NASA Astrophysics Data System (ADS)

Scott, Andrew J.; Mabesa, Jose R., Jr.; Gorsich, David; Rathgeb, Brian; Said, Ali A.; Dugan, Mark; Haddock, Tom F.; Bado, Philippe W.

2004-12-01

It is possible to dramatically improve the performance, reliability, and maintainability of vehicles and other similarly complex equipment if improved sensing and diagnostics systems are available. Each year military and commercial maintenance personnel unnecessarily replace, at scheduled intervals, significant amounts of lubricant fluids in vehicles, weapon systems, and supporting equipment. Personnel draw samples of fluids and send them to test labs for analysis to determine if replacement is necessary. Systematic use of either on-board (embedded) lubricant quality analysis capabilities will save millions of dollars each year in avoided fluid changes, saved labor, prevented damage to mechanical components while providing associated environmental benefits. This paper discusses the design, the manufacturing, and the evaluation of robust optical sensors designed to monitor the condition of industrial fluids. The sensors reported are manufactured from bulk fused silica substrates. They incorporate three-dimensional micro fluidic circuitry side-by-side with three-dimensional wave guided optical networks. The manufacturing of the optical waveguides are completed using a direct-write process based on the use of femtosecond laser pulses to locally alter the structure of the glass substrate at the nano-level. The microfluidic circuitry is produced using the same femtosecond laser based process, followed by an anisotropic wet chemical etching step. Data will be presented regarding the use of these sensors to monitor the quality of engine oil and possibly some other vehicle lubricants such as hydraulic oil.

Quantitative exposure matrix for asphalt fume, total particulate matter, and respirable crystalline silica among roofing and asphalt manufacturing workers.

PubMed

Fayerweather, William E; Trumbore, David C; Johnson, Kathleen A; Niebo, Ronald W; Maxim, L Daniel

2011-09-01

This paper summarizes available data on worker exposures to asphalt fume (soluble fraction), total particulate matter, and respirable crystalline silica (quartz) [hereinafter RCS] over a 30-year period in Owens Corning's asphalt production and roofing manufacturing plants. For the period 1977 through 2006, the air-monitoring database contains more than 1,400 personal samples for asphalt fume (soluble fraction), 2,400 personal samples for total particulate, and 1,300 personal samples for RCS. Unique process-job categories were identified for the asphalt production and roofing shingle manufacturing plants. Quantitative exposures were tabulated by agent, process-job, and calendar period to form an exposure matrix for use in subsequent epidemiologic studies of the respiratory health of these workers. Analysis of time trends in exposure data shows substantial and statistically significant exposure reductions for asphalt fume (soluble fraction), total particulate matter, and respirable crystalline silica at Owens Corning plants. Cumulative distribution plots for the most recent sampling period (2001-2006) show that 95% of the asphalt fume (soluble fraction) measurements were less than 0.25 mg/m3; 95% of the total particulate measurements were less than 2.2 mg/m3; and 95% of the RCS measurements were less than 0.05 mg/m3. Several recommendations are offered to improve the design of future monitoring efforts.

All-inkjet-printed flexible ZnO micro photodetector for a wearable UV monitoring device.

PubMed

Tran, Van-Thai; Wei, Yuefan; Yang, Hongyi; Zhan, Zhaoyao; Du, Hejun

2017-03-03

Fabrication of small-sized patterns of inorganic semiconductor onto flexible substrates is a major concern when manufacturing wearable devices for measuring either biometric or environmental parameters. In this study, micro-sized flexible ZnO UV photodetectors have been thoroughly prepared by a facile inkjet printing technology and followed with heat treatments. A simple ink recipe of zinc acetate precursor solution was investigated. It is found that the substrate temperature during zinc precursor ink depositing has significant effects on ZnO pattern shape, film morphology, and crystallization. The device fabricated from the additive manufacturing approach has good bendability, Ohmic contact, short response time as low as 0.3 s, and high on/off ratio of 3525. We observed the sensor's dependence of response/decay time by the illuminating UV light intensity. The whole process is based on additive manufacturing which has many benefits such as rapid prototyping, saving material, being environmentally friendly, and being capable of creating high-resolution patterns. In addition, this method can be applied to flexible substrates, which makes the device more applicable for applications requiring flexibility such as wearable devices. The proposed all-inkjet-printing approach for a micro-sized ZnO UV photodetector would significantly simplify the fabrication process of micro-sized inorganic semiconductor-based devices. A potential application is real-time monitoring of UV light exposure to warn users about unsafe direct sunlight to implement suitable avoidance solutions.

Modeling process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Yu, Cheng; Liu, Zeliang; Lian, Yanping; Wolff, Sarah; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-02-01

This paper presents our latest work on comprehensive modeling of process-structure-property relationships for additive manufacturing (AM) materials, including using data-mining techniques to close the cycle of design-predict-optimize. To illustrate the processstructure relationship, the multi-scale multi-physics process modeling starts from the micro-scale to establish a mechanistic heat source model, to the meso-scale models of individual powder particle evolution, and finally to the macro-scale model to simulate the fabrication process of a complex product. To link structure and properties, a highefficiency mechanistic model, self-consistent clustering analyses, is developed to capture a variety of material response. The model incorporates factors such as voids, phase composition, inclusions, and grain structures, which are the differentiating features of AM metals. Furthermore, we propose data-mining as an effective solution for novel rapid design and optimization, which is motivated by the numerous influencing factors in the AM process. We believe this paper will provide a roadmap to advance AM fundamental understanding and guide the monitoring and advanced diagnostics of AM processing.

Utility of optical heterodyne displacement sensing and laser ultrasonics as in situ process control diagnostic for additive manufacturing

NASA Astrophysics Data System (ADS)

Manzo, Anthony J.; Helvajian, Henry

2018-04-01

An in situ process control monitor is presented by way of experimental results and simulations, which utilizes a pulsed laser ultrasonic source as a probe and an optical heterodyne displacement meter as a sensor. The intent is for a process control system that operates in near real time, is nonintrusive, and in situ: A necessary requirement for a serial manufacturing technology such as additive manufacturing (AM). We show that the diagnostic approach has utility in characterizing the local temperature, the area of the heat-affected zone, and the surface roughness (Ra ˜ 0.4 μm). We further demonstrate that it can be used to identify solitary defects (i.e., holes) on the order of 10 to 20 μm in diameter. Moreover, the technique shows promise in measuring properties of materials with features that have a small radius of curvature. We present results for a thin wire of ˜650 μm in diameter. By applying multiple pairs of probe-sensor systems, the diagnostic could also measure the local cooling rate on the scale of 1 μs. Finally, while an obvious application is used in AM technology, then all optical diagnostics could be applied to other manufacturing technologies.

System-wide hybrid MPC-PID control of a continuous pharmaceutical tablet manufacturing process via direct compaction.

PubMed

Singh, Ravendra; Ierapetritou, Marianthi; Ramachandran, Rohit

2013-11-01

The next generation of QbD based pharmaceutical products will be manufactured through continuous processing. This will allow the integration of online/inline monitoring tools, coupled with an efficient advanced model-based feedback control systems, to achieve precise control of process variables, so that the predefined product quality can be achieved consistently. The direct compaction process considered in this study is highly interactive and involves time delays for a number of process variables due to sensor placements, process equipment dimensions, and the flow characteristics of the solid material. A simple feedback regulatory control system (e.g., PI(D)) by itself may not be sufficient to achieve the tight process control that is mandated by regulatory authorities. The process presented herein comprises of coupled dynamics involving slow and fast responses, indicating the requirement of a hybrid control scheme such as a combined MPC-PID control scheme. In this manuscript, an efficient system-wide hybrid control strategy for an integrated continuous pharmaceutical tablet manufacturing process via direct compaction has been designed. The designed control system is a hybrid scheme of MPC-PID control. An effective controller parameter tuning strategy involving an ITAE method coupled with an optimization strategy has been used for tuning of both MPC and PID parameters. The designed hybrid control system has been implemented in a first-principles model-based flowsheet that was simulated in gPROMS (Process System Enterprise). Results demonstrate enhanced performance of critical quality attributes (CQAs) under the hybrid control scheme compared to only PID or MPC control schemes, illustrating the potential of a hybrid control scheme in improving pharmaceutical manufacturing operations. Copyright © 2013 Elsevier B.V. All rights reserved.

On-line, continuous monitoring in solar cell and fuel cell manufacturing using spectral reflectance imaging

DOEpatents

Sopori, Bhushan; Rupnowski, Przemyslaw; Ulsh, Michael

2016-01-12

A monitoring system 100 comprising a material transport system 104 providing for the transportation of a substantially planar material 102, 107 through the monitoring zone 103 of the monitoring system 100. The system 100 also includes a line camera 106 positioned to obtain multiple line images across a width of the material 102, 107 as it is transported through the monitoring zone 103. The system 100 further includes an illumination source 108 providing for the illumination of the material 102, 107 transported through the monitoring zone 103 such that light reflected in a direction normal to the substantially planar surface of the material 102, 107 is detected by the line camera 106. A data processing system 110 is also provided in digital communication with the line camera 106. The data processing system 110 is configured to receive data output from the line camera 106 and further configured to calculate and provide substantially contemporaneous information relating to a quality parameter of the material 102, 107. Also disclosed are methods of monitoring a quality parameter of a material.

An Application of X-Ray Fluorescence as Process Analytical Technology (PAT) to Monitor Particle Coating Processes.

PubMed

Nakano, Yoshio; Katakuse, Yoshimitsu; Azechi, Yasutaka

2018-06-01

An attempt to apply X-Ray Fluorescence (XRF) analysis to evaluate small particle coating process as a Process Analytical Technologies (PAT) was made. The XRF analysis was used to monitor coating level in small particle coating process with at-line manner. The small particle coating process usually consists of multiple coating processes. This study was conducted by a simple coating particles prepared by first coating of a model compound (DL-methionine) and second coating by talc on spherical microcrystalline cellulose cores. The particles with two layered coating are enough to demonstrate the small particle coating process. From the result by the small particle coating process, it was found that the XRF signal played different roles, resulting that XRF signals by first coating (layering) and second coating (mask coating) could demonstrate the extent with different mechanisms for the coating process. Furthermore, the particle coating of the different particle size has also been investigated to evaluate size effect of these coating processes. From these results, it was concluded that the XRF could be used as a PAT in monitoring particle coating processes and become powerful tool in pharmaceutical manufacturing.

Application of agent-based system for bioprocess description and process improvement.

PubMed

Gao, Ying; Kipling, Katie; Glassey, Jarka; Willis, Mark; Montague, Gary; Zhou, Yuhong; Titchener-Hooker, Nigel J

2010-01-01

Modeling plays an important role in bioprocess development for design and scale-up. Predictive models can also be used in biopharmaceutical manufacturing to assist decision-making either to maintain process consistency or to identify optimal operating conditions. To predict the whole bioprocess performance, the strong interactions present in a processing sequence must be adequately modeled. Traditionally, bioprocess modeling considers process units separately, which makes it difficult to capture the interactions between units. In this work, a systematic framework is developed to analyze the bioprocesses based on a whole process understanding and considering the interactions between process operations. An agent-based approach is adopted to provide a flexible infrastructure for the necessary integration of process models. This enables the prediction of overall process behavior, which can then be applied during process development or once manufacturing has commenced, in both cases leading to the capacity for fast evaluation of process improvement options. The multi-agent system comprises a process knowledge base, process models, and a group of functional agents. In this system, agent components co-operate with each other in performing their tasks. These include the description of the whole process behavior, evaluating process operating conditions, monitoring of the operating processes, predicting critical process performance, and providing guidance to decision-making when coping with process deviations. During process development, the system can be used to evaluate the design space for process operation. During manufacture, the system can be applied to identify abnormal process operation events and then to provide suggestions as to how best to cope with the deviations. In all cases, the function of the system is to ensure an efficient manufacturing process. The implementation of the agent-based approach is illustrated via selected application scenarios, which demonstrate how such a framework may enable the better integration of process operations by providing a plant-wide process description to facilitate process improvement. Copyright 2009 American Institute of Chemical Engineers

In situ monitoring of cocrystals in formulation development using low-frequency Raman spectroscopy.

PubMed

Otaki, Takashi; Tanabe, Yuta; Kojima, Takashi; Miura, Masaru; Ikeda, Yukihiro; Koide, Tatsuo; Fukami, Toshiro

2018-05-05

In recent years, to guarantee a quality-by-design approach to the development of pharmaceutical products, it is important to identify properties of raw materials and excipients in order to determine critical process parameters and critical quality attributes. Feedback obtained from real-time analyses using various process analytical technology (PAT) tools has been actively investigated. In this study, in situ monitoring using low-frequency (LF) Raman spectroscopy (10-200 cm -1 ), which may have higher discriminative ability among polymorphs than near-infrared spectroscopy and conventional Raman spectroscopy (200-1800 cm -1 ), was investigated as a possible application to PAT. This is because LF-Raman spectroscopy obtains information about intermolecular and/or lattice vibrations in the solid state. The monitoring results obtained from Furosemide/Nicotinamide cocrystal indicate that LF-Raman spectroscopy is applicable to in situ monitoring of suspension and fluidized bed granulation processes, and is an effective technique as a PAT tool to detect the conversion risk of cocrystals. LF-Raman spectroscopy is also used as a PAT tool to monitor reactions, crystallizations, and manufacturing processes of drug substances and products. In addition, a sequence of conversion behaviors of Furosemide/Nicotinamide cocrystals was determined by performing in situ monitoring for the first time. Copyright © 2018 Elsevier B.V. All rights reserved.

Developments in hydrogenation technology for fine-chemical and pharmaceutical applications.

PubMed

Machado, R M; Heier, K R; Broekhuis, R R

2001-11-01

The continuous innovation in hydrogenation technology is testimony to its growing importance in the manufacture of specialty and fine chemicals. New developments in equipment, process intensification and catalysis represent major themes that have undergone recent advances. Developments in chiral catalysis, methods to support and fix homogeneous catalysts, novel reactor and mixing technology, high-throughput screening, supercritical processing, spectroscopic and electrochemical online process monitoring, monolithic and structured catalysts, and sonochemical activation methods illustrate the scope and breadth of evolving technology applied to hydrogenation.

Linear friction weld process monitoring of fixture cassette deformations using empirical mode decomposition

NASA Astrophysics Data System (ADS)

Bakker, O. J.; Gibson, C.; Wilson, P.; Lohse, N.; Popov, A. A.

2015-10-01

Due to its inherent advantages, linear friction welding is a solid-state joining process of increasing importance to the aerospace, automotive, medical and power generation equipment industries. Tangential oscillations and forge stroke during the burn-off phase of the joining process introduce essential dynamic forces, which can also be detrimental to the welding process. Since burn-off is a critical phase in the manufacturing stage, process monitoring is fundamental for quality and stability control purposes. This study aims to improve workholding stability through the analysis of fixture cassette deformations. Methods and procedures for process monitoring are developed and implemented in a fail-or-pass assessment system for fixture cassette deformations during the burn-off phase. Additionally, the de-noised signals are compared to results from previous production runs. The observed deformations as a consequence of the forces acting on the fixture cassette are measured directly during the welding process. Data on the linear friction-welding machine are acquired and de-noised using empirical mode decomposition, before the burn-off phase is extracted. This approach enables a direct, objective comparison of the signal features with trends from previous successful welds. The capacity of the whole process monitoring system is validated and demonstrated through the analysis of a large number of signals obtained from welding experiments.

A Statistical Representation of Pyrotechnic Igniter Output

NASA Astrophysics Data System (ADS)

Guo, Shuyue; Cooper, Marcia

2017-06-01

The output of simplified pyrotechnic igniters for research investigations is statistically characterized by monitoring the post-ignition external flow field with Schlieren imaging. Unique to this work is a detailed quantification of all measurable manufacturing parameters (e.g., bridgewire length, charge cavity dimensions, powder bed density) and associated shock-motion variability in the tested igniters. To demonstrate experimental precision of the recorded Schlieren images and developed image processing methodologies, commercial exploding bridgewires using wires of different parameters were tested. Finally, a statistically-significant population of manufactured igniters were tested within the Schlieren arrangement resulting in a characterization of the nominal output. Comparisons between the variances measured throughout the manufacturing processes and the calculated output variance provide insight into the critical device phenomena that dominate performance. Sandia National Laboratories is a multi-mission laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's NNSA under contract DE-AC04-94AL85000.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

PubMed

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

PubMed Central

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part’s porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented. PMID:26601041

Metrology for the manufacturing of freeform optics

NASA Astrophysics Data System (ADS)

Blalock, Todd; Myer, Brian; Ferralli, Ian; Brunelle, Matt; Lynch, Tim

2017-10-01

Recently the use of freeform surfaces have become a realization for optical designers. These non-symmetrical optical surfaces have allowed unique solutions to optical design problems. The implementation of freeform optical surfaces has been limited by manufacturing capabilities and quality. However over the past several years freeform fabrication processes have improved in capability and precision. But as with any manufacturing, proper metrology is required to monitor and verify the process. Typical optics metrology such as interferometry has its challenges and limitations with the unique shapes of freeform optics. Two contact metrology methods for freeform metrology are presented; a Leitz coordinate measurement machine (CMM) with an uncertainty of +/- 0.5 μm and a high resolution profilometer (Panasonic UA3P) with a measurement uncertainty of +/- 0.05 μm. We are also developing a non-contact high resolution technique based on the fringe reflection technique known as deflectometry. This fast non-contact metrology has the potential to compete with accuracies of the contact methods but also can acquire data in seconds rather than minutes or hours.

Process characterization and Design Space definition.

PubMed

Hakemeyer, Christian; McKnight, Nathan; St John, Rick; Meier, Steven; Trexler-Schmidt, Melody; Kelley, Brian; Zettl, Frank; Puskeiler, Robert; Kleinjans, Annika; Lim, Fred; Wurth, Christine

2016-09-01

Quality by design (QbD) is a global regulatory initiative with the goal of enhancing pharmaceutical development through the proactive design of pharmaceutical manufacturing process and controls to consistently deliver the intended performance of the product. The principles of pharmaceutical development relevant to QbD are described in the ICH guidance documents (ICHQ8-11). An integrated set of risk assessments and their related elements developed at Roche/Genentech were designed to provide an overview of product and process knowledge for the production of a recombinant monoclonal antibody (MAb). This chapter describes the tools used for the characterization and validation of MAb manufacturing process under the QbD paradigm. This comprises risk assessments for the identification of potential Critical Process Parameters (pCPPs), statistically designed experimental studies as well as studies assessing the linkage of the unit operations. Outcome of the studies is the classification of process parameters according to their criticality and the definition of appropriate acceptable ranges of operation. The process and product knowledge gained in these studies can lead to the approval of a Design Space. Additionally, the information gained in these studies are used to define the 'impact' which the manufacturing process can have on the variability of the CQAs, which is used to define the testing and monitoring strategy. Copyright © 2016 International Alliance for Biological Standardization. Published by Elsevier Ltd. All rights reserved.

Opportunities for Nondestructive Evaluation: Quantitative Characterization (Postprint)

DTIC Science & Technology

2017-07-01

between the design and the as- manufactured and, ultimately, the as-maintained state. As this occurs with the article of interest being placed in...TESTING (STINFO COPY) AIR FORCE RESEARCH LABORATORY MATERIALS AND MANUFACTURING DIRECTORATE WRIGHT-PATTERSON AIR FORCE BASE, OH 45433-7750 AIR FORCE...MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING AGENCY ACRONYM(S) Air Force Research Laboratory Materials and Manufacturing

A High Input Impedance Low Noise Integrated Front-End Amplifier for Neural Monitoring.

PubMed

Zhou, Zhijun; Warr, Paul A

2016-12-01

Within neural monitoring systems, the front-end amplifier forms the critical element for signal detection and pre-processing, which determines not only the fidelity of the biosignal, but also impacts power consumption and detector size. In this paper, a novel combined feedback loop-controlled approach is proposed to compensate for input leakage currents generated by low noise amplifiers when in integrated circuit form alongside signal leakage into the input bias network. This loop topology ensures the Front-End Amplifier (FEA) maintains a high input impedance across all manufacturing and operational variations. Measured results from a prototype manufactured on the AMS 0.35 [Formula: see text] CMOS technology is provided. This FEA consumes 3.1 [Formula: see text] in 0.042 [Formula: see text], achieves input impedance of 42 [Formula: see text], and 18.2 [Formula: see text] input-referred noise.

Cluster 1: commercializing additive manufacturing—hurdles in materials characterization and testing

DOE PAGES

Roach, R. A.; Gardner, S. H.

2017-10-20

A major challenge in the commercialization of additive manufactured (AM) materials and processes is the ability to achieve acceptance of processes and products. There has been some progress towards acceptance has been made by adapting legacy qualification paradigms to match with the very limited process control and monitoring offered by AM machines. The opportunity for in-situ measurement can provide process monitoring and control perhaps changing the way we qualify parts however it is limited by lack of adequate process measurement methods. New measurement techniques, sensors and correlations to relevant phenomena are needed that enable process control and monitoring for consistentlymore » producing high quality articles. Beyond process data we need to characterize uncertainties of performance in all aspects of material, process and final part. These are prerequisites to achieving articles that are indeed worthy of materials characterization efforts that establish a microstructural reference of desirable performance through process-structure-property relations. Only then can industry apply physics based understanding of the material, part and process to probabilistically predict performance of an AM part. Our paper provides a brief overview, discussion of hurdles and key areas where R&D investment is needed.« less

Cluster 1: commercializing additive manufacturing—hurdles in materials characterization and testing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Roach, R. A.; Gardner, S. H.

A major challenge in the commercialization of additive manufactured (AM) materials and processes is the ability to achieve acceptance of processes and products. There has been some progress towards acceptance has been made by adapting legacy qualification paradigms to match with the very limited process control and monitoring offered by AM machines. The opportunity for in-situ measurement can provide process monitoring and control perhaps changing the way we qualify parts however it is limited by lack of adequate process measurement methods. New measurement techniques, sensors and correlations to relevant phenomena are needed that enable process control and monitoring for consistentlymore » producing high quality articles. Beyond process data we need to characterize uncertainties of performance in all aspects of material, process and final part. These are prerequisites to achieving articles that are indeed worthy of materials characterization efforts that establish a microstructural reference of desirable performance through process-structure-property relations. Only then can industry apply physics based understanding of the material, part and process to probabilistically predict performance of an AM part. Our paper provides a brief overview, discussion of hurdles and key areas where R&D investment is needed.« less

Continuous welding of unidirectional fiber reinforced thermoplastic tape material

NASA Astrophysics Data System (ADS)

Schledjewski, Ralf

2017-10-01

Continuous welding techniques like thermoplastic tape placement with in situ consolidation offer several advantages over traditional manufacturing processes like autoclave consolidation, thermoforming, etc. However, still there is a need to solve several important processing issues before it becomes a viable economic process. Intensive process analysis and optimization has been carried out in the past through experimental investigation, model definition and simulation development. Today process simulation is capable to predict resulting consolidation quality. Effects of material imperfections or process parameter variations are well known. But using this knowledge to control the process based on online process monitoring and according adaption of the process parameters is still challenging. Solving inverse problems and using methods for automated code generation allowing fast implementation of algorithms on targets are required. The paper explains the placement technique in general. Process-material-property-relationships and typical material imperfections are described. Furthermore, online monitoring techniques and how to use them for a model based process control system are presented.

Planning for the semiconductor manufacturer of the future

NASA Technical Reports Server (NTRS)

Fargher, Hugh E.; Smith, Richard A.

1992-01-01

Texas Instruments (TI) is currently contracted by the Air Force Wright Laboratory and the Defense Advanced Research Projects Agency (DARPA) to develop the next generation flexible semiconductor wafer fabrication system called Microelectronics Manufacturing Science & Technology (MMST). Several revolutionary concepts are being pioneered on MMST, including the following: new single-wafer rapid thermal processes, in-situ sensors, cluster equipment, and advanced Computer Integrated Manufacturing (CIM) software. The objective of the project is to develop a manufacturing system capable of achieving an order of magnitude improvement in almost all aspects of wafer fabrication. TI was awarded the contract in Oct., 1988, and will complete development with a fabrication facility demonstration in April, 1993. An important part of MMST is development of the CIM environment responsible for coordinating all parts of the system. The CIM architecture being developed is based on a distributed object oriented framework made of several cooperating subsystems. The software subsystems include the following: process control for dynamic control of factory processes; modular processing system for controlling the processing equipment; generic equipment model which provides an interface between processing equipment and the rest of the factory; specification system which maintains factory documents and product specifications; simulator for modelling the factory for analysis purposes; scheduler for scheduling work on the factory floor; and the planner for planning and monitoring of orders within the factory. This paper first outlines the division of responsibility between the planner, scheduler, and simulator subsystems. It then describes the approach to incremental planning and the way in which uncertainty is modelled within the plan representation. Finally, current status and initial results are described.

76 FR 59542 - Mandatory Reporting of Greenhouse Gases: Changes to Provisions for Electronics Manufacturing To...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-09-27

... Mandatory Reporting of Greenhouse Gases: Changes to Provisions for Electronics Manufacturing To Provide... regulation to amend the calculation and monitoring provisions in the Electronics Manufacturing portion of the... Electronics Manufacturing 334111 Microcomputer manufacturing facilities. 334413 Semiconductor, photovoltaic...

Make-to-order manufacturing - new approach to management of manufacturing processes

NASA Astrophysics Data System (ADS)

Saniuk, A.; Waszkowski, R.

2016-08-01

Strategic management must now be closely linked to the management at the operational level, because only in such a situation the company can be flexible and can quickly respond to emerging opportunities and pursue ever-changing strategic objectives. In these conditions industrial enterprises seek constantly new methods, tools and solutions which help to achieve competitive advantage. They are beginning to pay more attention to cost management, economic effectiveness and performance of business processes. In the article characteristics of make-to-order systems (MTO) and needs associated with managing such systems is identified based on the literature analysis. The main aim of this article is to present the results of research related to the development of a new solution dedicated to small and medium enterprises manufacture products solely on the basis of production orders (make-to- order systems). A set of indicators to enable continuous monitoring and control of key strategic areas this type of company is proposed. A presented solution includes the main assumptions of the following concepts: the Performance Management (PM), the Balanced Scorecard (BSC) and a combination of strategic management with the implementation of operational management. The main benefits of proposed solution are to increase effectiveness of MTO manufacturing company management.

40 CFR 63.1383 - Monitoring requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

... manufacturing facility must prepare for each glass-melting furnace, rotary spin manufacturing line, and flame... glass-melting furnace, the owner or operator shall install, calibrate, maintain, and continuously... monitors. (v) A triboelectric bag leak detection system shall be installed, operated, adjusted, and...

Explosives mimic for testing, training, and monitoring

DOEpatents

Reynolds, John G.; Durban, Matthew M.; Gash, Alexander E.; Grapes, Michael D.; Kelley, Ryan S.; Sullivan, Kyle T.

2018-02-13

Additive Manufacturing (AM) is used to make mimics for explosives. The process uses mixtures of explosives and matrices commonly used in AM. The explosives are formulated into a mixture with the matrix and printed using AM techniques and equipment. The explosive concentrations are kept less than 10% by wt. of the mixture to conform to requirements of shipping and handling.

On-line photolithography modeling using spectrophotometry and Prolith/2

NASA Astrophysics Data System (ADS)

Engstrom, Herbert L.; Beacham, Jeanne E.

1994-05-01

Spectrophotometry has been applied to optimizing photolithography processes in semiconductor manufacturing. For many years thin film measurement systems have been used in manufacturing for controlling film deposition processes. The combination of film thickness mapping with photolithography modeling has expanded the applications of this technology. Experimental measurements of dose-to-clear, the minimum light exposure dose required to fully develop a photoresist, are described. It is shown how dose-to-clear and photoresist contrast may be determined rapidly and conveniently from measurements of a dose exposure matrix on a monitor wafer. Such experimental measurements may underestimate the dose-to- clear because of thickness variations of the photoresist and underlying layers on the product wafer. Online modeling of the photolithographic process together with film thickness maps of the entire wafer can overcome this problem. Such modeling also provides maps of dose-to- clear and resist linewidth that can be used to estimate and optimize yield.

Corporate ergonomics programme at BCM Airdrie. Boots Contract Manufacturing.

PubMed

Smyth, Joanne

2003-01-01

The production processes at the BCM Airdrie site range from manual loading tasks in the manufacturing areas to high frequency packaging assembly tasks on the production lines. Both are jobs that are known to carry risk to musculoskeletal health, so an ergonomist was appointed to design and co-ordinate an ergonomics programme for the site to control these risks. This paper details the programme that has evolved to proactively manage musculoskeletal risks in the design of both new and existing equipment and processes. The ergonomics procedures described primarily involve the engineers from all areas of the factory, and the process for ergonomics involvement with engineering design projects is described. Shop-floor personnel involvement is considered to be an essential part of the programme and 'Ergonomics Champions' are being trained on the packing lines to monitor the risks that are sometimes introduced with the different designs of product packaging.

Measurement Science for Prognostics and Health Management for Smart Manufacturing Systems: Key Findings from a Roadmapping Workshop

PubMed Central

Weiss, Brian A.; Vogl, Gregory; Helu, Moneer; Qiao, Guixiu; Pellegrino, Joan; Justiniano, Mauricio; Raghunathan, Anand

2017-01-01

The National Institute of Standards and Technology (NIST) hosted the Roadmapping Workshop – Measurement Science for Prognostics and Health Management for Smart Manufacturing Systems (PHM4SMS) in Fall 2014 to discuss the needs and priorities of stakeholders in the PHM4SMS technology area. The workshop brought together over 70 members of the PHM community. The attendees included representatives from small, medium, and large manufacturers; technology developers and integrators; academic researchers; government organizations; trade associations; and standards bodies. The attendees discussed the current and anticipated measurement science challenges to advance PHM methods and techniques for smart manufacturing systems; the associated research and development needed to implement condition monitoring, diagnostic, and prognostic technologies within manufacturing environments; and the priorities to meet the needs of PHM in manufacturing. This paper will summarize the key findings of this workshop, and present some of the critical measurement science challenges and corresponding roadmaps, i.e., suggested courses of action, to advance PHM for manufacturing. Milestones and targeted capabilities will be presented for each roadmap across three areas: PHM Manufacturing Process Techniques; PHM Performance Assessment; and PHM Infrastructure – Hardware, Software, and Integration. An analysis of these roadmaps and crosscutting themes seen across the breakout sessions is also discussed. PMID:28664163

Evaluation of an Environmental Monitoring Program for the Microbial Safety of Air and Surfaces in a Dairy Plant Environment.

PubMed

Zacharski, Krzysztof A; Southern, Mark; Ryan, Alan; Adley, Catherine C

2018-07-01

Microbiological hazards can occur when foodstuffs come into contact with contaminated surfaces or infectious agents dispersed by air currents in the manufacturing environment. An environmental monitoring program (EMP) is a critical aspect of sustainable and safe food manufacturing used to evaluate the effectiveness of the microbial controls in place. An effective EMP should be based on risk analysis, taking into account previous sampling history to determine the selection of the sampling points, the scope of the test, and the frequency of analysis. This study involved evaluation of the environmental monitoring regime and microbiological status of a medium-sized dairy plant manufacturing food ingredients, e.g., proteins, milk powders, and dairy fats. The data specific to microbial tests ( n = 3,468), recorded across 124 fixed sampling locations over a 2-year period (2014 to 2015) from air ( n = 1,787) and surfaces ( n = 1,681) were analyzed. The aim of this study was to highlight the strengths and weaknesses of the EMP in a select dairy processing plant. The results of this study outline the selection of sampling locations, the scope of the test, and the frequency of analysis. An analysis of variance revealed subsections of the manufacturing areas with high risk factors, especially the packaging subsection specified for bulk packaging, the atomizer, and the fluidized bed. The temporal and spatial analysis showed the potential to reduce or relocate the monitoring effort, most notably related to total coliforms and Staphylococcus aureus, across the dairy plant due to homogeneity across the sampling subsections with little or no deviations. The results suggest a need to reevaluate the current EMP and the corrective action plan, especially with regard to detection of pathogens. Recommendations for optimization of the EMP are presented to assist the dairy industry with reviewing and revising the control measures and hazard assessment with regard to existing contamination issues.

Application of Advanced Nondestructive Evaluation Techniques for Cylindrical Composite Test Samples

NASA Technical Reports Server (NTRS)

Martin, Richard E.; Roth, Donald J.; Salem, Jonathan A.

2013-01-01

Two nondestructive methods were applied to composite cylinder samples pressurized to failure in order to determine manufacturing quality and monitor damage progression under load. A unique computed tomography (CT) image processing methodology developed at NASA Glenn Research was used to assess the condition of the as-received samples while acoustic emission (AE) monitoring was used to identify both the extent and location of damage within the samples up to failure. Results show the effectiveness of both of these methods in identifying potentially critical fabrication issues and their resulting impact on performance.

In-line and Real-time Monitoring of Resonant Acoustic Mixing by Near-infrared Spectroscopy Combined with Chemometric Technology for Process Analytical Technology Applications in Pharmaceutical Powder Blending Systems.

PubMed

Tanaka, Ryoma; Takahashi, Naoyuki; Nakamura, Yasuaki; Hattori, Yusuke; Ashizawa, Kazuhide; Otsuka, Makoto

2017-01-01

Resonant acoustic ® mixing (RAM) technology is a system that performs high-speed mixing by vibration through the control of acceleration and frequency. In recent years, real-time process monitoring and prediction has become of increasing interest, and process analytical technology (PAT) systems will be increasingly introduced into actual manufacturing processes. This study examined the application of PAT with the combination of RAM, near-infrared spectroscopy, and chemometric technology as a set of PAT tools for introduction into actual pharmaceutical powder blending processes. Content uniformity was based on a robust partial least squares regression (PLSR) model constructed to manage the RAM configuration parameters and the changing concentration of the components. As a result, real-time monitoring may be possible and could be successfully demonstrated for in-line real-time prediction of active pharmaceutical ingredients and other additives using chemometric technology. This system is expected to be applicable to the RAM method for the risk management of quality.

Using process monitor wafers to understand directed self-assembly defects

NASA Astrophysics Data System (ADS)

Cao, Yi; Her, YoungJun; Delgadillo, Paulina R.; Vandenbroeck, Nadia; Gronheid, Roel; Chan, Boon Teik; Hashimoto, Yukio; Romo, Ainhoa; Somervell, Mark; Nafus, Kathleen; Nealey, Paul F.

2013-03-01

As directed self-assembly (DSA) has gained momentum over the past few years, questions about its application to high volume manufacturing have arisen. One of the major concerns is about the fundamental limits of defectivity that can be attained with the technology. If DSA applications demonstrate defectivity that rivals of traditional lithographic technologies, the pathway to the cost benefits of the technology creates a very compelling case for its large scale implementation. To address this critical question, our team at IMEC has established a process monitor flow to track the defectivity behaviors of an exemplary chemo-epitaxy application for printing line/space patterns. Through establishing this baseline, we have been able to understand both traditional lithographic defect sources in new materials as well as new classes of assembly defects associated with DSA technology. Moreover, we have explored new materials and processing to lower the level of the defectivity baseline. The robustness of the material sets and process is investigated as well. In this paper, we will report the understandings learned from the IMEC DSA process monitor flow.

Detailed Characterization of Human Induced Pluripotent Stem Cells Manufactured for Therapeutic Applications.

PubMed

Baghbaderani, Behnam Ahmadian; Syama, Adhikarla; Sivapatham, Renuka; Pei, Ying; Mukherjee, Odity; Fellner, Thomas; Zeng, Xianmin; Rao, Mahendra S

2016-08-01

We have recently described manufacturing of human induced pluripotent stem cells (iPSC) master cell banks (MCB) generated by a clinically compliant process using cord blood as a starting material (Baghbaderani et al. in Stem Cell Reports, 5(4), 647-659, 2015). In this manuscript, we describe the detailed characterization of the two iPSC clones generated using this process, including whole genome sequencing (WGS), microarray, and comparative genomic hybridization (aCGH) single nucleotide polymorphism (SNP) analysis. We compare their profiles with a proposed calibration material and with a reporter subclone and lines made by a similar process from different donors. We believe that iPSCs are likely to be used to make multiple clinical products. We further believe that the lines used as input material will be used at different sites and, given their immortal status, will be used for many years or even decades. Therefore, it will be important to develop assays to monitor the state of the cells and their drift in culture. We suggest that a detailed characterization of the initial status of the cells, a comparison with some calibration material and the development of reporter sublcones will help determine which set of tests will be most useful in monitoring the cells and establishing criteria for discarding a line.

Assessing the influence of component processing and donor characteristics on quality of red cell concentrates using quality control data.

PubMed

Jordan, A; Chen, D; Yi, Q-L; Kanias, T; Gladwin, M T; Acker, J P

2016-07-01

Quality control (QC) data collected by blood services are used to monitor production and to ensure compliance with regulatory standards. We demonstrate how analysis of quality control data can be used to highlight the sources of variability within red cell concentrates (RCCs). We merged Canadian Blood Services QC data with manufacturing and donor records for 28 227 RCC between June 2011 and October 2014. Units were categorized based on processing method, bag manufacturer, donor age and donor sex, then assessed based on product characteristics: haemolysis and haemoglobin levels, unit volume, leucocyte count and haematocrit. Buffy-coat method (top/bottom)-processed units exhibited lower haemolysis than units processed using the whole-blood filtration method (top/top). Units from female donors exhibited lower haemolysis than male donations. Processing method influenced unit volume and the ratio of additive solution to residual plasma. Stored red blood cell characteristics are influenced by prestorage processing and donor factors. Understanding the relationship between processing, donors and RCC quality will help blood services to ensure the safety of transfused products. © 2016 International Society of Blood Transfusion.

Multivariate statistical process control in product quality review assessment - A case study.

PubMed

Kharbach, M; Cherrah, Y; Vander Heyden, Y; Bouklouze, A

2017-11-01

According to the Food and Drug Administration and the European Good Manufacturing Practices (GMP) guidelines, Annual Product Review (APR) is a mandatory requirement in GMP. It consists of evaluating a large collection of qualitative or quantitative data in order to verify the consistency of an existing process. According to the Code of Federal Regulation Part 11 (21 CFR 211.180), all finished products should be reviewed annually for the quality standards to determine the need of any change in specification or manufacturing of drug products. Conventional Statistical Process Control (SPC) evaluates the pharmaceutical production process by examining only the effect of a single factor at the time using a Shewhart's chart. It neglects to take into account the interaction between the variables. In order to overcome this issue, Multivariate Statistical Process Control (MSPC) can be used. Our case study concerns an APR assessment, where 164 historical batches containing six active ingredients, manufactured in Morocco, were collected during one year. Each batch has been checked by assaying the six active ingredients by High Performance Liquid Chromatography according to European Pharmacopoeia monographs. The data matrix was evaluated both by SPC and MSPC. The SPC indicated that all batches are under control, while the MSPC, based on Principal Component Analysis (PCA), for the data being either autoscaled or robust scaled, showed four and seven batches, respectively, out of the Hotelling T 2 95% ellipse. Also, an improvement of the capability of the process is observed without the most extreme batches. The MSPC can be used for monitoring subtle changes in the manufacturing process during an APR assessment. Copyright © 2017 Académie Nationale de Pharmacie. Published by Elsevier Masson SAS. All rights reserved.

Prevalence of Listeria monocytogenes in Retail Lightly Pickled Vegetables and Its Successful Control at Processing Plants.

PubMed

Taguchi, Masumi; Kanki, Masashi; Yamaguchi, Yuko; Inamura, Hideichi; Koganei, Yosuke; Sano, Tetsuya; Nakamura, Hiromi; Asakura, Hiroshi

2017-03-01

Incidences of food poisoning traced to nonanimal food products have been increasingly reported. One of these was a recent large outbreak of Shiga toxin-producing Escherichia coli (STEC) O157 infection from the consumption of lightly pickled vegetables, indicating the necessity of imposing hygienic controls during manufacturing. However, little is known about the bacterial contamination levels in these minimally processed vegetables. Here we examined the prevalence of STEC, Salmonella spp., and Listeria monocytogenes in 100 lightly pickled vegetable products manufactured at 55 processing factories. Simultaneously, we also performed quantitative measurements of representative indicator bacteria (total viable counts, coliform counts, and β-glucuronidase-producing E. coli counts). STEC and Salmonella spp. were not detected in any of the samples; L. monocytogenes was detected in 12 samples manufactured at five of the factories. Microbiological surveillance at two factories (two surveys at factory A and three surveys at factory B) between June 2014 and January 2015 determined that the areas predominantly contaminated with L. monocytogenes included the refrigerators and packaging rooms. Genotyping provided further evidence that the contaminants found in these areas were linked to those found in the final products. Taken together, we demonstrated the prevalence of L. monocytogenes in lightly pickled vegetables sold at the retail level. Microbiological surveillance at the manufacturing factories further clarified the sources of the contamination in the retail products. These data indicate the necessity of implementing adequate monitoring programs to minimize health risks attributable to the consumption of these minimally processed vegetables.

FDA 2011 process validation guidance: lifecycle compliance model.

PubMed

Campbell, Cliff

2014-01-01

This article has been written as a contribution to the industry's efforts in migrating from a document-driven to a data-driven compliance mindset. A combination of target product profile, control engineering, and general sum principle techniques is presented as the basis of a simple but scalable lifecycle compliance model in support of modernized process validation. Unit operations and significant variables occupy pole position within the model, documentation requirements being treated as a derivative or consequence of the modeling process. The quality system is repositioned as a subordinate of system quality, this being defined as the integral of related "system qualities". The article represents a structured interpretation of the U.S. Food and Drug Administration's 2011 Guidance for Industry on Process Validation and is based on the author's educational background and his manufacturing/consulting experience in the validation field. The U.S. Food and Drug Administration's Guidance for Industry on Process Validation (2011) provides a wide-ranging and rigorous outline of compliant drug manufacturing requirements relative to its 20(th) century predecessor (1987). Its declared focus is patient safety, and it identifies three inter-related (and obvious) stages of the compliance lifecycle. Firstly, processes must be designed, both from a technical and quality perspective. Secondly, processes must be qualified, providing evidence that the manufacturing facility is fully "roadworthy" and fit for its intended purpose. Thirdly, processes must be verified, meaning that commercial batches must be monitored to ensure that processes remain in a state of control throughout their lifetime.

Wafer-level colinearity monitoring for TFH applications

NASA Astrophysics Data System (ADS)

Moore, Patrick; Newman, Gary; Abreau, Kelly J.

2000-06-01

Advances in thin film head (TFH) designs continue to outpace those in the IC industry. The transition to giant magneto resistive (GMR) designs is underway along with the push toward areal densities in the 20 Gbit/inch2 regime and beyond. This comes at a time when the popularity of the low-cost personal computer (PC) is extremely high, and PC prices are continuing to fall. Consequently, TFH manufacturers are forced to deal with pricing pressure in addition to technological demands. New methods of monitoring and improving yield are required along with advanced head designs. TFH manufacturing is a two-step process. The first is a wafer-level process consisting of manufacturing devices on substrates using processes similar to those in the IC industry. The second half is a slider-level process where wafers are diced into 'rowbars' containing many heads. Each rowbar is then lapped to obtain the desired performance from each head. Variation in the placement of specific layers of each device on the bar, known as a colinearity error, causes a change in device performance and directly impacts yield. The photolithography tool and process contribute to colinearity errors. These components include stepper lens distortion errors, stepper stage errors, reticle fabrication errors, and CD uniformity errors. Currently, colinearity is only very roughly estimated during wafer-level TFH production. An absolute metrology tool, such as a Nikon XY, could be used to quantify colinearity with improved accuracy, but this technique is impractical since TFH manufacturers typically do not have this type of equipment at the production site. More importantly, this measurement technique does not provide the rapid feedback needed in a high-volume production facility. Consequently, the wafer-fab must rely on resistivity-based measurements from slider-fab to quantify colinearity errors. The feedback of this data may require several weeks, making it useless as a process diagnostic. This study examines a method of quickly estimating colinearity at the wafer-level with a test reticle and metrology equipment routinely found in TFH facilities. Colinearity results are correlated to slider-fab measurements on production devices. Stepper contributions to colinearity are estimated, and compared across multiple steppers and stepper generations. Multiple techniques of integrating this diagnostic into production are investigated and discussed.

All-inkjet-printed flexible ZnO micro photodetector for a wearable UV monitoring device

NASA Astrophysics Data System (ADS)

Tran, Van-Thai; Wei, Yuefan; Yang, Hongyi; Zhan, Zhaoyao; Du, Hejun

2017-03-01

Fabrication of small-sized patterns of inorganic semiconductor onto flexible substrates is a major concern when manufacturing wearable devices for measuring either biometric or environmental parameters. In this study, micro-sized flexible ZnO UV photodetectors have been thoroughly prepared by a facile inkjet printing technology and followed with heat treatments. A simple ink recipe of zinc acetate precursor solution was investigated. It is found that the substrate temperature during zinc precursor ink depositing has significant effects on ZnO pattern shape, film morphology, and crystallization. The device fabricated from the additive manufacturing approach has good bendability, Ohmic contact, short response time as low as 0.3 s, and high on/off ratio of 3525. We observed the sensor’s dependence of response/decay time by the illuminating UV light intensity. The whole process is based on additive manufacturing which has many benefits such as rapid prototyping, saving material, being environmentally friendly, and being capable of creating high-resolution patterns. In addition, this method can be applied to flexible substrates, which makes the device more applicable for applications requiring flexibility such as wearable devices. The proposed all-inkjet-printing approach for a micro-sized ZnO UV photodetector would significantly simplify the fabrication process of micro-sized inorganic semiconductor-based devices. A potential application is real-time monitoring of UV light exposure to warn users about unsafe direct sunlight to implement suitable avoidance solutions.

Multivariate statistical process control of a continuous pharmaceutical twin-screw granulation and fluid bed drying process.

PubMed

Silva, A F; Sarraguça, M C; Fonteyne, M; Vercruysse, J; De Leersnyder, F; Vanhoorne, V; Bostijn, N; Verstraeten, M; Vervaet, C; Remon, J P; De Beer, T; Lopes, J A

2017-08-07

A multivariate statistical process control (MSPC) strategy was developed for the monitoring of the ConsiGma™-25 continuous tablet manufacturing line. Thirty-five logged variables encompassing three major units, being a twin screw high shear granulator, a fluid bed dryer and a product control unit, were used to monitor the process. The MSPC strategy was based on principal component analysis of data acquired under normal operating conditions using a series of four process runs. Runs with imposed disturbances in the dryer air flow and temperature, in the granulator barrel temperature, speed and liquid mass flow and in the powder dosing unit mass flow were utilized to evaluate the model's monitoring performance. The impact of the imposed deviations to the process continuity was also evaluated using Hotelling's T 2 and Q residuals statistics control charts. The influence of the individual process variables was assessed by analyzing contribution plots at specific time points. Results show that the imposed disturbances were all detected in both control charts. Overall, the MSPC strategy was successfully developed and applied. Additionally, deviations not associated with the imposed changes were detected, mainly in the granulator barrel temperature control. Copyright © 2017 Elsevier B.V. All rights reserved.

A novel rapid analysis using mass spectrometry to evaluate downstream refolding of recombinant human insulin-like growth factor-1 (mecasermin).

PubMed

Furuki, Kenichiro; Toyo'oka, Toshimasa; Yamaguchi, Hideto

2017-08-15

Mecasermin is used to treat elevated blood sugar as well as growth-hormone-resistant Laron-type dwarfism. Mecasermin isolated from inclusion bodies in extracts of E. coli must be refolded to acquire sufficient activity. However, there is no rapid analytical method for monitoring refolding during the purification process. We prepared mecasermin drug product, in-process samples during the oxidation of mecasermin, forced-reduced mecasermin, and aerially oxidized mecasermin after forced reduction. Desalted mecasermin samples were analyzed using MALDI-ISD. The peak intensity ratio of product to precursor ion was determined. The charge-state distribution (CSD) of mecasermin ions was evaluated using ESI-MS coupled with SEC-mode HPLC. The drift time and collision cross-sectional area (CCS) of mecasermin ions were evaluated using ESI-IMS-MS coupled with SEC-mode HPLC. MALDI-ISD data, CSD values determined using ESI-MS, and the CCS acquired using ESI-IMS-MS revealed the relationship between the folded and unfolded proteoforms of forced-reduced mecasermin and aerially oxidized mecasermin with the free-SH:protein ratio of mecasermin drug product. The CCS area, which is determined using ESI-IMS-MS, provided proteoform information through rapid monitoring (<2 min) of in-process samples during the manufacture of mecasermin. ESI-IMS-MS coupled with SEC-mode HPLC is a rapid and robust method for analyzing the free-SH:protein ratio of mecasermin that allows proteoform changes to be evaluated and monitored during the oxidation of mecasermin. ESI-IMS-MS is applicable as a process analytical technology tool for identifying the "critical quality attributes" and implementing "quality by design" for manufacturing mecasermin. Copyright © 2017 John Wiley & Sons, Ltd.

Investigation into the use of microwave sensors to monitor particulate manufacturing processes

NASA Astrophysics Data System (ADS)

Austin, John Samuel, III

Knowledge of a material's properties in-line during manufacture is of critical importance to many industries, including the pharmaceutical industry, and can be used for either process or quality control. Different microwave sensor configurations were tested to determine both the moisture content and the bulk density in pharmaceutical powders during processing on-line. Although these parameters can significantly affect a material's flowability, compressibility, and cohesivity, in the presence of blends, the picture is incomplete. Due to the ease with which particulate blends tend to segregate, blend uniformity and chemical composition are two critical parameters in nearly all solids manufacturing industries. The prevailing wisdom has been that microwave sensors are not capable of or sensitive enough to measure the relative concentrations of components in a blend. Consequently, it is common to turn to near infrared sensing to determine material composition on-line. In this study, a novel microwave sensor was designed and utilized to determine, separately, the concentrations of different components in a blend of pharmaceutical powders. This custom microwave sensor was shown to have comparable accuracy to the state-of-the-art for both chemical composition and moisture content determination.

A laboratory evaluation of four quality control devices for radiographic processing.

PubMed

Rushton, V E; Horner, K

1994-08-01

Quality assurance programmes for radiographic processing traditionally employ expensive sensitometric and densitometric techniques. However cheap and simple devices for monitoring radiographic processing are available. The aim of this study was to make a comparison of four such devices in terms of their ability to detect variations in radiographic density of clinical significance. Three of the devices are commercially available while the fourth is easily manufactured from waste materials. Ideal bitewing exposure times were selected for four different kilovoltage/film speed combinations. Phantom bitewing radiographs, exposed using these exposure times, were processed using a variety of times and developer temperatures to simulate variations in radiographic quality due to inadequate processing conditions. Test films, produced using the four monitoring devices, were exposed and processed under identical conditions. The phantom bitewings were judged to have 'acceptable' quality when the optical density of that part of the film not showing calcified structures was within +/- 0.5 of that of the film processed under optimal conditions. The efficacy of the monitoring devices in indicating the adequacy of processing was assessed by a comparison of their readings with those made from the phantom bitewings. None of the monitoring devices was ideal for all the kilovoltage/film speed combinations tested, but the homemade device proved to be the most generally effective. We conclude that guidelines to dentists on radiographic quality assurance should include reference to and details of this simple device.

Review of bilayer tablet technology.

PubMed

Abebe, Admassu; Akseli, Ilgaz; Sprockel, Omar; Kottala, Niranjan; Cuitiño, Alberto M

2014-01-30

Therapeutic strategies based on oral delivery of bilayer (and multilayer) tablets are gaining more acceptance among brand and generic products due to a confluence of factors including advanced delivery strategies, patient compliance and combination therapy. Successful manufacturing of these ever more complex systems needs to overcome a series of challenges from formulation design to tablet press monitoring and control. This article provides an overview of the state-of-the-art of bilayer tablet technology, highlighting the main benefits of this type of oral dosage forms while providing a description of current challenges and advances toward improving manufacturing practices and product quality. Several aspects relevant to bilayer tablet manufacturing are addressed including material properties, lubrication, layer ordering, layer thickness, layer weight control, as well as first and final compression forces. A section is also devoted to bilayer tablet characterization that present additional complexities associated with interfaces between layers. The available features of the manufacturing equipment for bilayer tablet production are also described indicating the different strategies for sensing and controls offered by bilayer tablet press manufacturers. Finally, a roadmap for bilayer tablet manufacturing is advanced as a guideline to formulation design and selection of process parameters and equipment. Copyright © 2013 Elsevier B.V. All rights reserved.

Fiber optic sensor design for chemical process and environmental monitoring

NASA Astrophysics Data System (ADS)

Mahendran, R. S.; Harris, D.; Wang, L.; Machavaram, V. R.; Chen, R.; Kukureka, St. N.; Fernando, G. F.

2007-07-01

Cure monitoring is a term that is used to describe the cross-linking reactions in a thermosetting resin system. Advanced fiber reinforced composites are being used increasingly in a number of industrial sectors including aerospace, marine, sport, automotive and civil engineering. There is a general realization that the processing conditions that are used to manufacture the composites can have a major influence on its hot-wet mechanical properties. This paper is concerned with the design and demonstration of a number of sensor designs for in-situ cure monitoring of a model thermosetting resin system. Simple fixtures were constructed to enable a pair of cleaved optical fibers with a defined gap between the end-faces to be held in position. The resin system was introduced into this gap and the cure kinetics were followed by transmission infrared spectroscopy. A semi-empirical model was used to describe the cure process using the data obtained at different cure temperatures. The same sensor system was used to detect the ingress of moisture in the cured resin system.

In-situ measurement of thermoset resin degree of cure using embedded fiber optic

NASA Astrophysics Data System (ADS)

Breglio, Giovanni; Cusano, Andrea; Cutolo, Antonello; Calabro, Antonio M.; Cantoni, Stefania; Di Vita, Gandolfo; Buonocore, Vincenzo; Giordano, Michele; Nicolais, Luigi, II

1999-12-01

In this work, a fiber optic sensor based on Fresnel principle is presented. It is used to monitor the variations of the refractive index due to the cure process of an epoxy based resin. These materials are widely used in polymer- matrix composites. The process of thermoset matrix based composite involves mass and heat transfer coupled with irreversible chemical reactions inducing physical changes: the transformation of a fluid resin into a rubber and then into a solid glass. To improve the quality and the reliability of these materials key points are the cure monitoring and the optimization of the manufacturing process. To this aim, the fiber optic embedded sensor has been designed, developed and tested. Preliminary results on sensor capability to monitor the cure kinetics are shown. Correlation between the sensor output and conversion advancement has been proposed following the Lorentz-Lorenz law. Isothermal data form the sensor have been compared with calorimetric analysis of an epoxy based resin.

76 FR 36472 - Mandatory Reporting of Greenhouse Gases; Changes to Provisions for Electronics Manufacturing...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-06-22

... Mandatory Reporting of Greenhouse Gases; Changes to Provisions for Electronics Manufacturing (Subpart I) To... proposing changes to the calculation and monitoring provisions in the Electronics Manufacturing portion... Category Examples of affected Category NAICS facilities Electronics Manufacturing......... 334111...

Yet another cause for blocked sidestream capnogram--beware of the non-threaded cap mount in heat and moisture exchangers.

PubMed

Umesh, Goneppanavar; Jasvinder, Kaur; Shetty, Nanda

2009-08-01

Heat and moisture exchangers (HME) are commonly used during general anaesthesia and intensive care of patients on mechanical ventilators. Some of the HME manufacturers provide HMEs with a Luer lock fitting for connecting side stream CO(2) monitoring line, Luer lock cap, and a non-threaded cap mount. However, HMEs from different manufacturers and HMEs meant for use in children and for adults from the same manufacturer vary in the presence/absence of non-threaded cap mount. This can create confusion to the clinicians and can result in inadvertent connection of the CO(2) monitoring line to the non-threaded cap mount resulting in blocked CO(2) monitoring line and leak in the circuit. We caution all the anaesthesiologists and intensivists regarding this possibility while using HMEs from different manufacturers.

High accuracy digital aging monitor based on PLL-VCO circuit

NASA Astrophysics Data System (ADS)

Yuejun, Zhang; Zhidi, Jiang; Pengjun, Wang; Xuelong, Zhang

2015-01-01

As the manufacturing process is scaled down to the nanoscale, the aging phenomenon significantly affects the reliability and lifetime of integrated circuits. Consequently, the precise measurement of digital CMOS aging is a key aspect of nanoscale aging tolerant circuit design. This paper proposes a high accuracy digital aging monitor using phase-locked loop and voltage-controlled oscillator (PLL-VCO) circuit. The proposed monitor eliminates the circuit self-aging effect for the characteristic of PLL, whose frequency has no relationship with circuit aging phenomenon. The PLL-VCO monitor is implemented in TSMC low power 65 nm CMOS technology, and its area occupies 303.28 × 298.94 μm2. After accelerating aging tests, the experimental results show that PLL-VCO monitor improves accuracy about high temperature by 2.4% and high voltage by 18.7%.

Wireless physiological monitoring system for psychiatric patients.

PubMed

Rademeyer, A J; Blanckenberg, M M; Scheffer, C

2009-01-01

Patients in psychiatric hospitals that are sedated or secluded are at risk of death or injury if they are not continuously monitored. Some psychiatric patients are restless and aggressive, and hence the monitoring device should be robust and must transmit the data wirelessly. Two devices, a glove that measures oxygen saturation and a dorsally-mounted device that measures heart rate, skin temperature and respiratory rate were designed and tested. Both devices connect to one central monitoring station using two separate Bluetooth connections, ensuring a completely wireless setup. A Matlab graphical user interface (GUI) was developed for signal processing and monitoring of the vital signs of the psychiatric patient. Detection algorithms were implemented to detect ECG arrhythmias such as premature ventricular contraction and atrial fibrillation. The prototypes were manufactured and tested in a laboratory setting on healthy volunteers.

Analysis and quality control of carbohydrates in therapeutic proteins with fluorescence HPLC

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liu, Kun; Huang, Jian; Center for Informational Biology, University of Electronic Science and Technology of China, Chengdu 610054

Conbercept is an Fc fusion protein with very complicated carbohydrate profiles which must be carefully monitored through manufacturing process. Here, we introduce an optimized fluorescence derivatization high-performance liquid chromatographic method for glycan mapping in conbercept. Compared with conventional glycan analysis method, this method has much better resolution and higher reproducibility making it excellent for product quality control.

Infrared spectroscopic monitoring of urea addition to oriented strandboard resins

Treesearch

Chi-Leung So; Thomas L. Eberhardt; Ernest Hsu; Brian K. Via; Chung Y. Hse

2007-01-01

One of the variables in phenol formaldehyde adhesive resin formulation is the addition of urea, which allows the resin manufacturer to manipulate both product functionality and cost. Nitrogen content can be used as a measure of the level of urea addition because most of the nitrogen present is derived from urea added at the end of the preparation process. Nitrogen...

Technology’s present situation and the development prospects of energy efficiency monitoring as well as performance testing & analysis for process flow compressors

NASA Astrophysics Data System (ADS)

Li, L.; Zhao, Y.; Wang, L.; Yang, Q.; Liu, G.; Tang, B.; Xiao, J.

2017-08-01

In this paper, the background of performance testing of in-service process flow compressors set in user field are introduced, the main technique barriers faced in the field test are summarized, and the factors that result in real efficiencies of most process flow compressors being lower than the guaranteed by manufacturer are analysed. The authors investigated the present operational situation of process flow compressors in China and found that low efficiency operation of flow compressors is because the compressed gas is generally forced to flow back into the inlet pipe for adapting to the process parameters variety. For example, the anti-surge valve is always opened for centrifugal compressor. To improve the operation efficiency of process compressors the energy efficiency monitoring technology was overviewed and some suggestions are proposed in the paper, which is the basis of research on energy efficiency evaluation and/or labelling of process compressors.

Cellulose nanocrystals the next big nano-thing?

NASA Astrophysics Data System (ADS)

Postek, Michael T.; Vladar, Andras; Dagata, John; Farkas, Natalia; Ming, Bin; Sabo, Ronald; Wegner, Theodore H.; Beecher, James

2008-08-01

Biomass surrounds us from the smallest alga to the largest redwood tree. Even the largest trees owe their strength to a newly-appreciated class of nanomaterials known as cellulose nanocrystals (CNC). Cellulose, the world's most abundant natural, renewable, biodegradable polymer, occurs as whisker like microfibrils that are biosynthesized and deposited in plant material in a continuous fashion. Therefore, the basic raw materials for a future of new nanomaterials breakthroughs already abound in the environment and are available to be utilized in an array of future materials once the manufacturing processes and nanometrology are fully developed. This presentation will discuss some of the instrumentation, metrology and standards issues associated with nanomanufacturing of cellulose nanocrystals. The use of lignocellulosic fibers derived from sustainable, annually renewable resources as a reinforcing phase in polymeric matrix composites provides positive environmental benefits with respect to ultimate disposability and raw material use. Today we lack the essential metrology infrastructure that would enable the manufacture of nanotechnology-based products based on CNCs (or other new nanomaterial) to significantly impact the U.S. economy. The basic processes common to manufacturing - qualification of raw materials, continuous synthesis methods, process monitoring and control, in-line and off-line characterization of product for quality control purposes, validation by standard reference materials - are not generally in place for nanotechnology based products, and thus are barriers to innovation. One advantage presented by the study of CNCs is that, unlike other nanomaterials, at least, cellulose nanocrystal manufacturing is already a sustainable and viable bulk process. Literally tons of cellulose nanocrystals can be generated each day, producing other viable byproducts such as glucose (for alternative fuel) and gypsum (for buildings).There is an immediate need for the development of the basic manufacturing metrology infrastructure to implement fundamental best practices for manufacturing and in the determination of properties for these for nanoscale materials and the resultant products.

Method for automatically evaluating a transition from a batch manufacturing technique to a lean manufacturing technique

DOEpatents

Ivezic, Nenad; Potok, Thomas E.

2003-09-30

A method for automatically evaluating a manufacturing technique comprises the steps of: receiving from a user manufacturing process step parameters characterizing a manufacturing process; accepting from the user a selection for an analysis of a particular lean manufacturing technique; automatically compiling process step data for each process step in the manufacturing process; automatically calculating process metrics from a summation of the compiled process step data for each process step; and, presenting the automatically calculated process metrics to the user. A method for evaluating a transition from a batch manufacturing technique to a lean manufacturing technique can comprise the steps of: collecting manufacturing process step characterization parameters; selecting a lean manufacturing technique for analysis; communicating the selected lean manufacturing technique and the manufacturing process step characterization parameters to an automatic manufacturing technique evaluation engine having a mathematical model for generating manufacturing technique evaluation data; and, using the lean manufacturing technique evaluation data to determine whether to transition from an existing manufacturing technique to the selected lean manufacturing technique.

Monitoring in situ in real time of resin infusion for thermoset composite structures

NASA Astrophysics Data System (ADS)

Faci, A.; Wang, P.; Cochrane, C.; Koncar, V.

2017-10-01

The presented work investigates changes in electrical resistance of embedded sensory yarns as a method to monitor the resin flow front position and curing degree of resin during manufacturing of composite structures by vacuum infusion technology. The sensor concept is based on Piezo-resistive sensors integrated to the flax fabric, having almost identical propriety and dimensions as the flax threads used for the production of reinforcements. In the first time sensors have been characterized and first measures of the resin infusion have been realized in order to demonstrate the feasibility of the proposed approach. Then, the measures in real time were realized with fibrous sensors added to the flax fabric (green composites) to monitor the flow front of resin. A large amount of data recorded, filtered, examined, analysed and processed in order to understand and to optimize the infusion and polymerization process.

Development of an atmospheric monitoring plan for space station

NASA Technical Reports Server (NTRS)

Casserly, Dennis M.

1989-01-01

An environmental health monitoring plan for Space Station will ensure crew health during prolonged habitation. The Space Station, Freedom, will operate for extended periods, 90+ days, without resupply. A regenerative, closed loop life support system will be utilized in order to minimize resupply logistics and costs. Overboard disposal of wastes and venting of gases to space will be minimal. All waste material will be treated and recycled. The concentrated wastes will be stabilized and stored for ground disposal. The expected useful life of the station (decades) and the diversity of materials brought aboard for experimental or manufacturing purposes, increases the likelihood of cabin contamination. Processes by which cabin contamination can occur include: biological waste production, material off-gassing, process leakage, accidental containment breach, and accumulation due to poor removal efficiencies of the purification units. An industrial hygiene approach was taken to rationalize monitoring needs and to identify the substances likely to be present, the amount, and their hazard.

Emissions of volatile organic compounds (VOCs) from the food and drink industries of the European community

NASA Astrophysics Data System (ADS)

Passant, Neil R.; Richardson, Stephen J.; Swannell, Richard P. J.; Gibson, N.; Woodfield, M. J.; van der Lugt, Jan Pieter; Wolsink, Johan H.; Hesselink, Paul G. M.

Estimates were made of the amounts of volatile organic compounds (VOCs) released into the atmosphere as a result of the industrial manufacture and processing of food and drink in the European Community. The estimates were based on a review of literature sources, industrial and government contacts and recent measurements. Data were found on seven food manufacturing sectors (baking, vegetable oil extraction, solid fat processing, animal rendering, fish meal processing, coffee production and sugar beet processing) and three drink manufacturing sectors (brewing, spirit production and wine making). The principle of a data quality label is advocated to illustrate the authors' confidence in the data, and to highlight areas for further research. Emissions of ethanol from bread baking and spirit maturation were found to be the principle sources. However, significant losses of hexane and large quantities of an ill-defined mixture of partially oxidized hydrocarbons were noted principally from seed oil extraction and the drying of plant material, respectively. This latter mixture included low molecular weight aldehydes, carboxylic acids, ketones, amines and esters. However, the precise composition of many emissions were found to be poorly understood. The total emission from the food and drink industry in the EC was calculated as 260 kt yr -1. However, many processes within the target industry were found to be completely uncharacterized and therefore not included in the overall estimate (e.g. soft drink manufacture, production of animal food, flavourings, vinegar, tea, crisps and other fried snacks). Moreover, the use of data quality labels illustrated the fact that many of our estimates were based on limited data. Hence, further emissions monitoring is recommended from identified sources (e.g. processing of sugar beet, solid fat and fish meal) and from uncharacterized sources.

Vibration Sensor Monitoring of Nickel-Titanium Alloy Turning for Machinability Evaluation.

PubMed

Segreto, Tiziana; Caggiano, Alessandra; Karam, Sara; Teti, Roberto

2017-12-12

Nickel-Titanium (Ni-Ti) alloys are very difficult-to-machine materials causing notable manufacturing problems due to their unique mechanical properties, including superelasticity, high ductility, and severe strain-hardening. In this framework, the aim of this paper is to assess the machinability of Ni-Ti alloys with reference to turning processes in order to realize a reliable and robust in-process identification of machinability conditions. An on-line sensor monitoring procedure based on the acquisition of vibration signals was implemented during the experimental turning tests. The detected vibration sensorial data were processed through an advanced signal processing method in time-frequency domain based on wavelet packet transform (WPT). The extracted sensorial features were used to construct WPT pattern feature vectors to send as input to suitably configured neural networks (NNs) for cognitive pattern recognition in order to evaluate the correlation between input sensorial information and output machinability conditions.

Vibration Sensor Monitoring of Nickel-Titanium Alloy Turning for Machinability Evaluation

PubMed Central

Segreto, Tiziana; Karam, Sara; Teti, Roberto

2017-01-01

Nickel-Titanium (Ni-Ti) alloys are very difficult-to-machine materials causing notable manufacturing problems due to their unique mechanical properties, including superelasticity, high ductility, and severe strain-hardening. In this framework, the aim of this paper is to assess the machinability of Ni-Ti alloys with reference to turning processes in order to realize a reliable and robust in-process identification of machinability conditions. An on-line sensor monitoring procedure based on the acquisition of vibration signals was implemented during the experimental turning tests. The detected vibration sensorial data were processed through an advanced signal processing method in time-frequency domain based on wavelet packet transform (WPT). The extracted sensorial features were used to construct WPT pattern feature vectors to send as input to suitably configured neural networks (NNs) for cognitive pattern recognition in order to evaluate the correlation between input sensorial information and output machinability conditions. PMID:29231864

Onsite aerosol measurements for various engineered nanomaterials at industrial manufacturing plants

NASA Astrophysics Data System (ADS)

Ogura, I.; Sakurai, H.; Gamo, M.

2011-07-01

Evaluation of the health impact of and control over exposure to airborne engineered nanomaterials (ENMs) requires information, inter alia, the magnitude of environmental release during various industrial processes, as well as the size distribution and morphology of the airborne ENM particles. In this study, we performed onsite aerosol measurements for various ENMs at industrial manufacturing plants. The industrial processes investigated were the collection of SiC from synthesis reactors, synthesis and bagging of LiFePO4, and bagging of ZnO. Real-time aerosol monitoring using condensation particle counters, optical particle counters, and an electrical low-pressure impactor revealed frequent increases in the number concentrations of submicron- and micron-sized aerosol particles, but few increases in the number concentrations of nanoparticles. In the SEM observations, a large number of submicron- and micron-sized agglomerated ENM particles were observed.

In-Line Monitoring of Fab Processing Using X-Ray Diffraction

NASA Astrophysics Data System (ADS)

Gittleman, Bruce; Kozaczek, Kris

2005-09-01

As the materials shift that started with Cu continues to advance in the semiconductor industry, new issues related to materials microstructure have arisen. While x-ray diffraction (XRD) has long been used in development applications, in this paper we show that results generated in real time by a unique, high throughput, fully automated XRD metrology tool can be used to develop metrics for qualification and monitoring of critical processes in current and future manufacturing. It will be shown that these metrics provide a unique set of data that correlate to manufacturing issues. For example, ionized-sputtering is the current deposition method of choice for both the Cu seed and TaNx/Ta barrier layers. The alpha phase of Ta is widely used in production for the upper layer of the barrier stack, but complete elimination of the beta phase requires a TaNx layer with sufficient N content, but not so much as to start poisoning the target and generating particle issues. This is a well documented issue, but traditional monitoring by sheet resistance methods cannot guarantee the absence of the beta phase, whereas XRD can determine the presence of even small amounts of beta. Nickel silicide for gate metallization is another example where monitoring of phase is critical. As well being able to qualify an anneal process that gives only the desired NiSi phase everywhere across the wafer, XRD can be used to determine if full silicidation of the Ni has occurred and characterize the crystallographic microstructure of the Ni to determine any effect of that microstructure on the anneal process. The post-anneal nickel silicide phase and uniformity of the silicide microstructure can all be monitored in production. Other examples of the application of XRD to process qualification and production monitoring are derived from the dependence of certain processes, some types of defect generation, and device performance on crystallographic texture. The data presented will show that CMP dishing problems could be traced to texture of the barrier layer and mitigated by adjusting the barrier process. The density of pits developed during CMP of electrochemically deposited (ECD) Cu depends on the fraction of (111) oriented grains. It must be emphasized that the crystallographic texture is not only a key parameter for qualification of high yielding and reliable processes, but also serves as a critical parameter for monitoring tool health. The texture of Cu and W are sensitive not only to deviations in performance of the tool depositing or annealing a particular film, but also highly sensitive to the texture of the barrier underlayers and thus any performance deviations in those tools. The XRD metrology tool has been designed with production monitoring in mind and has been fully integrated into both 200 mm and 300 mm fabs. Rapid analysis is achieved by using a high intensity fixed x-ray source, coupled with a large area 2D detector. The output metrics from one point are generated while the tool is measuring a subsequent point, giving true on-the-fly analysis; no post-processing of data is necessary. Spatial resolution on the wafer surface ranging from 35 μm to 1 mm is available, making the tool suitable for monitoring of product wafers. Typical analysis times range from 10 seconds to 2 minutes per point, depending on the film thickness and spot size. Current metrics used for process qualification and production monitoring are phase, FWHM of the primary phase peaks (for mean grain size tracking), and crystallographic texture.

[Application progress on near infrared spectroscopy in quality control and process monitoring of traditional Chinese medicine].

PubMed

Li, Wenlong; Qu, Haibin

2017-01-25

The industry of traditional Chinese medicine (TCM) encounters problems like quality fluctuation of raw materials and unstandardized production process. Near infrared (NIR) spectroscopy technology is widely used in quality control of TCM because of its abundant information, fast and nondestructive characters. The main applications include quantitative analysis of Chinese medicinal materials, intermediates and Chinese patent medicines; the authenticity of TCM, species, origins and manufacturers; monitoring and control of the extraction, alcohol precipitation, column chromatography and blending process. This article reviews the progress on the application of NIR spectroscopy technology in TCM field. In view of the problems existing in the application, the article proposes that the standardization of NIR analysis method should be developed according to specific characteristics of TCM, which will promote the application of NIR technology in the TCM industry.

Good manufacturing practice and viral safety.

PubMed

Kerner, B

1995-07-01

The concept of virus inactivation during the manufacture of blood products raises questions about possible recontamination of the product by the environment. A strict regime of good manufacturing practice (GMP) is mandatory. The guidelines originally issued by the World Health Organization (WHO), and now law in most countries, are an excellent basis for the operation of a production plant. The following elements of GMP require special concern: (i) All functions shall be defined in a clear organization chart. (ii) Personnel shall be appropriately trained for the job and to perfect hygiene. (iii) Buildings and facilities, as well as supply systems, shall exclude the possibility of recontamination of already virus-inactivated materials. (iv) Equipment shall be easy to clean and fully sterilizable. (v) Production shall follow appropriate written procedures. (vi) The Quality Control Organization shall monitor the process by in-process controls and review the records for possible deviations. All GMP issues are coordinated by a Quality Assurance Organization that also reviews the overall performance of the operation. The maintenance of viral safety of the products basically depends upon the full commitment of all bodies involved to proper and non-negotiable GMP.

A Complex Shaped Reinforced Thermoplastic Composite Part Made of Commingled Yarns With Integrated Sensor

NASA Astrophysics Data System (ADS)

Risicato, Jean-Vincent; Kelly, Fern; Soulat, Damien; Legrand, Xavier; Trümper, Wolfgang; Cochrane, Cedric; Koncar, Vladan

2015-02-01

This paper focuses on the design and one shot manufacturing process of complex shaped composite parts based on the overbraiding of commingled yarns. The commingled yarns contain thermoplastic fibres used as the matrix and glass fibres as the reinforcement material. This technology reduces the flow path length for the melted thermoplastic and aims to improve the impregnation of materials with high viscosity. The tensile strength behaviour of the material was firstly investigated in order to evaluate the influence of the manufacturing parameters on flat structured braids that have been consolidated on a heating press. A good compatibility between the required geometry and the braiding process was observed. Additionally, piezo-resistive sensor yarns, based on glass yarns coated with PEDOT: PSS, have been successfully integrated within the composite structure. The sensor yarns have been inserted into the braided fabric, before consolidation. The inserted sensors provide the ability to monitor the structural health of the composite part in a real time. The design and manufacture of the complete complex shaped part has then been successfully achieved.

Manufacturing of Wearable Sensors for Human Health and Performance Monitoring

NASA Astrophysics Data System (ADS)

Alizadeh, Azar

2015-03-01

Continuous monitoring of physiological and biological parameters is expected to improve performance and medical outcomes by assessing overall health status and alerting for life-saving interventions. Continuous monitoring of these parameters requires wearable devices with an appropriate form factor (lightweight, comfortable, low energy consuming and even single-use) to avoid disrupting daily activities thus ensuring operation relevance and user acceptance. Many previous efforts to implement remote and wearable sensors have suffered from high cost and poor performance, as well as low clinical and end-use acceptance. New manufacturing and system level design approaches are needed to make the performance and clinical benefits of these sensors possible while satisfying challenging economic, regulatory, clinical, and user-acceptance criteria. In this talk we will review several recent design and manufacturing efforts aimed at designing and building prototype wearable sensors. We will discuss unique opportunities and challenges provided by additive manufacturing, including 3D printing, to drive innovation through new designs, faster prototyping and manufacturing, distributed networks, and new ecosystems. We will also show alternative hybrid self-assembly based integration techniques for low cost large scale manufacturing of single use wearable devices. Coauthors: Prabhjot Singh and Jeffrey Ashe.

Implementation of quality by design toward processing of food products.

PubMed

Rathore, Anurag S; Kapoor, Gautam

2017-05-28

Quality by design (QbD) is a systematic approach that begins with predefined objectives and emphasizes product and process understanding and process control. It is an approach based on principles of sound science and quality risk management. As the food processing industry continues to embrace the idea of in-line, online, and/or at-line sensors and real-time characterization for process monitoring and control, the existing gaps with regard to our ability to monitor multiple parameters/variables associated with the manufacturing process will be alleviated over time. Investments made for development of tools and approaches that facilitate high-throughput analytical and process development, process analytical technology, design of experiments, risk analysis, knowledge management, and enhancement of process/product understanding would pave way for operational and economic benefits later in the commercialization process and across other product pipelines. This article aims to achieve two major objectives. First, to review the progress that has been made in the recent years on the topic of QbD implementation in processing of food products and second, present a case study that illustrates benefits of such QbD implementation.

Using microwave Doppler radar in automated manufacturing applications

NASA Astrophysics Data System (ADS)

Smith, Gregory C.

Since the beginning of the Industrial Revolution, manufacturers worldwide have used automation to improve productivity, gain market share, and meet growing or changing consumer demand for manufactured products. To stimulate further industrial productivity, manufacturers need more advanced automation technologies: "smart" part handling systems, automated assembly machines, CNC machine tools, and industrial robots that use new sensor technologies, advanced control systems, and intelligent decision-making algorithms to "see," "hear," "feel," and "think" at the levels needed to handle complex manufacturing tasks without human intervention. The investigator's dissertation offers three methods that could help make "smart" CNC machine tools and industrial robots possible: (1) A method for detecting acoustic emission using a microwave Doppler radar detector, (2) A method for detecting tool wear on a CNC lathe using a Doppler radar detector, and (3) An online non-contact method for detecting industrial robot position errors using a microwave Doppler radar motion detector. The dissertation studies indicate that microwave Doppler radar could be quite useful in automated manufacturing applications. In particular, the methods developed may help solve two difficult problems that hinder further progress in automating manufacturing processes: (1) Automating metal-cutting operations on CNC machine tools by providing a reliable non-contact method for detecting tool wear, and (2) Fully automating robotic manufacturing tasks by providing a reliable low-cost non-contact method for detecting on-line position errors. In addition, the studies offer a general non-contact method for detecting acoustic emission that may be useful in many other manufacturing and non-manufacturing areas, as well (e.g., monitoring and nondestructively testing structures, materials, manufacturing processes, and devices). By advancing the state of the art in manufacturing automation, the studies may help stimulate future growth in industrial productivity, which also promises to fuel economic growth and promote economic stability. The study also benefits the Department of Industrial Technology at Iowa State University and the field of Industrial Technology by contributing to the ongoing "smart" machine research program within the Department of Industrial Technology and by stimulating research into new sensor technologies within the University and within the field of Industrial Technology.

Manufacturing technology of integrated textile-based sensor networks for in situ monitoring applications of composite wind turbine blades

NASA Astrophysics Data System (ADS)

Haentzsche, Eric; Mueller, Ralf; Huebner, Matthias; Ruder, Tristan; Unger, Reimar; Nocke, Andreas; Cherif, Chokri

2016-10-01

Based on in situ strain sensors consisting of piezo-resistive carbon filament yarns (CFYs), which have been successfully integrated into textile reinforcement structures during their textile-technological manufacturing process, a continuous load of fibre-reinforced plastic (FRP) components has been realised. These sensors are also suitable for structural health monitoring (SHM) applications. The two-dimensional sensor layout is made feasible by the usage of a modular warp yarn path manipulation unit. Using a functional model of a small wind turbine blade in thermoset composite design, the sensor function for basic SHM applications (e.g. static load monitoring) are demonstrated. Any mechanical loads along the pressure or suction side of the wind turbine blade can be measured and calculated via a correlative change in resistance of the CFYs within the textile reinforcement plies. Performing quasi-static load tests on both tensile specimen and full-scale wind turbine blade, elementary results have been obtained concerning electro-mechanical behaviour and spatial resolution of global and even local static stresses according to the CFY sensor integration length. This paper demonstrates the great potential of textile-based and textile-technological integrated sensors in reinforcement structures for future SHM applications of FRPs.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simpson, L.; Britt, J.; Birkmire, R.

ITN Energy Systems, Inc., and Global Solar Energy, Inc., assisted by NREL's PV Manufacturing R&D program, have continued to advance CIGS production technology by developing trajectory-oriented predictive/control models, fault-tolerance control, control platform development, in-situ sensors, and process improvements. Modeling activities included developing physics-based and empirical models for CIGS and sputter-deposition processing, implementing model-based control, and applying predictive models to the construction of new evaporation sources and for control. Model-based control is enabled by implementing reduced or empirical models into a control platform. Reliability improvement activities include implementing preventive maintenance schedules; detecting failed sensors/equipment and reconfiguring to tinue processing; and systematicmore » development of fault prevention and reconfiguration strategies for the full range of CIGS PV production deposition processes. In-situ sensor development activities have resulted in improved control and indicated the potential for enhanced process status monitoring and control of the deposition processes. Substantial process improvements have been made, including significant improvement in CIGS uniformity, thickness control, efficiency, yield, and throughput. In large measure, these gains have been driven by process optimization, which in turn have been enabled by control and reliability improvements due to this PV Manufacturing R&D program.« less

Mid-IR fused fiber couplers

NASA Astrophysics Data System (ADS)

Stevens, G.; Woodbridge, T.

2016-03-01

We present results from our recent efforts on developing single-mode fused couplers in ZBLAN fibre. We have developed a custom fusion workstation for working with lower melting temperature fibres, such as ZBLAN and chalcogenide fibres. Our workstation uses a precisely controlled electrical heater designed to operate at temperatures between 100 - 250°C as our heat source. The heated region of the fibers was also placed in an inert atmosphere to avoid the formation of microcrystal inclusions during fusion. We firstly developed a process for pulling adiabatic tapers in 6/125 μm ZBLAN fibre. The tapers were measured actively during manufacture using a 2000 nm source. The process was automated so that the heater temperature and motor speed automatically adjusted to pull the taper at constant tension. This process was then further developed so that we could fuse and draw two parallel 6/125 μm ZBLAN fibres, forming a single-mode coupler. Low ratio couplers (1-10%) that could be used as power monitors were manufactured that had an excess loss of 0.76 dB. We have also manufactured 50/50 splitters and wavelength division multiplexers (WDMs). However, the excess loss of these devices was typically 2 - 3 dB. The increased losses were due to localised necking and surface defects forming as the tapers were pulled further to achieve a greater coupling ratio. Initial experiments with chalcogenide fibre have shown that our process can be readily adapted for chalcogenide fibres. A 5% coupler with 1.5 dB insertion loss was manufactured using commercial of the shelf (COTS) fibres.

In-Plant Reuse of Pollution Abated Waters.

DTIC Science & Technology

1984-08-01

Carbon Treatment Facility Prefilters D-10 Spent Carbon Receiving Tank EZ D-11 Powdered Carbon Feeder System E. Process Chemical Assay/Monitoring...PBA manufacturing complex, several wastewater treatment facilities were built to treat wastewater from various plants . This task deals with...all of which discharge to the Central Treatment Facility (Appendix K-I). The plant is permitted (Appendix I-I) by EPA and consists of a lime/alum

Annual Fuze Conference and Munitions Technology Symposium VI (43rd)

DTIC Science & Technology

1999-04-07

part manufacture and assembly and identify the parameters that we must control through production. Analyzing the coefficients of variation and the...processing energetic materials. The extruder is equipped with four independent temperature control zones, segmented screws, a jacketed die block capable of...and has vacuum capability. Data monitoring capabilities include melt temperature and pressure, torque, screw speed, and temperatures in all of the

Acoustical experiment of yogurt fermentation process.

PubMed

Ogasawara, H; Mizutani, K; Ohbuchi, T; Nakamura, T

2006-12-22

One of the important factors through food manufacturing is hygienic management. Thus, food manufactures prove their hygienic activities by taking certifications like a Hazard Analysis and Critical Control Point (HACCP). This concept also applies to food monitoring. Acoustical measurements have advantage for other measurement in food monitoring because they make it possible to measure with noncontact and nondestructive. We tried to monitor lactic fermentation of yogurt by a probing sensor using a pair of acoustic transducers. Temperature of the solution changes by the reaction heat of fermentation. Consequently the sound velocity propagated through the solution also changes depending on the temperature. At the same time, the solution change its phase from liquid to gel. The transducers usage in the solution indicates the change of the temperature as the change of the phase difference between two transducers. The acoustic method has advantages of nondestructive measurement that reduces contamination of food product by measuring instrument. The sensor was inserted into milk with lactic acid bacterial stain of 19 degrees C and monitored phase retardation of propagated acoustic wave and its temperature with thermocouples in the mild. The monitoring result of fermentation from milk to Caspian Sea yogurt by the acoustic transducers with the frequency of 3.7 MHz started to show gradient change in temperature caused by reaction heat of fermentation but stop the gradient change at the end although the temperature still change. The gradient change stopped its change because of phase change from liquid to gel. The present method will be able to measure indirectly by setting transducers outside of the measuring object. This noncontact sensing method will have great advantage of reduces risk of food contamination from measuring instrument because the measurement probes are set out of fermentation reactor or food containers. Our proposed method will contribute to the hygienization for the food manufacture industry.

Comparison of different incubation conditions for microbiological environmental monitoring.

PubMed

Gordon, Oliver; Berchtold, Manfred; Staerk, Alexandra; Roesti, David

2014-01-01

Environmental monitoring represents an integral part of the microbiological quality control system of a pharmaceutical manufacturing operation. However, guidance documents differ regarding recommendation of a procedure, particularly regarding incubation time, incubation temperature, or nutrient media. Because of these discrepancies, many manufacturers decide for a particular environmental monitoring sample incubation strategy and support this decision with validation data. Such validations are typically laboratory-based in vitro studies, meaning that these are based on comparing incubation conditions and nutrient media through use of cultured microorganisms. An informal survey of the results of these in vitro studies performed at Novartis or European manufacturing sites of different pharmaceutical companies highlighted that no consensus regarding the optimal incubation conditions for microbial recovery existed. To address this question differently, we collected a significant amount of samples directly from air, inanimate surfaces, and personnel in pharmaceutical production and packaging rooms during manufacturing operation (in situ study). Samples were incubated under different conditions suggested in regulatory guidelines, and recovery of total aerobic microorganisms as well as moulds was assessed. We found the highest recovery of total aerobic count from areas with personnel flow using a general microbiological growth medium incubated at 30-35 °C. The highest recovery of moulds was obtained with mycological medium incubated at 20-25 °C. Single-plate strategies (two-temperature incubation or an intermediate incubation temperature of 25-30 °C) also yielded reasonable recovery of total aerobic count and moulds. However, recovery of moulds was found to be highly inefficient at 30-35 °C compared to lower incubation temperatures. This deficiency could not be rectified by subsequent incubation at 20-25 °C. A laboratory-based in vitro study performed in parallel was inconclusive. We consider our results potentially conferrable to other pharmaceutical manufacturing sites in moderate climate zones and believe that these should represent a valuable reference for definition of the incubation strategy of microbiological environmental monitoring samples. Microbiological environmental monitoring confirms that pharmaceutical cleanrooms are in an appropriate hygienic condition for manufacturing of drug products. Guidance documents from different health authorities or expert groups differ regarding recommendation of the applied incubation time, incubation temperature, or nutrient media. Therefore, many pharmaceutical manufacturers perform studies that aim to identify the optimal incubation setup for environmental monitoring samples. An informal survey of the results of such studies, which had been performed at Novartis or European manufacturing sites of different pharmaceutical companies, highlighted no consensus regarding the optimal incubation conditions for microbial recovery. All these studies had been conducted in the laboratory using selections of cultured microbial strains. We tried to solve this disagreement by collecting a significant amount of real environmental monitoring samples directly from the environment in pharmaceutical production and packaging rooms during manufacturing operation. These samples were then incubated under different conditions suggested in the regulatory guidelines. We believe that the results of our study are more meaningful than laboratory-based experiments because we used environmental samples with microorganisms directly isolated from the manufacturing area. Therefore, we believe that our results should represent a valuable reference for definition of the incubation strategy of microbiological environmental monitoring samples. © PDA, Inc. 2014.

Wireless device monitoring methods, wireless device monitoring systems, and articles of manufacture

DOEpatents

McCown, Steven H [Rigby, ID; Derr, Kurt W [Idaho Falls, ID; Rohde, Kenneth W [Idaho Falls, ID

2012-05-08

Wireless device monitoring methods, wireless device monitoring systems, and articles of manufacture are described. According to one embodiment, a wireless device monitoring method includes accessing device configuration information of a wireless device present at a secure area, wherein the device configuration information comprises information regarding a configuration of the wireless device, accessing stored information corresponding to the wireless device, wherein the stored information comprises information regarding the configuration of the wireless device, comparing the device configuration information with the stored information, and indicating the wireless device as one of authorized and unauthorized for presence at the secure area using the comparing.

Optimal control of build height utilizing optical profilometry in cold spray deposits

NASA Astrophysics Data System (ADS)

Chakraborty, Abhijit; Shishkin, Sergey; Birnkrant, Michael J.

2017-04-01

Part-to-part variability and poor part quality due to failure to maintain geometric specifications pose a challenge for adopting Additive Manufacturing (AM) as a viable manufacturing process. In recent years, In-process Monitoring and Control (InPMC) has received a lot of attention as an approach to overcome these obstacles. The ability to sense geometry of the deposited layers accurately enables effective process monitoring and control of AM application. This paper demonstrates an application of geometry sensing technique for the coating deposition Cold Spray process, where solid powders are accelerated through a nozzle, collides with the substrate and adheres to it. Often the deposited surface has shape irregularities. This paper proposes an approach to suppress the iregularities by controlling the deposition height. An analytical control-oriented model is developed that expresses the resulting height of deposit as an integral function of nozzle velocity and angle. In order to obtain height information at each layer, a Micro-Epsilon laser line scanner was used for surface profiling after each deposition. This surface profile information, specifically the layer height, was then fed back to an optimal control algorithm which manipulated the nozzle speed to control the layer height to a pre specified height. While the problem is heavily nonlinear, we were able to transform it into equivalent Optimal Control problem linear w.r.t. input. That enabled development of two solution methods: one is fast and approximate, while another is more accurate but still efficient.

Radio Frequency Scanning and Simulation of Oriented Strand Board Material Property

NASA Astrophysics Data System (ADS)

Liu, Xiaojian; Zhang, Jilei; Steele, Philip. H.; Donohoe, J. Patrick

2008-02-01

Oriented strandboard (OSB) is a wood composite product with the largest market share in U.S. residential and commercial construction. Wood specific gravity (SG) and moisture content (MC) play an important role in the OSB manufacturing process. They are the two of the critical variables that manufacturers are required to monitor, locate, and control in order to produce a product with consistent quality. In this study, radio frequency scanning nondestructive evaluation (NDE) technologies evaluated the local area MC and SG of OSB panels following panel production by hot pressing. A finite element software simulation tool was used to optimize the sensor geometry and for investigating the interaction between electromagnetic field and wood dielectric properties. Our results indicate the RF scanning response is closely correlated to the MC and SG variations in OSB panels. Radio frequency NDE appears to have potential as an effective method for insuring OSB panel quality during manufacturing.

Control Systems Engineering in Continuous Pharmaceutical Manufacturing May 20-21, 2014 Continuous Manufacturing Symposium.

PubMed

Myerson, Allan S; Krumme, Markus; Nasr, Moheb; Thomas, Hayden; Braatz, Richard D

2015-03-01

This white paper provides a perspective of the challenges, research needs, and future directions for control systems engineering in continuous pharmaceutical processing. The main motivation for writing this paper is to facilitate the development and deployment of control systems technologies so as to ensure quality of the drug product. Although the main focus is on small-molecule pharmaceutical products, most of the same statements apply to biological drug products. An introduction to continuous manufacturing and control systems is followed by a discussion of the current status and technical needs in process monitoring and control, systems integration, and risk analysis. Some key points are that: (1) the desired objective in continuous manufacturing should be the satisfaction of all critical quality attributes (CQAs), not for all variables to operate at steady-state values; (2) the design of start-up and shutdown procedures can significantly affect the economic operation of a continuous manufacturing process; (3) the traceability of material as it moves through the manufacturing facility is an important consideration that can at least in part be addressed using residence time distributions; and (4) the control systems technologies must assure quality in the presence of disturbances, dynamics, uncertainties, nonlinearities, and constraints. Direct measurement, first-principles and empirical model-based predictions, and design space approaches are described for ensuring that CQA specifications are met. Ways are discussed for universities, regulatory bodies, and industry to facilitate working around or through barriers to the development of control systems engineering technologies for continuous drug manufacturing. Industry and regulatory bodies should work with federal agencies to create federal funding mechanisms to attract faculty to this area. Universities should hire faculty interested in developing first-principles models and control systems technologies for drug manufacturing that are easily transportable to industry. Industry can facilitate the move to continuous manufacturing by working with universities on the conception of new continuous pharmaceutical manufacturing process unit operations that have the potential to make major improvements in product quality, controllability, or reduced capital and/or operating costs. Regulatory bodies should ensure that: (1) regulations and regulatory practices promote, and do not derail, the development and implementation of continuous manufacturing and control systems engineering approaches; (2) the individuals who approve specific regulatory filings are sufficiently trained to make good decisions regarding control systems approaches; (3) provide regulatory clarity and eliminate/reduce regulatory risks; (4) financially support the development of high-quality training materials for use of undergraduate students, graduate students, industrial employees, and regulatory staff; (5) enhance the training of their own technical staff by financially supporting joint research projects with universities in the development of continuous pharmaceutical manufacturing processes and the associated control systems engineering theory, numerical algorithms, and software; and (6) strongly encourage the federal agencies that support research to fund these research areas. © 2014 Wiley Periodicals, Inc. and the American Pharmacists Association. © 2014 Wiley Periodicals, Inc. and the American Pharmacists Association.

Control systems engineering in continuous pharmaceutical manufacturing. May 20-21, 2014 Continuous Manufacturing Symposium.

PubMed

Myerson, Allan S; Krumme, Markus; Nasr, Moheb; Thomas, Hayden; Braatz, Richard D

2015-03-01

This white paper provides a perspective of the challenges, research needs, and future directions for control systems engineering in continuous pharmaceutical processing. The main motivation for writing this paper is to facilitate the development and deployment of control systems technologies so as to ensure quality of the drug product. Although the main focus is on small-molecule pharmaceutical products, most of the same statements apply to biological drug products. An introduction to continuous manufacturing and control systems is followed by a discussion of the current status and technical needs in process monitoring and control, systems integration, and risk analysis. Some key points are that: (1) the desired objective in continuous manufacturing should be the satisfaction of all critical quality attributes (CQAs), not for all variables to operate at steady-state values; (2) the design of start-up and shutdown procedures can significantly affect the economic operation of a continuous manufacturing process; (3) the traceability of material as it moves through the manufacturing facility is an important consideration that can at least in part be addressed using residence time distributions; and (4) the control systems technologies must assure quality in the presence of disturbances, dynamics, uncertainties, nonlinearities, and constraints. Direct measurement, first-principles and empirical model-based predictions, and design space approaches are described for ensuring that CQA specifications are met. Ways are discussed for universities, regulatory bodies, and industry to facilitate working around or through barriers to the development of control systems engineering technologies for continuous drug manufacturing. Industry and regulatory bodies should work with federal agencies to create federal funding mechanisms to attract faculty to this area. Universities should hire faculty interested in developing first-principles models and control systems technologies for drug manufacturing that are easily transportable to industry. Industry can facilitate the move to continuous manufacturing by working with universities on the conception of new continuous pharmaceutical manufacturing process unit operations that have the potential to make major improvements in product quality, controllability, or reduced capital and/or operating costs. Regulatory bodies should ensure that: (1) regulations and regulatory practices promote, and do not derail, the development and implementation of continuous manufacturing and control systems engineering approaches; (2) the individuals who approve specific regulatory filings are sufficiently trained to make good decisions regarding control systems approaches; (3) provide regulatory clarity and eliminate/reduce regulatory risks; (4) financially support the development of high-quality training materials for use of undergraduate students, graduate students, industrial employees, and regulatory staff; (5) enhance the training of their own technical staff by financially supporting joint research projects with universities in the development of continuous pharmaceutical manufacturing processes and the associated control systems engineering theory, numerical algorithms, and software; and (6) strongly encourage the federal agencies that support research to fund these research areas. © 2014 Wiley Periodicals, Inc. and the American Pharmacists Association.

Review of Portable and Low-Cost Sensors for the Ambient Air Monitoring of Benzene and Other Volatile Organic Compounds

PubMed Central

Kok, Gertjan; Persijn, Stefan; Sauerwald, Tilman

2017-01-01

This article presents a literature review of sensors for the monitoring of benzene in ambient air and other volatile organic compounds. Combined with information provided by stakeholders, manufacturers and literature, the review considers commercially available sensors, including PID-based sensors, semiconductor (resistive gas sensors) and portable on-line measuring devices as for example sensor arrays. The bibliographic collection includes the following topics: sensor description, field of application at fixed sites, indoor and ambient air monitoring, range of concentration levels and limit of detection in air, model descriptions of the phenomena involved in the sensor detection process, gaseous interference selectivity of sensors in complex VOC matrix, validation data in lab experiments and under field conditions. PMID:28657595

Review of Portable and Low-Cost Sensors for the Ambient Air Monitoring of Benzene and Other Volatile Organic Compounds.

PubMed

Spinelle, Laurent; Gerboles, Michel; Kok, Gertjan; Persijn, Stefan; Sauerwald, Tilman

2017-06-28

This article presents a literature review of sensors for the monitoring of benzene in ambient air and other volatile organic compounds. Combined with information provided by stakeholders, manufacturers and literature, the review considers commercially available sensors, including PID-based sensors, semiconductor (resistive gas sensors) and portable on-line measuring devices as for example sensor arrays. The bibliographic collection includes the following topics: sensor description, field of application at fixed sites, indoor and ambient air monitoring, range of concentration levels and limit of detection in air, model descriptions of the phenomena involved in the sensor detection process, gaseous interference selectivity of sensors in complex VOC matrix, validation data in lab experiments and under field conditions.

A Novel Approach to Monitoring the Curing of Epoxy in Closed Tools by Use of Ultrasonic Spectroscopy

PubMed Central

2017-01-01

The increasing use of composite materials has led to a greater demand for efficient curing cycles to reduce costs and speed up production cycles in manufacturing. One method to achieve this goal is in-line cure monitoring to determine the exact curing time. This article proposes a novel method through which to monitor the curing process inside closed tools by employing ultrasonic spectroscopy. A simple experiment is used to demonstrate the change in the ultrasonic spectrum during the cure cycle of an epoxy. The results clearly reveal a direct correlation between the amplitude and state of cure. The glass transition point is indicated by a global minimum of the reflected amplitude. PMID:29301222

Micromachined needles and lancets with design adjustable bevel angles

NASA Astrophysics Data System (ADS)

Sparks, Douglas; Hubbard, Timothy

2004-08-01

A new method of micromachining hollow needles and two-dimensional needle arrays from single crystal silicon is described. The process involves a combination of fusion bonding, photolithography and anisotropic plasma etching. The cannula produced with this process can have design adjustable bevel angles, wall thickness and channel dimensions. A subset of processing steps can be employed to produce silicon blades and lancets with design adjustable bevel angles and shaft dimensions. Applications for this technology include painless drug infusion, blood diagnosis, glucose monitoring, cellular injection and the manufacture of microkeratomes for ocular, vascular and neural microsurgery.

Walk-through survey report: Control technology for integrated circuit fabrication, Xerox Corporation, El Segundo, California

NASA Astrophysics Data System (ADS)

Mihlan, G. J.; Ungers, L. J.; Smith, R. K.; Mitchell, R. I.; Jones, J. H.

1983-05-01

A preliminary control technology assessment survey was conducted at the facility which manufactures N-channel metal oxide semiconductor (NMOS) integrated circuits. The facility has industrial hygiene review procedures for evaluating all new and existing process equipment. Employees are trained in safety, use of personal protective equipment, and emergency response. Workers potentially exposed to arsenic are monitored for urinary arsenic levels. The facility should be considered a candidate for detailed study based on the diversity of process operations encountered and the use of state-of-the-art technology and process equipment.

On-line monitoring of extraction process of Flos Lonicerae Japonicae using near infrared spectroscopy combined with synergy interval PLS and genetic algorithm

NASA Astrophysics Data System (ADS)

Yang, Yue; Wang, Lei; Wu, Yongjiang; Liu, Xuesong; Bi, Yuan; Xiao, Wei; Chen, Yong

2017-07-01

There is a growing need for the effective on-line process monitoring during the manufacture of traditional Chinese medicine to ensure quality consistency. In this study, the potential of near infrared (NIR) spectroscopy technique to monitor the extraction process of Flos Lonicerae Japonicae was investigated. A new algorithm of synergy interval PLS with genetic algorithm (Si-GA-PLS) was proposed for modeling. Four different PLS models, namely Full-PLS, Si-PLS, GA-PLS, and Si-GA-PLS, were established, and their performances in predicting two quality parameters (viz. total acid and soluble solid contents) were compared. In conclusion, Si-GA-PLS model got the best results due to the combination of superiority of Si-PLS and GA. For Si-GA-PLS, the determination coefficient (Rp2) and root-mean-square error for the prediction set (RMSEP) were 0.9561 and 147.6544 μg/ml for total acid, 0.9062 and 0.1078% for soluble solid contents, correspondingly. The overall results demonstrated that the NIR spectroscopy technique combined with Si-GA-PLS calibration is a reliable and non-destructive alternative method for on-line monitoring of the extraction process of TCM on the production scale.

24 CFR 3282.552 - Manufacturer reports for joint monitoring fees.

Code of Federal Regulations, 2011 CFR

2011-04-01

..., and the State of first location, after leaving the manufacturing plant, of such manufactured homes. The State of first location for the purpose of this report is the State of the premises of the distributor, dealer or purchaser to whom the manufactured home is first shipped. The report for each month...

24 CFR 3282.552 - Manufacturer reports for joint monitoring fees.

Code of Federal Regulations, 2012 CFR

2012-04-01

..., and the State of first location, after leaving the manufacturing plant, of such manufactured homes. The State of first location for the purpose of this report is the State of the premises of the distributor, dealer or purchaser to whom the manufactured home is first shipped. The report for each month...

UV-sensitive scientific CCD image sensors

NASA Astrophysics Data System (ADS)

Vishnevsky, Grigory I.; Kossov, Vladimir G.; Iblyaminova, A. F.; Lazovsky, Leonid Y.; Vydrevitch, Michail G.

1997-06-01

An investigation of probe laser irradiation interaction with substances containing in an environment has long since become a recognized technique for contamination detection and identification. For this purpose, a near and midrange-IR laser irradiation is traditionally used. However, as many works presented on last ecology monitoring conferences show, in addition to traditional systems, rapidly growing are systems with laser irradiation from near-UV range (250 - 500 nm). Use of CCD imagers is one of the prerequisites for this allowing the development of a multi-channel computer-based spectral research system. To identify and analyze contaminating impurities on an environment, such methods as laser fluorescence analysis, UV absorption and differential spectroscopy, Raman scattering are commonly used. These methods are used to identify a large number of impurities (petrol, toluene, Xylene isomers, SO2, acetone, methanol), to detect and identify food pathogens in real time, to measure a concentration of NH3, SO2 and NO in combustion outbursts, to detect oil products in a water, to analyze contaminations in ground waters, to define ozone distribution in the atmosphere profile, to monitor various chemical processes including radioactive materials manufacturing, heterogeneous catalytic reactions, polymers production etc. Multi-element image sensor with enhanced UV sensitivity, low optical non-uniformity, low intrinsic noise and high dynamic range is a key element of all above systems. Thus, so called Virtual Phase (VP) CCDs possessing all these features, seems promising for ecology monitoring spectral measuring systems. Presently, a family of VP CCDs with different architecture and number of pixels is developed and being manufactured. All CCDs from this family are supported with a precise slow-scan digital image acquisition system that can be used in various image processing systems in astronomy, biology, medicine, ecology etc. An image is displayed directly on a PC monitor through a software support.

Electroacoustics modeling of piezoelectric welders for ultrasonic additive manufacturing processes

NASA Astrophysics Data System (ADS)

Hehr, Adam; Dapino, Marcelo J.

2016-04-01

Ultrasonic additive manufacturing (UAM) is a recent 3D metal printing technology which utilizes ultrasonic vibrations from high power piezoelectric transducers to additively weld similar and dissimilar metal foils. CNC machining is used intermittent of welding to create internal channels, embed temperature sensitive components, sensors, and materials, and for net shaping parts. Structural dynamics of the welder and work piece influence the performance of the welder and part quality. To understand the impact of structural dynamics on UAM, a linear time-invariant model is used to relate system shear force and electric current inputs to the system outputs of welder velocity and voltage. Frequency response measurements are combined with in-situ operating measurements of the welder to identify model parameters and to verify model assumptions. The proposed LTI model can enhance process consistency, performance, and guide the development of improved quality monitoring and control strategies.

An unobtrusive liquid sensor utilizing a micromilled RF spark gap transmitter and resonant cavity

NASA Astrophysics Data System (ADS)

Berry, H.; Wilson, C.

2009-09-01

This paper reports on a new dielectric liquid sensor that utilizes an RF sparkgap transmitter coupled with an aluminum microwave resonant cavity. The transmitter is a micromilled polymer transmitter housing with patterned copper electrodes that generate micro-arcs. This transmitter which operates outside the measured liquid generates a directed ultrawideband signal which is received by the aluminum waveguide. Absorption resonances in the microwave cavity, measured with a spectrum analyzer are a function of the liquids' dielectric constant at lower frequencies, as well as from molecular vibrations/rotations at higher frequencies. In many chemical manufacturing processes, liquids being manufactured are removed, tested in a lab, and then disposed of, or else they will contaminate the full batch. In beer brewing, for instance, samples are removed, density tested for alcohol content, then disposed of. Using this sensor, the chemical process could be continuously monitored by a computerized system without risk of contamination.

Piezoresistive Sensor with High Elasticity Based on 3D Hybrid Network of Sponge@CNTs@Ag NPs.

PubMed

Zhang, Hui; Liu, Nishuang; Shi, Yuling; Liu, Weijie; Yue, Yang; Wang, Siliang; Ma, Yanan; Wen, Li; Li, Luying; Long, Fei; Zou, Zhengguang; Gao, Yihua

2016-08-31

Pressure sensors with high elasticity are in great demand for the realization of intelligent sensing, but there is a need to develope a simple, inexpensive, and scalable method for the manufacture of the sensors. Here, we reported an efficient, simple, facile, and repeatable "dipping and coating" process to manufacture a piezoresistive sensor with high elasticity, based on homogeneous 3D hybrid network of carbon nanotubes@silver nanoparticles (CNTs@Ag NPs) anchored on a skeleton sponge. Highly elastic, sensitive, and wearable sensors are obtained using the porous structure of sponge and the synergy effect of CNTs/Ag NPs. Our sensor was also tested for over 2000 compression-release cycles, exhibiting excellent elasticity and cycling stability. Sensors with high performance and a simple fabrication process are promising devices for commercial production in various electronic devices, for example, sport performance monitoring and man-machine interfaces.

The role of engineering in the flight equipment purchasing process

NASA Technical Reports Server (NTRS)

1977-01-01

The role of the airline engineering department in the flight equipment acquisition process is examined. The data for the study was collected from six airlines. The principal findings of the study include: (1) engineering activities permeate, but do not dominate the airline flight equipment decision process. (2) The principal criterion for the flight equipment acquisition decision is return on investment. (3) The principal sources of information for the airline engineering departments in the monitoring process are the manufacturers of equipment. Subsidiary information sources include NASA publications and conferences, among others and (4) The engineering department is the principal communication channel for technical information.

The association of occupational metals exposure and oxidative damage, telomere shortening in fitness equipments manufacturing workers

PubMed Central

KO, Jiunn-Liang; CHENG, Yu-Jung; LIU, Guan-Cen; HSIN, I-Lun; CHEN, Hsiu-Ling

2017-01-01

The welding is the major working process in fitness equipment manufacturing industry, and International Agency for Research on Cancer has classified welding fumes as possibly carcinogenic to humans (Group 2B). The present study aimed to evaluate associations between the occupational exposure of metals and oxidative damage and telomere length shortening in workers involved in the manufacture of fitness equipment. The blood metal concentrations were monitored and malondialdehyde (MDA), alkaline Comet assay was determined as oxidative damage in 117 workers from two representative fitness equipment manufacturing plants. MDA levels varied according to workers’ roles at the manufacturing plants, and showed a trend as cutting>painting>welding>administration workers. Welders had marginally shorter average telomere lengths than the administrative workers (p=0.058). Cr and Mn levels were significantly greater in welders than they were in administrative workers. There were significantly positive correlations between MDA and Cr and Mn levels, the major components of welding fume. However, the association would be eliminated if co-metals exposure were considered simultaneously. In future, telomere length and MDA might be potential biomarkers for predicting cardiovascular disease in co-metals exposed workers. PMID:28420806

Water resource use and management by the United States forest products industry.

PubMed

Wiegand, P S; Flinders, C A; Ice, G G; Malmberg, B J; Fisher, R P

2009-01-01

The connections between forest products operations and water resources in the United States is considered and, where possible, quantified. Manufacture of wood, pulp, and paper products and the influences of forest management and forest products manufacture on water quality are discussed. Most fresh water in the US originates in forested areas. Responsible harvesting strategies, best management practices, and forest re-growth combine to minimize or eliminate changes in water availability and degradation of water quality due to harvesting. Relative to alternative land uses and large-scale disturbance events, forested areas produce the highest quality of fresh water. Water inputs for the manufacture of forest products total about 5.8 billion m(3) per year, an amount equal about 0.4% of the surface and groundwater yield from timberland. Approximately 88% of water used in manufacturing is treated and returned directly to surface waters, about 11% is converted to water vapor and released during the manufacturing process, and 1% is imparted to products or solid residuals. Extensive study and continued monitoring of treated effluents suggest few or no concerns regarding the compatibility of current effluents with healthy aquatic systems.

Production of rotational parts in small-series and computer-aided planning of its production engineering

NASA Astrophysics Data System (ADS)

Dudas, Illes; Berta, Miklos; Cser, Istvan

1998-12-01

Up-to-date manufacturing equipments of production of rotational parts in small series are lathe-centers and CNC grinding machines with high concentration of manufacturing operations. By the use of these machine tools it can be produced parts with requirements of increased accuracy and surface quality. In the lathe centers, which contain the manufacturing procedures of lathes using stationary tools and of drilling-milling machine tools using rotational tools, non-rotational surfaces of rotational parts can also be produced. The high concentration of manufacturing operations makes necessary the planning and programing of the measuring, monitoring and quality control into the technological process during manufacturing operation. In this way, taking into consideration the technological possibilities of lathe canters, the scope of computer aided technological planning duties significantly increases. It is trivial requirement to give only once the descriptions of the prefabricated parts and ready made parts. Starting taking into account these careful considerations we have been developing the planning system of technology of body of revolution on the base of GTIPROG/EC system which useful for programming of lathe centers. Out paper deals with the results of development and the occurring problems.

Optical sensor for real-time weld defect detection

NASA Astrophysics Data System (ADS)

Ancona, Antonio; Maggipinto, Tommaso; Spagnolo, Vincenzo; Ferrara, Michele; Lugara, Pietro M.

2002-04-01

In this work we present an innovative optical sensor for on- line and non-intrusive welding process monitoring. It is based on the spectroscopic analysis of the optical VIS emission of the welding plasma plume generated in the laser- metal interaction zone. Plasma electron temperature has been measured for different chemical species composing the plume. Temperature signal evolution has been recorded and analyzed during several CO2-laser welding processes, under variable operating conditions. We have developed a suitable software able to real time detect a wide range of weld defects like crater formation, lack of fusion, excessive penetration, seam oxidation. The same spectroscopic approach has been applied for electric arc welding process monitoring. We assembled our optical sensor in a torch for manual Gas Tungsten Arc Welding procedures and tested the prototype in a manufacturing industry production line. Even in this case we found a clear correlation between the signal behavior and the welded joint quality.

Characterization of polymer composites during autoclave manufacturing by Fourier transform Raman spectroscopy

NASA Astrophysics Data System (ADS)

Farquharson, Stuart; Smith, Wayne W.; Rigas, Elias J.; Granville, Dana

2001-02-01

12 The superior engineering properties of fiber reinforced polymer matrix composites, primarily the high strength-to- weight ratio, make them suitable to applications ranging from sporting goods to aircraft components (e.g. helicopter blades). Unfortunately, consistent fabrication of components with desired mechanical properties has proven difficult, and has led to high production costs. This is largely due to the inability to monitor and control polymer cure, loosely defined as the process of polymer chain extension and cross- linking. Even with stringent process control, slight variations in the pre-polymer formulations (e.g. prepreg) can influence reaction rates, reaction mechanisms, and ultimately, product properties. In an effort to optimize the performance of thermoset composite, we have integrated fiber optic probes between the plies of laminates and monitored cure by Raman spectroscopy, with the eventual goal of process control. Here we present real-time measurements of two high performance aerospace companies cured within an industrial autoclave.

40 CFR 63.1352 - Additional test methods.

Code of Federal Regulations, 2010 CFR

2010-07-01

... Standards for Hazardous Air Pollutants From the Portland Cement Manufacturing Industry Monitoring and... bypass stacks at portland cement manufacturing facilities, for use in applicability determinations under... kiln/raw mills and associated bypass stacks at portland cement manufacturing facilities, for use in...

Characterization of exposure to silver nanoparticles in a manufacturing facility

NASA Astrophysics Data System (ADS)

Park, Junsu; Kwak, Byoung Kyu; Bae, Eunjoo; Lee, Jeongjin; Kim, Younghun; Choi, Kyunghee; Yi, Jongheop

2009-10-01

An assessment of the extent of exposure to nanomaterials in the workplace will be helpful in improving the occupational safety of workers. It is essential that the exposure data in the workplace are concerned with risk management to evaluate and reduce worker exposure. In a manufacturing facility dealing with nanomaterials, some exposure data for gas-phase reactions are available, but much less information is available regarding liquid-phase reactions. Although the potential for inhaling nanomaterials in a liquid-phase process is less than that for gas-phase, the risks of exposure during wet-chemistry processes are not negligible. In this study, we monitored and analyzed the exposure characteristics of silver nanoparticles during a liquid-phase process in a commercial production facility. Based on the measured exposure data, the source of Ag nanoparticles emitted during the production processes was indentified and a mechanism for the growth of Ag nanoparticle released is proposed. The data reported in this study could be used to establish occupational safety guidelines in the nanotechnology workplace, especially in a liquid-phase production facility.

Development of Process Analytical Technology (PAT) methods for controlled release pellet coating.

PubMed

Avalle, P; Pollitt, M J; Bradley, K; Cooper, B; Pearce, G; Djemai, A; Fitzpatrick, S

2014-07-01

This work focused on the control of the manufacturing process for a controlled release (CR) pellet product, within a Quality by Design (QbD) framework. The manufacturing process was Wurster coating: firstly layering active pharmaceutical ingredient (API) onto sugar pellet cores and secondly a controlled release (CR) coating. For each of these two steps, development of a Process Analytical Technology (PAT) method is discussed and also a novel application of automated microscopy as the reference method. Ultimately, PAT methods should link to product performance and the two key Critical Quality Attributes (CQAs) for this CR product are assay and release rate, linked to the API and CR coating steps respectively. In this work, the link between near infra-red (NIR) spectra and those attributes was explored by chemometrics over the course of the coating process in a pilot scale industrial environment. Correlations were built between the NIR spectra and coating weight (for API amount), CR coating thickness and dissolution performance. These correlations allow the coating process to be monitored at-line and so better control of the product performance in line with QbD requirements. Copyright © 2014 Elsevier B.V. All rights reserved.

Materials and manufacturing processes for increased life/reliability. [of turbine wheels

NASA Technical Reports Server (NTRS)

Duttweiler, R. E.

1977-01-01

Improvements in both quality and durability of disk raw material for both military and commercial engines necessitated an entirely new concept in raw material process control which imposes careful selection, screening and sampling of the basic alloy ingredients, followed by careful monitoring of the melting parameters in all phases of the vacuum melting sequence. Special care is taken to preclude solidification conditions that produce adverse levels of segregation. Melt furnaces are routinely cleaned and inspected for contamination. Ingots are also cleaned and inspected before entering the final melt step.

Filament Breakage Monitoring in Fused Deposition Modeling Using Acoustic Emission Technique

PubMed Central

Jin, Li; Yan, Youruiling; Mei, Yiming

2018-01-01

Polymers are being used in a wide range of Additive Manufacturing (AM) applications and have been shown to have tremendous potential for producing complex, individually customized parts. In order to improve part quality, it is essential to identify and monitor the process malfunctions of polymer-based AM. The present work endeavored to develop an alternative method for filament breakage identification in the Fused Deposition Modeling (FDM) AM process. The Acoustic Emission (AE) technique was applied due to the fact that it had the capability of detecting bursting and weak signals, especially from complex background noises. The mechanism of filament breakage was depicted thoroughly. The relationship between the process parameters and critical feed rate was obtained. In addition, the framework of filament breakage detection based on the instantaneous skewness and relative similarity of the AE raw waveform was illustrated. Afterwards, we conducted several filament breakage tests to validate their feasibility and effectiveness. Results revealed that the breakage could be successfully identified. Achievements of the present work could be further used to develop a comprehensive in situ FDM monitoring system with moderate cost. PMID:29494559

Manufacturing process applications team (MATEAM). [technology transfer in the areas of machine tools and robots

NASA Technical Reports Server (NTRS)

1979-01-01

The transfer of NASA technology to the industrial sector is reported. Presentations to the machine tool and robot industries and direct technology transfers of the Adams Manipulator arm, a-c motor control, and the bolt tension monitor are discussed. A listing of proposed RTOP programs with strong potential is included. A detailed description of the rotor technology available to industry is given.

Monitoring of Free Water and Particulate Contamination of F-24 Fuel

DTIC Science & Technology

2016-04-20

Reference herein to any specific commercial company, product , process, or service by trade name, trademark, manufacturer, or otherwise, does not...advertising or product endorsement purposes. Contracted Author As the author(s) is(are) not a Government employee(s), this document was only...14. ABSTRACT A study was conducted on the contaminant detection methods of fuel sensors which are capable of quantifying both free water (0

NMR Based Sensors for In Situ Monitoring of Changes in Groundwater Chemistry

DTIC Science & Technology

2017-04-21

herein to any specific commercial product, process, or service by trade name, trademark, manufacturer , or otherwise, does not necessarily constitute or...relaxation sensor employed in the field would need to be calibrated against a non- contaminated water sample taken from the same source, and... contaminants may prove more fruitful. For example, the original development of these sensors was aimed at detecting trace concentrations of specific

Bridging the gap between PAT concepts and implementation: An integrated software platform for fermentation.

PubMed

Chopda, Viki R; Gomes, James; Rathore, Anurag S

2016-01-01

Bioreactor control significantly impacts both the amount and quality of the product being manufactured. The complexity of the control strategy that is implemented increases with reactor size, which may vary from thousands to tens of thousands of litres in commercial manufacturing. The Process Analytical Technology (PAT) initiative has highlighted the need for having robust monitoring tools and effective control schemes that are capable of taking real time information about the critical quality attributes (CQA) and the critical process parameters (CPP) and executing immediate response as soon as a deviation occurs. However, the limited flexibility that present commercial software packages offer creates a hurdle. Visual programming environments have gradually emerged as potential alternatives to the available text based languages. This paper showcases development of an integrated programme using a visual programming environment for a Sartorius BIOSTAT® B Plus 5L bioreactor through which various peripheral devices are interfaced. The proposed programme facilitates real-time access to data and allows for execution of control actions to follow the desired trajectory. Major benefits of such integrated software system include: (i) improved real time monitoring and control; (ii) reduced variability; (iii) improved performance; (iv) reduced operator-training time; (v) enhanced knowledge management; and (vi) easier PAT implementation. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Measurement accuracy of a stressed contact lens during its relaxation period

NASA Astrophysics Data System (ADS)

Compertore, David C.; Ignatovich, Filipp V.

2018-02-01

We examine the dioptric power and transmitted wavefront of a contact lens as it releases its handling stresses. Handling stresses are introduced as part of the contact lens loading process and are common across all contact lens measurement procedures and systems. The latest advances in vision correction require tighter quality control during the manufacturing of the contact lenses. The optical power of contact lenses is one of the critical characteristics for users. Power measurements are conducted in the hydrated state, where the lens is resting inside a solution-filled glass cuvette. In a typical approach, the contact lens must be subject to long settling times prior to any measurements. Alternatively, multiple measurements must be averaged. Apart from potential operator dependency of such approach, it is extremely time-consuming, and therefore it precludes higher rates of testing. Comprehensive knowledge about the settling process can be obtained by monitoring multiple parameters of the lens simultaneously. We have developed a system that combines co-aligned a Shack-Hartmann transmitted wavefront sensor and a time-domain low coherence interferometer to measure several optical and physical parameters (power, cylinder power, aberrations, center thickness, sagittal depth, and diameter) simultaneously. We monitor these parameters during the stress relaxation period and show correlations that can be used by manufacturers to devise methods for improved quality control procedures.

Chiral Process Monitoring Using Fourier Transform Microwave Spectroscopy

NASA Astrophysics Data System (ADS)

Neill, Justin L.; Muckle, Matt; Pate, Brooks

2017-06-01

We present the application of Fourier transform microwave (FTMW) spectroscopy in monitoring the chiral purity of components in a reaction mixture. This is of particular interest due to the increasing use of continuous pharmaceutical manufacturing processes, in which a number of attributes (including the chiral purity of the product) can change on short time scales. Therefore, new techniques that can accomplish this measurement rapidly are desired. The excellent specificity of FTMW spectroscopy, coupled with newly developed techniques for measuring enantiomeric excess in a mixture, have motivated this work. In collaboration with B. Frank Gupton (Virginia Commonwealth University), we are testing this application first with the synthesis of artemisinin. Artemisinin, a common drug for malaria treatment, is of high global health interest and subject to supply shortages, and therefore a strong candidate for continuous manufacturing. It also has moderately high molecular weight (282 amu) and seven chiral centers, making it a good candidate to test the capabilities of FTMW spectroscopy. Using a miniature cavity-enhanced FTMW spectrometer design, we aim to demonstrate selective component quantification in the reaction mixture. Future work that will be needed to fully realize this application will be discussed. R.D. Suenram, J.U. Grabow, A.Zuban, and I.Leonov, Rev. Sci. Instrum. 70, 2127 (1999).

Condition monitoring of turning process using infrared thermography technique - An experimental approach

NASA Astrophysics Data System (ADS)

Prasad, Balla Srinivasa; Prabha, K. Aruna; Kumar, P. V. S. Ganesh

2017-03-01

In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated. In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.

Audio signal analysis for tool wear monitoring in sheet metal stamping

NASA Astrophysics Data System (ADS)

Ubhayaratne, Indivarie; Pereira, Michael P.; Xiang, Yong; Rolfe, Bernard F.

2017-02-01

Stamping tool wear can significantly degrade product quality, and hence, online tool condition monitoring is a timely need in many manufacturing industries. Even though a large amount of research has been conducted employing different sensor signals, there is still an unmet demand for a low-cost easy to set up condition monitoring system. Audio signal analysis is a simple method that has the potential to meet this demand, but has not been previously used for stamping process monitoring. Hence, this paper studies the existence and the significance of the correlation between emitted sound signals and the wear state of sheet metal stamping tools. The corrupting sources generated by the tooling of the stamping press and surrounding machinery have higher amplitudes compared to that of the sound emitted by the stamping operation itself. Therefore, a newly developed semi-blind signal extraction technique was employed as a pre-processing technique to mitigate the contribution of these corrupting sources. The spectral analysis results of the raw and extracted signals demonstrate a significant qualitative relationship between wear progression and the emitted sound signature. This study lays the basis for employing low-cost audio signal analysis in the development of a real-time industrial tool condition monitoring system.

Autonomous Agents for Dynamic Process Planning in the Flexible Manufacturing System

NASA Astrophysics Data System (ADS)

Nik Nejad, Hossein Tehrani; Sugimura, Nobuhiro; Iwamura, Koji; Tanimizu, Yoshitaka

Rapid changes of market demands and pressures of competition require manufacturers to maintain highly flexible manufacturing systems to cope with a complex manufacturing environment. This paper deals with development of an agent-based architecture of dynamic systems for incremental process planning in the manufacturing systems. In consideration of alternative manufacturing processes and machine tools, the process plans and the schedules of the manufacturing resources are generated incrementally and dynamically. A negotiation protocol is discussed, in this paper, to generate suitable process plans for the target products real-timely and dynamically, based on the alternative manufacturing processes. The alternative manufacturing processes are presented by the process plan networks discussed in the previous paper, and the suitable process plans are searched and generated to cope with both the dynamic changes of the product specifications and the disturbances of the manufacturing resources. We initiatively combine the heuristic search algorithms of the process plan networks with the negotiation protocols, in order to generate suitable process plans in the dynamic manufacturing environment.

Lightweight, Room-Temperature CO2 Gas Sensor Based on Rare-Earth Metal-Free Composites-An Impedance Study.

PubMed

Willa, Christoph; Schmid, Alexander; Briand, Danick; Yuan, Jiayin; Koziej, Dorota

2017-08-02

We report a light, flexible, and low-power poly(ionic liquid)/alumina composite CO 2 sensor. We monitor the direct-current resistance changes as a function of CO 2 concentration and relative humidity and demonstrate fast and reversible sensing kinetics. Moreover, on the basis of the alternating-current impedance measurements we propose a sensing mechanism related to proton conduction and gas diffusion. The findings presented herein will promote the development of organic/inorganic composite CO 2 gas sensors. In the future, such sensors will be useful for numerous practical applications ranging from indoor air quality control to the monitoring of manufacturing processes.

Computational metrology: enabling full-lot high-density fingerprint information without adding wafer metrology budget, and driving improved monitoring and process control

NASA Astrophysics Data System (ADS)

Kim, Hyun-Sok; Hyun, Min-Sung; Ju, Jae-Wuk; Kim, Young-Sik; Lambregts, Cees; van Rhee, Peter; Kim, Johan; McNamara, Elliott; Tel, Wim; Böcker, Paul; Oh, Nang-Lyeom; Lee, Jun-Hyung

2018-03-01

Computational metrology has been proposed as the way forward to resolve the need for increased metrology density, resulting from extending correction capabilities, without adding actual metrology budget. By exploiting TWINSCAN based metrology information, dense overlay fingerprints for every wafer can be computed. This extended metrology dataset enables new use cases, such as monitoring and control based on fingerprints for every wafer of the lot. This paper gives a detailed description, discusses the accuracy of the fingerprints computed, and will show results obtained in a DRAM HVM manufacturing environment. Also an outlook for improvements and extensions will be shared.

Vaccination policies and programs: the federal government's role in making the system work.

PubMed

Schwartz, B; Orenstein, W A

2001-12-01

Government agencies play a key role, from preclinical development to postlicensure monitoring, in making vaccinations one of the leading public health interventions. Important steps in this process include development and testing of vaccine antigens, evaluation of clinical and manufacturing data leading to licensure, formulation of recommendations, vaccine purchase, defining strategies to improve coverage, compensation of those injured by vaccine adverse reactions, and monitoring vaccine impact and safety. Using examples of newly recommended vaccines, this article describes the infrastructure that underlies a safe and effective program and highlights some of the opportunities and threats likely to impact the system in coming years.

Risk assessment of occupational exposure to heavy metal mixtures: a study protocol.

PubMed

Omrane, Fatma; Gargouri, Imed; Khadhraoui, Moncef; Elleuch, Boubaker; Zmirou-Navier, Denis

2018-03-05

Sfax is a very industrialized city located in the southern region of Tunisia where heavy metals (HMs) pollution is now an established matter of fact. The health of its residents mainly those engaged in industrial metals-based activities is under threat. Indeed, such workers are being exposed to a variety of HMs mixtures, and this exposure has cumulative properties. Whereas current HMs exposure assessment is mainly carried out using direct air monitoring approaches, the present study aims to assess health risks associated with chronic occupational exposure to HMs in industry, using a modeling approach that will be validated later on. To this end, two questionnaires were used. The first was an identification/descriptive questionnaire aimed at identifying, for each company: the specific activities, materials used, manufactured products and number of employees exposed. The second related to the job-task of the exposed persons, workplace characteristics (dimensions, ventilation, etc.), type of metals and emission configuration in space and time. Indoor air HMs concentrations were predicted, based on the mathematical models generally used to estimate occupational exposure to volatile substances (such as solvents). Later on, and in order to validate the adopted model, air monitoring will be carried out, as well as some biological monitoring aimed at assessing HMs excretion in the urine of workers volunteering to participate. Lastly, an interaction-based hazard index HI int and a decision support tool will be used to predict the cumulative risk assessment for HMs mixtures. One hundred sixty-one persons working in the 5 participating companies have been identified. Of these, 110 are directly engaged with HMs in the course of the manufacturing process. This model-based prediction of occupational exposure represents an alternative tool that is both time-saving and cost-effective in comparison with direct air monitoring approaches. Following validation of the different models according to job processes, via comparison with direct measurements and exploration of correlations with biological monitoring, these estimates will allow a cumulative risk characterization.

Solid State Lighting Program (Falcon)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Meeks, Steven

2012-06-30

Over the past two years, KLA-Tencor and partners successfully developed and deployed software and hardware tools that increase product yield for High Brightness LED (HBLED) manufacturing and reduce product development and factory ramp times. This report summarizes our development effort and details of how the results of the Solid State Light Program (Falcon) have started to help HBLED manufacturers optimize process control by enabling them to flag and correct identified killer defect conditions at any point of origin in the process manufacturing flow. This constitutes a quantum leap in yield management over current practice. Current practice consists of die dispositioningmore » which is just rejection of bad die at end of process based upon probe tests, loosely assisted by optical in-line monitoring for gross process deficiencies. For the first time, and as a result of our Solid State Lighting Program, our LED manufacturing partners have obtained the software and hardware tools that optimize individual process steps to control killer defects at the point in the processes where they originate. Products developed during our two year program enable optimized inspection strategies for many product lines to minimize cost and maximize yield. The Solid State Lighting Program was structured in three phases: i) the development of advanced imaging modes that achieve clear separation between LED defect types, improves signal to noise and scan rates, and minimizes nuisance defects for both front end and back end inspection tools, ii) the creation of defect source analysis (DSA) software that connect the defect maps from back-end and front-end HBLED manufacturing tools to permit the automatic overlay and traceability of defects between tools and process steps, suppress nuisance defects, and identify the origin of killer defects with process step and conditions, and iii) working with partners (Philips Lumileds) on product wafers, obtain a detailed statistical correlation of automated defect and DSA map overlay to failed die identified using end product probe test results. Results from our two year effort have led to “automated end-to-end defect detection” with full defect traceability and the ability to unambiguously correlate device killer defects to optically detected features and their point of origin within the process. Success of the program can be measured by yield improvements at our partner’s facilities and new product orders.« less

Workplace exposure to nanoparticles and the application of provisional nanoreference values in times of uncertain risks

NASA Astrophysics Data System (ADS)

van Broekhuizen, Pieter; van Broekhuizen, Fleur; Cornelissen, Ralf; Reijnders, Lucas

2012-03-01

Nano reference values (NRVs) for occupational use of nanomaterials were tested as provisional substitute for Occupational Exposure Limits (OELs). NRVs can be used as provisional limit values until Health-Based OELs or derived no-effect levels (DNEL) become available. NRVs were defined for 8 h periods (time weighted average) and for short-term exposure periods (15 min-time weighted average). To assess the usefulness of these NRVs, airborne number concentrations of nanoparticles (NPs) in the workplace environment were measured during paint manufacturing, electroplating, light equipment manufacturing, non-reflective glass production, production of pigment concentrates and car refinishing. Activities monitored were handling of solid engineered NPs (ENP), abrasion, spraying and heating during occupational use of nanomaterials (containing ENPs) and machining nanosurfaces. The measured concentrations are often presumed to contain ENPs as well as process-generated NPs (PGNP). The PGNP are found to be a significant source for potential exposure and cannot be ignored in risk assessment. Levels of NPs identified in workplace air were up to several millions of nanoparticles/cm3. Conventional components in paint manufacturing like CaCO3 and talc may contain a substantial amount of nanosized particulates giving rise to airborne nanoparticle concentrations. It is argued that risk assessments carried out for e.g. paint manufacturing processes using conventional non-nano components should take into account potential nanoparticle emissions as well. The concentrations measured were compared with particle-based NRVs and with mass-based values that have also been proposed for workers protection. It is concluded that NRVs can be used for risk management for handling or processing of nanomaterials at workplaces provided that the scope of NRVs is not limited to ENPs only, but extended to the exposure to process-generated NPs as well.

Additive technology of soluble mold tooling for embedded devices in composite structures: A study on manufactured tolerances

NASA Astrophysics Data System (ADS)

Roy, Madhuparna

Composite textiles have found widespread use and advantages in various industries and applications. The constant demand for high quality products and services requires companies to minimize their manufacturing costs, and delivery time in order to compete in general and niche marketplaces. Advanced manufacturing methods aim to provide economical methods of mold production. Creation of molding and tooling options for advanced composites encompasses a large portion of the fabrication time, making it a costly process and restraining factor. This research discusses a preliminary investigation into the use of soluble polymer compounds and additive manufacturing to fabricate soluble molds. These molds suffer from dimensional errors due to several factors, which have also been characterized. The basic soluble mold of a composite is 3D printed to meet the desired dimensions and geometry of holistic structures or spliced components. The time taken to dissolve the mold depends on the rate of agitation of the solvent. This process is steered towards enabling the implantation of optoelectronic devices within the composite to provide sensing capability for structural health monitoring. The shape deviation of the 3D printed mold is also studied and compared to its original dimensions to optimize the dimensional quality to produce dimensionally accurate parts. Mechanical tests were performed on compact tension (CT) resin samples prepared from these 3D printed molds and revealed crack propagation towards an embedded intact optical fiber.

Contact and non-contact ultrasonic measurement in the food industry: a review

NASA Astrophysics Data System (ADS)

Taufiq Mohd Khairi, Mohd; Ibrahim, Sallehuddin; Yunus, Mohd Amri Md; Faramarzi, Mahdi

2016-01-01

The monitoring of the food manufacturing process is vital since it determines the safety and quality level of foods which directly affect the consumers’ health. Companies which produce high quality products will gain trust from consumers. This factor helps the companies to make profits. The use of efficient and appropriate sensors for the monitoring process can also reduce cost. The food assessing process based on an ultrasonic sensor has attracted the attention of the food industry due to its excellent capabilities in several applications. The utilization of low or high frequencies for the ultrasonic transducer has provided an enormous benefit for analysing, modifying and guaranteeing the quality of food. The contact and non-contact ultrasonic modes for measurement also contributed significantly to the food processing. This paper presents a review of the application of the contact and non-contact mode of ultrasonic measurement focusing on safety and quality control areas. The results from previous researches are shown and elaborated.

A novel methodology for in-process monitoring of flow forming

NASA Astrophysics Data System (ADS)

Appleby, Andrew; Conway, Alastair; Ion, William

2017-10-01

Flow forming (FF) is an incremental cold working process with near-net-shape forming capability. Failures by fracture due to high deformation can be unexpected and sometimes catastrophic, causing tool damage. If process failures can be identified in real time, an automatic cut-out could prevent costly tool damage. Sound and vibration monitoring is well established and commercially viable in the machining sector to detect current and incipient process failures, but not for FF. A broad-frequency microphone was used to record the sound signature of the manufacturing cycle for a series of FF parts. Parts were flow formed using single and multiple passes, and flaws were introduced into some of the parts to simulate the presence of spontaneously initiated cracks. The results show that this methodology is capable of identifying both introduced defects and spontaneous failures during flow forming. Further investigation is needed to categorise and identify different modes of failure and identify further potential applications in rotary forming.

Performance analysis of Supply Chain Management with Supply Chain Operation reference model

NASA Astrophysics Data System (ADS)

Hasibuan, Abdurrozzaq; Arfah, Mahrani; Parinduri, Luthfi; Hernawati, Tri; Suliawati; Harahap, Bonar; Rahmah Sibuea, Siti; Krianto Sulaiman, Oris; purwadi, Adi

2018-04-01

This research was conducted at PT. Shamrock Manufacturing Corpora, the company is required to think creatively to implement competition strategy by producing goods/services that are more qualified, cheaper. Therefore, it is necessary to measure the performance of Supply Chain Management in order to improve the competitiveness. Therefore, the company is required to optimize its production output to meet the export quality standard. This research begins with the creation of initial dimensions based on Supply Chain Management process, ie Plan, Source, Make, Delivery, and Return with hierarchy based on Supply Chain Reference Operation that is Reliability, Responsiveness, Agility, Cost, and Asset. Key Performance Indicator identification becomes a benchmark in performance measurement whereas Snorm De Boer normalization serves to equalize Key Performance Indicator value. Analiytical Hierarchy Process is done to assist in determining priority criteria. Measurement of Supply Chain Management performance at PT. Shamrock Manufacturing Corpora produces SC. Responsiveness (0.649) has higher weight (priority) than other alternatives. The result of performance analysis using Supply Chain Reference Operation model of Supply Chain Management performance at PT. Shamrock Manufacturing Corpora looks good because its monitoring system between 50-100 is good.

Ground-water quality of the Upper Floridan Aquifer near an abandoned manufactured gas plant in Albany, Georgia

USGS Publications Warehouse

Chapman, M.J.

1993-01-01

Manufactured gas plants produced gas for heating and lighting in the United States from as early as 1816 into the 1960's. By-products including, but not limited to, oil residues and tar, were generated during the gas-manufacturing process. Organic compounds (hydrocarbons) were detected in water in the upper water-bearing zone of the Upper Floridan aquifer near an abandoned manufactured gas plant (MGP) in Albany, Georgia, during an earlier investigation in 1990. Chemical analyses of ground-water samples collected from five existing monitoring wells in 1991 verify the presence of hydrocarbons and metals in the upper water-beating zone of the Upper Floridan aquifer. One well was drilled into the lower water-beating zone of the Upper Floridan aquifer in 1991 for water-quality sampling and water-level monitoring. Analyses of ground water sampled from this well did not show evidence of benzene, toluene, xylene, napthalene, acenaphthlene, or other related compounds detected in the upper water-bearing zone in the study area. Low concentrations of tetrachloroethane, trichloromethane, and l,2-cisdichloroethene were detected in a water sample from the deeper well; however, these compounds were not detected in the upper water-bearing zone in the study area. Inorganic constituent concentrations also were substantially lower in the deeper well. Overall, ground water sampled from the lower water-bearing zone had lower specific conductance and alkalinity; and lower concentrations of dissolved solids, iron, and manganese compared to ground water sampled from the upper water-bearing zone. Water levels for the upper and lower water-bearing zones were similar throughout the study period.

Quantifying Availability in SCADA Environments Using the Cyber Security Metric MFC

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aissa, Anis Ben; Rabai, Latifa Ben Arfa; Abercrombie, Robert K

2014-01-01

Supervisory Control and Data Acquisition (SCADA) systems are distributed networks dispersed over large geographic areas that aim to monitor and control industrial processes from remote areas and/or a centralized location. They are used in the management of critical infrastructures such as electric power generation, transmission and distribution, water and sewage, manufacturing/industrial manufacturing as well as oil and gas production. The availability of SCADA systems is tantamount to assuring safety, security and profitability. SCADA systems are the backbone of the national cyber-physical critical infrastructure. Herein, we explore the definition and quantification of an econometric measure of availability, as it applies tomore » SCADA systems; our metric is a specialization of the generic measure of mean failure cost.« less

A continuous process for the development of Kodak Aerochrome Infrared Film 2443 as a negative

NASA Astrophysics Data System (ADS)

Klimes, D.; Ross, D. I.

1993-02-01

A process for the continuous dry-to-dry development of Kodak Aerochrome Infrared Film 2443 as a negative (CIR-neg) is described. The process is well suited for production processing of long film lengths. Chemicals from three commercial film processes are used with modifications. Sensitometric procedures are recommended for the monitoring of processing quality control. Sensitometric data and operational aerial exposures indicate that films developed in this process have approximately the same effective aerial film speed as films processed in the reversal process recommended by the manufacturer (Kodak EA-5). The CIR-neg process is useful when aerial photography is acquired for resources management applications which require print reproductions. Originals can be readily reproduced using conventional production equipment (electronic dodging) in black and white or color (color compensation).

Automated process control for plasma etching

NASA Astrophysics Data System (ADS)

McGeown, Margaret; Arshak, Khalil I.; Murphy, Eamonn

1992-06-01

This paper discusses the development and implementation of a rule-based system which assists in providing automated process control for plasma etching. The heart of the system is to establish a correspondence between a particular data pattern -- sensor or data signals -- and one or more modes of failure, i.e., a data-driven monitoring approach. The objective of this rule based system, PLETCHSY, is to create a program combining statistical process control (SPC) and fault diagnosis to help control a manufacturing process which varies over time. This can be achieved by building a process control system (PCS) with the following characteristics. A facility to monitor the performance of the process by obtaining and analyzing the data relating to the appropriate process variables. Process sensor/status signals are input into an SPC module. If trends are present, the SPC module outputs the last seven control points, a pattern which is represented by either regression or scoring. The pattern is passed to the rule-based module. When the rule-based system recognizes a pattern, it starts the diagnostic process using the pattern. If the process is considered to be going out of control, advice is provided about actions which should be taken to bring the process back into control.

Demonstration and Methodology of Structural Monitoring of Stringer Runs out Composite Areas by Embedded Optical Fiber Sensors and Connectors Integrated during Production in a Composite Plant.

PubMed

Miguel Giraldo, Carlos; Zúñiga Sagredo, Juan; Sánchez Gómez, José; Corredera, Pedro

2017-07-21

Embedding optical fibers sensors into composite structures for Structural Health Monitoring purposes is not just one of the most attractive solutions contributing to smart structures, but also the optimum integration approach that insures maximum protection and integrity of the fibers. Nevertheless this intended integration level still remains an industrial challenge since today there is no mature integration process in composite plants matching all necessary requirements. This article describes the process developed to integrate optical fiber sensors in the Production cycle of a test specimen. The sensors, Bragg gratings, were integrated into the laminate during automatic tape lay-up and also by a secondary bonding process, both in the Airbus Composite Plant. The test specimen, completely representative of the root joint of the lower wing cover of a real aircraft, is comprised of a structural skin panel with the associated stringer run out. The ingress-egress was achieved through the precise design and integration of miniaturized optical connectors compatible with the manufacturing conditions and operational test requirements. After production, the specimen was trimmed, assembled and bolted to metallic plates to represent the real triform and buttstrap, and eventually installed into the structural test rig. The interrogation of the sensors proves the effectiveness of the integration process; the analysis of the strain results demonstrate the good correlation between fiber sensors and electrical gauges in those locations where they are installed nearby, and the curvature and load transfer analysis in the bolted stringer run out area enable demonstration of the consistency of the fiber sensors measurements. In conclusion, this work presents strong evidence of the performance of embedded optical sensors for structural health monitoring purposes, where in addition and most importantly, the fibers were integrated in a real production environment and the ingress-egress issue was solved by the design and integration of miniaturized connectors compatible with the manufacturing and structural test phases.

Demonstration and Methodology of Structural Monitoring of Stringer Runs out Composite Areas by Embedded Optical Fiber Sensors and Connectors Integrated during Production in a Composite Plant

PubMed Central

Miguel Giraldo, Carlos; Zúñiga Sagredo, Juan; Sánchez Gómez, José; Corredera, Pedro

2017-01-01

Embedding optical fibers sensors into composite structures for Structural Health Monitoring purposes is not just one of the most attractive solutions contributing to smart structures, but also the optimum integration approach that insures maximum protection and integrity of the fibers. Nevertheless this intended integration level still remains an industrial challenge since today there is no mature integration process in composite plants matching all necessary requirements. This article describes the process developed to integrate optical fiber sensors in the Production cycle of a test specimen. The sensors, Bragg gratings, were integrated into the laminate during automatic tape lay-up and also by a secondary bonding process, both in the Airbus Composite Plant. The test specimen, completely representative of the root joint of the lower wing cover of a real aircraft, is comprised of a structural skin panel with the associated stringer run out. The ingress-egress was achieved through the precise design and integration of miniaturized optical connectors compatible with the manufacturing conditions and operational test requirements. After production, the specimen was trimmed, assembled and bolted to metallic plates to represent the real triform and buttstrap, and eventually installed into the structural test rig. The interrogation of the sensors proves the effectiveness of the integration process; the analysis of the strain results demonstrate the good correlation between fiber sensors and electrical gauges in those locations where they are installed nearby, and the curvature and load transfer analysis in the bolted stringer run out area enable demonstration of the consistency of the fiber sensors measurements. In conclusion, this work presents strong evidence of the performance of embedded optical sensors for structural health monitoring purposes, where in addition and most importantly, the fibers were integrated in a real production environment and the ingress-egress issue was solved by the design and integration of miniaturized connectors compatible with the manufacturing and structural test phases. PMID:28754009

Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

NASA Astrophysics Data System (ADS)

Perez Regalado, Waldo Josue

The real-time ultrasonic spot weld monitoring system, introduced by our research group, has been designed for the unsupervised quality characterization of the spot welding process. It comprises the ultrasonic transducer (probe) built into one of the welding electrodes and an electronics hardware unit which gathers information from the transducer, performs real-time weld quality characterization and communicates with the robot programmable logic controller (PLC). The system has been fully developed for the inspection of spot welds manufactured in steel alloys, and has been mainly applied in the automotive industry. In recent years, a variety of materials have been introduced to the automotive industry. These include high strength steels, magnesium alloys, and aluminum alloys. Aluminum alloys have been of particular interest due to their high strength-to-weight ratio. Resistance spot welding requirements for aluminum vary greatly from those of steel. Additionally, the oxide film formed on the aluminum surface increases the heat generation between the copper electrodes and the aluminum plates leading to accelerated electrode deterioration. Preliminary studies showed that the real-time quality inspection system was not able to monitor spot welds manufactured with aluminum. The extensive experimental research, finite element modelling of the aluminum welding process and finite difference modeling of the acoustic wave propagation through the aluminum spot welds presented in this dissertation, revealed that the thermodynamics and hence the acoustic wave propagation through an aluminum and a steel spot weld differ significantly. For this reason, the hardware requirements and the algorithms developed to determine the welds quality from the ultrasonic data used on steel, no longer apply on aluminum spot welds. After updating the system and designing the required algorithms, parameters such as liquid nugget penetration and nugget diameter were available in the ultrasonic data acquired during the aluminum welding process. Finally, a fuzzy system was designed to receive these parameters and determine the weld quality.

Belousov Zhabotinsky Autonomic Hydrogel Composites: Regulating Waves via Asymmetry (Postprint)

DTIC Science & Technology

2016-09-23

distribution unlimited. © 2016 AMERICAN ASSOCIATION FOR THE ADVANCEMENT OF SCIENCE (STINFO COPY) AIR FORCE RESEARCH LABORATORY MATERIALS AND...MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING AGENCY ACRONYM(S) Air Force Research Laboratory Materials and Manufacturing...EARCH ART I C L EPHYS I CAL SC I ENCEFunctional Materials Division, Materials and Manufacturing Directorate, Air Force Re- search Laboratory, 2179 12th

One size fits all electronics for insole-based activity monitoring.

PubMed

Hegde, Nagaraj; Bries, Matthew; Melanson, Edward; Sazonov, Edward

2017-07-01

Footwear based wearable sensors are becoming prominent in many areas of monitoring health and wellness, such as gait and activity monitoring. In our previous research we introduced an insole based wearable system SmartStep, which is completely integrated in a socially acceptable package. From a manufacturing perspective, SmartStep's electronics had to be custom made for each shoe size, greatly complicating the manufacturing process. In this work we explore the possibility of making a universal electronics platform for SmartStep - SmartStep 3.0, which can be used in the most common insole sizes without modifications. A pilot human subject experiments were run to compare the accuracy between the one-size fits all (SmartStep 3.0) and custom size SmartStep 2.0. A total of ~10 hours of data was collected in the pilot study involving three participants performing different activities of daily living while wearing SmartStep 2.0 and SmartStep 3.0. Leave one out cross validation resulted in a 98.5% average accuracy from SmartStep 2.0, while SmartStep 3.0 resulted in 98.3% accuracy, suggesting that the SmartStep 3.0 can be as accurate as SmartStep 2.0, while fitting most common shoe sizes.

Monitoring of manufacturing processes in the automotive industry using indoor location system

NASA Astrophysics Data System (ADS)

Ionescu, LM; Belu, N.; Rachieru, N.; Mazăre, AG; Anghel, D.-C.

2016-08-01

This paper presents a method for locating the operators, equipment and parts using radio communications systems. Specifically there will be radio transceiver arranged in a network of active and passive radio receivers placed on personnel, equipment or parts. Based on a radio triangulation method, it is determined the location of the all resources and parts involved in manufacturing process. The transceivers communicate with each other via “routers” - also components of the network. Such a structure may extend over large distances even in indoor spaces where there are obstacles (walls between rooms). The location is done by determining the power of transmission signal for at least three end points. The receiver position is then transmitted over the network through routers, to a central server where all positions of the resources are centralized. Our solution is a non-invasive and low cost method for determining resource position in the factory. The system can be used for both resource planning production for current process more efficient and for further analysis of the movement of resources during previous processes with possible adjustments to the workspace and re-planning of resources for future processes.

Relationship between mozzarella yield and milk composition, processing factors, and recovery of whey constituents.

PubMed

Sales, D C; Rangel, A H N; Urbano, S A; Freitas, Alfredo R; Tonhati, Humberto; Novaes, L P; Pereira, M I B; Borba, L H F

2017-06-01

Our aim was to identify the relationship between mozzarella cheese yield and buffalo milk composition, processing factors, and recovery of whey constituents. A production of 30 batches of mozzarella cheese at a dairy industry in northeast Brazil (Rio Grande do Norte) was monitored between March and November 2015. Mozzarella yield and 32 other variables were observed for each batch, and divided into 3 groups: milk composition variables (12); variables involved in the cheesemaking process (14); and variables for recovery of whey constituents (6). Data were analyzed using descriptive statistics, Pearson correlation, and principal component analysis. Most of the correlations between milk composition variables and between the variables of the manufacturing processes were not significant. Significant correlations were mostly observed between variables for recovery of whey constituents. Yield only showed significant correlation with time elapsed between curd cuttings and age of the starter culture, and it showed greater association with age of the starter culture, time elapsed between curd cuttings, and during stretching, as well as with milk pH and density. Thus, processing factors and milk characteristics are closely related to dairy efficiency in mozzarella manufacturing. Copyright © 2017 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

In-Situ monitoring and modeling of metal additive manufacturing powder bed fusion

NASA Astrophysics Data System (ADS)

Alldredge, Jacob; Slotwinski, John; Storck, Steven; Kim, Sam; Goldberg, Arnold; Montalbano, Timothy

2018-04-01

One of the major challenges in metal additive manufacturing is developing in-situ sensing and feedback control capabilities to eliminate build errors and allow qualified part creation without the need for costly and destructive external testing. Previously, many groups have focused on high fidelity numerical modeling and true temperature thermal imaging systems. These approaches require large computational resources or costly hardware that requires complex calibration and are difficult to integrate into commercial systems. In addition, due to the rapid change in the state of the material as well as its surface properties, getting true temperature is complicated and difficult. Here, we describe a different approach where we implement a low cost thermal imaging solution allowing for relative temperature measurements sufficient for detecting unwanted process variability. We match this with a faster than real time qualitative model that allows the process to be rapidly modeled during the build. The hope is to combine these two, allowing for the detection of anomalies in real time, enabling corrective action to potentially be taken, or parts to be stopped immediately after the error, saving material and time. Here we describe our sensor setup, its costs and abilities. We also show the ability to detect in real time unwanted process deviations. We also show that the output of our high speed model agrees qualitatively with experimental results. These results lay the groundwork for our vision of an integrated feedback and control scheme that combines low cost, easy to use sensors and fast modeling for process deviation monitoring.

An evolutionary sensor approach for self-organizing production chains

NASA Astrophysics Data System (ADS)

Mocan, M.; Gillich, E. V.; Mituletu, I. C.; Korka, Z. I.

2018-01-01

Industry 4.0 is the actual great step in industrial progress. Convergence of industrial equipment with the power of advanced computing and analysis, low-cost sensing, and new connecting technologies are presumed to bring unexpected advancements in automation, flexibility, and efficiency. In this context, sensors ensure information regarding three essential areas: the number of processed elements, the quality of production and the condition of tools and equipment. To obtain this valuable information, the data resulted from a sensor has to be firstly processed and afterward used by the different stakeholders. If machines are linked together, this information can be employed to organize the production chain with few or without human intervention. We describe here the implementation of a sensor in a milling machine that is part of a simple production chain, capable of providing information regarding the number of manufactured pieces. It is used by the other machines in the production chain, in order to define the type and number of pieces to be manufactured by them and/or to set optimal parameters for their working regime. Secondly, the information achieved by monitoring the machine and manufactured piece dynamic behavior is used to evaluate the product quality. This information is used to warn about the need of maintenance, being transmitted to the specialized department. It is also transmitted to the central unit, in order to reorganize the production by involving other machines or by reconsidering the manufacturing regime of the existing machines. A special attention is drawn on analyzing and classifying the signals acquired via optical sensor from simulated processes.

Real-time process monitoring in a semi-continuous fluid-bed dryer - microwave resonance technology versus near-infrared spectroscopy.

PubMed

Peters, Johanna; Teske, Andreas; Taute, Wolfgang; Döscher, Claas; Höft, Michael; Knöchel, Reinhard; Breitkreutz, Jörg

2018-02-15

The trend towards continuous manufacturing in the pharmaceutical industry is associated with an increasing demand for advanced control strategies. It is a mandatory requirement to obtain reliable real-time information on critical quality attributes (CQA) during every process step as the decision on diversion of material needs to be performed fast and automatically. Where possible, production equipment should provide redundant systems for in-process control (IPC) measurements to ensure continuous process monitoring even if one of the systems is not available. In this paper, two methods for real-time monitoring of granule moisture in a semi-continuous fluid-bed drying unit are compared. While near-infrared (NIR) spectroscopy has already proven to be a suitable process analytical technology (PAT) tool for moisture measurements in fluid-bed applications, microwave resonance technology (MRT) showed difficulties to monitor moistures above 8% until recently. The results indicate, that the newly developed MRT sensor operating at four resonances is capable to compete with NIR spectroscopy. While NIR spectra were preprocessed by mean centering and first derivative before application of partial least squares (PLS) regression to build predictive models (RMSEP = 0.20%), microwave moisture values of two resonances sufficed to build a statistically close multiple linear regression (MLR) model (RMSEP = 0.07%) for moisture prediction. Thereby, it could be verified that moisture monitoring by MRT sensor systems could be a valuable alternative to NIR spectroscopy or could be used as a redundant system providing great ease of application. Copyright © 2017 Elsevier B.V. All rights reserved.

Analysis of cutting force signals by wavelet packet transform for surface roughness monitoring in CNC turning

NASA Astrophysics Data System (ADS)

García Plaza, E.; Núñez López, P. J.

2018-01-01

On-line monitoring of surface finish in machining processes has proven to be a substantial advancement over traditional post-process quality control techniques by reducing inspection times and costs and by avoiding the manufacture of defective products. This study applied techniques for processing cutting force signals based on the wavelet packet transform (WPT) method for the monitoring of surface finish in computer numerical control (CNC) turning operations. The behaviour of 40 mother wavelets was analysed using three techniques: global packet analysis (G-WPT), and the application of two packet reduction criteria: maximum energy (E-WPT) and maximum entropy (SE-WPT). The optimum signal decomposition level (Lj) was determined to eliminate noise and to obtain information correlated to surface finish. The results obtained with the G-WPT method provided an in-depth analysis of cutting force signals, and frequency ranges and signal characteristics were correlated to surface finish with excellent results in the accuracy and reliability of the predictive models. The radial and tangential cutting force components at low frequency provided most of the information for the monitoring of surface finish. The E-WPT and SE-WPT packet reduction criteria substantially reduced signal processing time, but at the expense of discarding packets with relevant information, which impoverished the results. The G-WPT method was observed to be an ideal procedure for processing cutting force signals applied to the real-time monitoring of surface finish, and was estimated to be highly accurate and reliable at a low analytical-computational cost.

Considerations for an institution for evaluation of diabetes technology devices to improve their quality in the European Union.

PubMed

Heinemann, Lutz; Freckmann, Guido; Koschinsky, Theodor

2013-03-01

All medical devices used for self-monitoring of blood glucose (BG), insulin injection, continuous subcutaneous insulin infusion, and continuous glucose monitoring in the European Union (EU) must have a Communauté Européenne (CE) mark. However, the approval process for obtaining this mark is different from that used by the European Medicines Agency in the EU for drugs or by the Food and Drug Administration in the United States for such medical and in vitro diagnostic devices. The notified bodies involved in the CE mark process perform this evaluation in cooperation with the manufacturers. They have only limited diabetes know-how; they have to handle all kinds of medical devices. There are devices for therapy on the market in the EU (i.e., they have market approval) that do not fulfill quality requirements, as indicated, for example, in the international norm ISO 15197 for BG test systems. Evaluation of the performance of such systems is usually provided by the manufacturers. What is missing in the EU is an independent institution that performs regular and critical evaluation of the quality of devices used for diabetes therapy before and also after their market approval. The work of such an institution would focus on BG test systems (these represent two-thirds of the market of medical devices for diabetes treatment) but would also evaluate the performance of other devices. It has to be clarified what legal framework is required for such an institution and how it can be financed; probably this can be done in a shared manner by the manufacturers of such devices and the health insurance companies. Positive evaluation results should be a prerequisite prior to any reimbursement for such devices. © 2013 Diabetes Technology Society.

Vapor Phase Hydrogen Peroxide Sanitization of an Isolator for Aseptic Filling of Monoclonal Antibody Drug Product - Hydrogen Peroxide Uptake and Impact on Protein Quality.

PubMed

Hubbard, Aaron; Reodl, Thomas; Hui, Ada; Knueppel, Stephanie; Eppler, Kirk; Lehnert, Siegfried; Maa, Yuh-Fun

2018-03-15

A monoclonal antibody drug product (DP) manufacturing process was transferred to a different production site, where aseptic filling took place within an isolator that was sanitized using vapor phase hydrogen peroxide (VPHP). A quality-by-design approach was applied for study design to understand the impact of VPHP uptake in the isolator on DP quality. A combination of small-scale and manufacturing-scale studies was performed to evaluate the sensitivity of the monoclonal antibody to hydrogen peroxide (H2O2) as well as VPHP uptake mechanisms during the filling process. The acceptable H2O2 level was determined to be 100 ng/mL for the antibody in the H2O2 spiking study; protein oxidation was observed above this threshold. The most prominent sources of VPHP uptake were identified to be via the silicone tubing assembly (associated with the peristaltic pumps) and open, filled vials. Silicone tubing, an effective depot to H2O2, could absorb VPHP during different stages of the filling process and discharge H2O2 into the DP solution during filling interruptions. A small-scale isolator model, established to simulate manufacturing-scale conditions, was a useful tool in understanding H2O2 uptake in relation to tubing dimensions and VPHP concentration in the isolator air (or atmosphere). Although the tubing assembly had absorbed a substantial amount of VPHP during the decontamination phase, the majority of H2O2 could be removed during tubing cleaning and sterilization in the subsequent isolator aeration phase, demonstrating that H2O2 in the DP solution is taken up primarily via atmospheric VPHP residues in the isolator during filling. Picarro sensor monitoring suggested that the validated VPHP aeration process generates reproducible residual VPHP profiles in isolator air, thus allowing small-scale studies to provide more relevant recommendations on tubing size and interruption time limits for commercial manufacturing. The recommended process parameters were demonstrated to be acceptable and rendered no product quality impact as demonstrated in six consecutive manufacturing batches in the process validation campaign. Overall, this case study would provide process development scientists/engineers an in-depth understanding of the VPHP process and a science-based approach to mitigating DP quality impact. Copyright © 2018, Parenteral Drug Association.

Manufacturing Methods and Technology Program Automatic In-Process Microcircuit Evaluation.

DTIC Science & Technology

1980-10-01

methods of controlling the AIME system are with the computer and associated inter- face (CPU control), and with controls located on the front panels...Sync and Blanking signals When the AIME system is being operated by the front panel controls , the computer does not influence the system operation. SU...the color video monitor display. The operator controls these parameters by 1) depressing the appropriate key on the keyboard, 2) observing on the

Linear Temporal Logic (LTL) Based Monitoring of Smart Manufacturing Systems.

PubMed

Heddy, Gerald; Huzaifa, Umer; Beling, Peter; Haimes, Yacov; Marvel, Jeremy; Weiss, Brian; LaViers, Amy

2015-01-01

The vision of Smart Manufacturing Systems (SMS) includes collaborative robots that can adapt to a range of scenarios. This vision requires a classification of multiple system behaviors, or sequences of movement, that can achieve the same high-level tasks. Likewise, this vision presents unique challenges regarding the management of environmental variables in concert with discrete, logic-based programming. Overcoming these challenges requires targeted performance and health monitoring of both the logical controller and the physical components of the robotic system. Prognostics and health management (PHM) defines a field of techniques and methods that enable condition-monitoring, diagnostics, and prognostics of physical elements, functional processes, overall systems, etc. PHM is warranted in this effort given that the controller is vulnerable to program changes, which propagate in unexpected ways, logical runtime exceptions, sensor failure, and even bit rot. The physical component's health is affected by the wear and tear experienced by machines constantly in motion. The controller's source of faults is inherently discrete, while the latter occurs in a manner that builds up continuously over time. Such a disconnect poses unique challenges for PHM. This paper presents a robotic monitoring system that captures and resolves this disconnect. This effort leverages supervisory robotic control and model checking with linear temporal logic (LTL), presenting them as a novel monitoring system for PHM. This methodology has been demonstrated in a MATLAB-based simulator for an industry inspired use-case in the context of PHM. Future work will use the methodology to develop adaptive, intelligent control strategies to evenly distribute wear on the joints of the robotic arms, maximizing the life of the system.

Superfund Record of Decision (EPA Region 7): Bee Cee Manufacturing Co., Malden, MO, September 30, 1997

DOE Office of Scientific and Technical Information (OSTI.GOV)

NONE

This decision document presents the remedial action selected to cleanup groundwater contaminant at the Bee Cee Manufacturing site in Malden, Missouri. The remedy selected to remediate contaminated groundwater at the Bee Cee Manufacturing site is natural attenuation, groundwater monitoring and institutional controls.

Additively Manufactured Pneumatically Driven Skin Electrodes.

PubMed

Schubert, Martin; Schmidt, Martin; Wolter, Paul; Malberg, Hagen; Zaunseder, Sebastian; Bock, Karlheinz

2017-12-23

Telemedicine focuses on improving the quality of health care, particularly in out-of-hospital settings. One of the most important applications is the continuous remote monitoring of vital parameters. Long-term monitoring of biopotentials requires skin-electrodes. State-of-the-art electrodes such as Ag/AgCl wet electrodes lead, especially during long-term application, to complications, e.g., skin irritations. This paper presents a low-cost, on-demand electrode approach for future long-term applications. The fully printed module comprises a polymeric substrate with electrodes on a flexible membrane, which establishes skin contact only for short time in case of measurement. The membranes that produce airtight seals for pressure chambers can be pneumatically dilated and pressed onto the skin to ensure good contact, and subsequently retracted. The dilatation depends on the pressure and membrane thickness, which has been tested up to 150 kPa. The electrodes were fabricated in screen and inkjet printing technology, and compared during exemplary electrodermal activity measurement (EDA). The results show less amplitude compared to conventional EDA electrodes but similar behavior. Because of the manufacturing process the module enables high individuality for future applications.

Using manufacturing message specification for monitor and control at Venus

NASA Technical Reports Server (NTRS)

Heuser, W. Randy; Chen, Richard L.; Stockett, Michael H.

1993-01-01

The flexibility and robustness of a monitor and control (M&C) system are a direct result of the underlying interprocessor communications architecture. A new architecture for M&C at the Deep Space Communications Complexes (DSCC's) has been developed based on the Manufacturing Message Specification (MMS) process control standard of the Open System Interconnection (OSI) suite of protocols. This architecture has been tested both in a laboratory environment and under operational conditions at the Deep Space Network (DSN) experimental Venus station (DSS-13). The Venus experience in the application of OSI standards to support M&C has been extremely successful. MMS meets the functional needs of the station and provides a level of flexibility and responsiveness previously unknown in that environment. The architecture is robust enough to meet current operational needs and flexible enough to provide a migration path for new subsystems. This paper will describe the architecture of the Venus M&C system, discuss how MMS was used and the requirements this imposed on other parts of the system, and provide results from systems and operational testing at the Venus site.

Multicenter Cell Processing for Cardiovascular Regenerative Medicine Applications - The Cardiovascular Cell Therapy Research Network (CCTRN) Experience

PubMed Central

Gee, Adrian P.; Richman, Sara; Durett, April; McKenna, David; Traverse, Jay; Henry, Timothy; Fisk, Diann; Pepine, Carl; Bloom, Jeannette; Willerson, James; Prater, Karen; Zhao, David; Koç, Jane Reese; Ellis, Steven; Taylor, Doris; Cogle, Christopher; Moyé, Lemuel; Simari, Robert; Skarlatos, Sonia

2013-01-01

Background Aims Multi-center cellular therapy clinical trials require the establishment and implementation of standardized cell processing protocols and associated quality control mechanisms. The aims here were to develop such an infrastructure in support of the Cardiovascular Cell Therapy Research Network (CCTRN) and to report on the results of processing for the first 60 patients. Methods Standardized cell preparations, consisting of autologous bone marrow mononuclear cells, prepared using the Sepax device were manufactured at each of the five processing facilities that supported the clinical treatment centers. Processing staff underwent centralized training that included proficiency evaluation. Quality was subsequently monitored by a central quality control program that included product evaluation by the CCTRN biorepositories. Results Data from the first 60 procedures demonstrate that uniform products, that met all release criteria, could be manufactured at all five sites within 7 hours of receipt of the bone marrow. Uniformity was facilitated by use of the automated systems (the Sepax for processing and the Endosafe device for endotoxin testing), standardized procedures and centralized quality control. Conclusions Complex multicenter cell therapy and regenerative medicine protocols can, where necessary, successfully utilize local processing facilities once an effective infrastructure is in place to provide training, and quality control. PMID:20524773

Process design and control of a twin screw hot melt extrusion for continuous pharmaceutical tamper-resistant tablet production.

PubMed

Baronsky-Probst, J; Möltgen, C-V; Kessler, W; Kessler, R W

2016-05-25

Hot melt extrusion (HME) is a well-known process within the plastic and food industries that has been utilized for the past several decades and is increasingly accepted by the pharmaceutical industry for continuous manufacturing. For tamper-resistant formulations of e.g. opioids, HME is the most efficient production technique. The focus of this study is thus to evaluate the manufacturability of the HME process for tamper-resistant formulations. Parameters such as the specific mechanical energy (SME), as well as the melt pressure and its standard deviation, are important and will be discussed in this study. In the first step, the existing process data are analyzed by means of multivariate data analysis. Key critical process parameters such as feed rate, screw speed, and the concentration of the API in the polymers are identified, and critical quality parameters of the tablet are defined. In the second step, a relationship between the critical material, product and process quality attributes are established by means of Design of Experiments (DoEs). The resulting SME and the temperature at the die are essential data points needed to indirectly qualify the degradation of the API, which should be minimal. NIR-spectroscopy is used to monitor the material during the extrusion process. In contrast to most applications in which the probe is directly integrated into the die, the optical sensor is integrated into the cooling line of the strands. This saves costs in the probe design and maintenance and increases the robustness of the chemometric models. Finally, a process measurement system is installed to monitor and control all of the critical attributes in real-time by means of first principles, DoE models, soft sensor models, and spectroscopic information. Overall, the process is very robust as long as the screw speed is kept low. Copyright © 2015 Elsevier B.V. All rights reserved.

Development of new structural health monitoring techniques

NASA Astrophysics Data System (ADS)

Fekrmandi, Hadi

During the past two decades, many researchers have developed methods for the detection of structural defects at the early stages to operate the aerospace vehicles safely and to reduce the operating costs. The Surface Response to Excitation (SuRE) method is one of these approaches developed at FIU to reduce the cost and size of the equipment. The SuRE method excites the surface at a series of frequencies and monitors the propagation characteristics of the generated waves. The amplitude of the waves reaching to any point on the surface varies with frequency; however, it remains consistent as long as the integrity and strain distribution on the part is consistent. These spectral characteristics change when cracks develop or the strain distribution changes. The SHM methods may be used for many applications, from the detection of loose screws to the monitoring of manufacturing operations. A scanning laser vibrometer was used in this study to investigate the characteristics of the spectral changes at different points on the parts. The study started with detecting a load on a plate and estimating its location. The modifications on the part with manufacturing operations were detected and the Part-Based Manufacturing Process Performance Monitoring (PbPPM) method was developed. Hardware was prepared to demonstrate the feasibility of the proposed methods in real time. Using low-cost piezoelectric elements and the non-contact scanning laser vibrometer successfully, the data was collected for the SuRE and PbPPM methods. Locational force, loose bolts and material loss could be easily detected by comparing the spectral characteristics of the arriving waves. On-line methods used fast computational methods for estimating the spectrum and detecting the changing operational conditions from sum of the squares of the variations. Neural networks classified the spectrums when the desktop -- DSP combination was used. The results demonstrated the feasibility of the SuRE and PbPPM methods.

Primary response of high-aspect-ratio thermoresistive sensors

NASA Astrophysics Data System (ADS)

Majlesein, H. R.; Mitchell, D. L.; Bhattacharya, Pradeep K.; Singh, A.; Anderson, James A.

1997-07-01

There is a growing need for sensors in monitoring performance in modern quality products such as in electronics to monitor heat build up, substrate delaminations, and thermal runaway. In processing instruments, intelligent sensors are needed to measure deposited layer thickness and resistivities for process control, and in environmental electrical enclosures, they are used for climate monitoring and control. A yaw sensor for skid prevention utilizes very fine moveable components, and an automobile engine controller blends a microprocessor and sensor on the same chip. An Active-Pixel Image Sensor is integrated with a digital readout circuit to perform most of the functions in a video camera. Magnetostrictive transducers sense and damp vibrations. Improved acoustic sensors will be used in flow detection of air and other fluids, even at subsonic speeds. Optoelectronic sensor systems are being developed for installation on rocket engines to monitor exhaust gases for signs of wear in the engines. With new freon-free coolants being available the problems of A/C system corrosion have gone up in automobiles and need to be monitored more frequently. Defense cutbacks compel the storage of hardware in safe-custody for an indeterminate period of time, and this makes monitoring more essential. Just-in-time customized manufacturing in modern industries also needs dramatic adjustment in productivity of various selected items, leaving some manufacturing equipment idle for a long time, and therefore, it will be prone to more corrosion, and corrosion sensors are needed. In the medical device industry, development of implantable medical devices using both potentiometric and amperometric determination of parameters has, until now, been used with insufficient micro miniaturization, and thus, requires surgical implantation. In many applications, high-aspect- ratio devices, made possible by the use of synchrotron radiation lithography, allow more useful devices to be produced. High-aspect-ratio sensors will permit industries and various other users to attain more accurate measurements of physical properties and chemical compositions in many systems. Considerable engineering research has recently been focused on this type of fabrication effect. This paper looks at a high-aspect-ratio sensor bus thermorestrictive device with increased aspect-ratio of the interconnects to the device, using unique simulation software resources.

A Self-Aware Machine Platform in Manufacturing Shop Floor Utilizing MTConnect Data

DTIC Science & Technology

2014-10-02

condition monitoring , and equipment time to failure prediction in manufacturing 1 ANNUAL CONFERENCE OF THE PROGNOSTICS AND HEALTH MANAGEMENT SOCIETY 2014 589...Component Level Health Monitoring and Prediction One of the characteristics of a self-aware machine is to be able to detect its components...the annual conference of the prognostics and health management society. Filzmoser, P., Garrett, R. G., & Reimann, C . (2005). Mul- tivariate outlier

Cyber Enabled Direct Digital Manufacturing

DTIC Science & Technology

2015-05-15

5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) The Pennsylvania State University Applied Research Labotatory Office of...MONITORING AGENCY NAME(S) AND ADDRESS(ES) Office of Naval Research 875 North Randolph Street Arlington, VA 22203-1995 10. SPONSOR/MONITOR’S ACRONYM(S...the Office of Naval Research "Cyber Enabled Direct Digital Manufacturing" program, award N00014-11-1-0668 are discussed. Achievements include the

Carbon doped PDMS: conductance stability over time and implications for additive manufacturing of stretchable electronics

NASA Astrophysics Data System (ADS)

Tavakoli, Mahmoud; Rocha, Rui; Osorio, Luis; Almeida, Miguel; de Almeida, Anibal; Ramachandran, Vivek; Tabatabai, Arya; Lu, Tong; Majidi, Carmel

2017-03-01

Carbon doped PDMS (cPDMS), has been used as a conductive polymer for stretchable electronics. Compared to liquid metals, cPDMS is low cost and is easier to process or to print with an additive manufacturing process. However, changes on the conductance of the carbon based conductive PDMS (cPDMS) were observed over time, in particular after integration of cPDMS and the insulating polymer. In this article we investigate the process parameters that lead to improved stability over conductance of the cPDMS over time. Slight modifications to the fabrication process parameters were conducted and changes on the conductance of the samples for each method were monitored. Results suggested that change of the conductance happens mostly after integration of a pre-polymer over a cured cPDMS, and not after integration of the cPDMS over a cured insulating polymer. We show that such changes can be eliminated by adjusting the integration priority between the conductive and insulating polymers, by selecting the right curing temperature, changing the concentration of the carbon particles and the thickness of the conductive traces, and when possible by changing the insulating polymer material. In this way, we obtained important conclusions regarding the effect of these parameters on the change of the conductance over time, that should be considered for additive manufacturing of soft electronics. Also, we show that these changes can be possibly due to the diffusion from PDMS into cPDMS.

Integrated hot-melt extrusion - injection molding continuous tablet manufacturing platform: Effects of critical process parameters and formulation attributes on product robustness and dimensional stability.

PubMed

Desai, Parind M; Hogan, Rachael C; Brancazio, David; Puri, Vibha; Jensen, Keith D; Chun, Jung-Hoon; Myerson, Allan S; Trout, Bernhardt L

2017-10-05

This study provides a framework for robust tablet development using an integrated hot-melt extrusion-injection molding (IM) continuous manufacturing platform. Griseofulvin, maltodextrin, xylitol and lactose were employed as drug, carrier, plasticizer and reinforcing agent respectively. A pre-blended drug-excipient mixture was fed from a loss-in-weight feeder to a twin-screw extruder. The extrudate was subsequently injected directly into the integrated IM unit and molded into tablets. Tablets were stored in different storage conditions up to 20 weeks to monitor physical stability and were evaluated by polarized light microscopy, DSC, SEM, XRD and dissolution analysis. Optimized injection pressure provided robust tablet formulations. Tablets manufactured at low and high injection pressures exhibited the flaws of sink marks and flashing respectively. Higher solidification temperature during IM process reduced the thermal induced residual stress and prevented chipping and cracking issues. Polarized light microscopy revealed a homogeneous dispersion of crystalline griseofulvin in an amorphous matrix. DSC underpinned the effect of high tablet residual moisture on maltodextrin-xylitol phase separation that resulted in dimensional instability. Tablets with low residual moisture demonstrated long term dimensional stability. This study serves as a model for IM tablet formulations for mechanistic understanding of critical process parameters and formulation attributes required for optimal product performance. Copyright © 2017 Elsevier B.V. All rights reserved.

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rebak, Raul B.; Lou, Xiaoyuan

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclearmore » industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.« less

Unattended reaction monitoring using an automated microfluidic sampler and on-line liquid chromatography.

PubMed

Patel, Darshan C; Lyu, Yaqi Fara; Gandarilla, Jorge; Doherty, Steve

2018-04-03

In-process sampling and analysis is an important aspect of monitoring kinetic profiles and impurity formation or rejection, both in development and during commercial manufacturing. In pharmaceutical process development, the technology of choice for a substantial portion of this analysis is high-performance liquid chromatography (HPLC). Traditionally, the sample extraction and preparation for reaction characterization have been performed manually. This can be time consuming, laborious, and impractical for long processes. Depending on the complexity of the sample preparation, there can be variability introduced by different analysts, and in some cases, the integrity of the sample can be compromised during handling. While there are commercial instruments available for on-line monitoring with HPLC, they lack capabilities in many key areas. Some do not provide integration of the sampling and analysis, while others afford limited flexibility in sample preparation. The current offerings provide a limited number of unit operations available for sample processing and no option for workflow customizability. This work describes development of a microfluidic automated program (MAP) which fully automates the sample extraction, manipulation, and on-line LC analysis. The flexible system is controlled using an intuitive Microsoft Excel based user interface. The autonomous system is capable of unattended reaction monitoring that allows flexible unit operations and workflow customization to enable complex operations and on-line sample preparation. The automated system is shown to offer advantages over manual approaches in key areas while providing consistent and reproducible in-process data. Copyright © 2017 Elsevier B.V. All rights reserved.

Importance of good manufacturing practices in microbiological monitoring in processing human tissues for transplant.

PubMed

Pianigiani, Elisa; Ierardi, Francesca; Fimiani, Michele

2013-12-01

Skin allografts represent an important therapeutic resource in the treatment of severe skin loss. The risk associated with application of processed tissues in humans is very low, however, human material always carries the risk of disease transmission. To minimise the risk of contamination of grafts, processing is carried out in clean rooms where air quality is monitored. Procedures and quality control tests are performed to standardise the production process and to guarantee the final product for human use. Since we only validate and distribute aseptic tissues, we conducted a study to determine what type of quality controls for skin processing are the most suitable for detecting processing errors and intercurrent contamination, and for faithfully mapping the process without unduly increasing production costs. Two different methods for quality control were statistically compared using the Fisher exact test. On the basis of the current study we selected our quality control procedure based on pre- and post-processing tissue controls, operator and environmental controls. Evaluation of the predictability of our control methods showed that tissue control was the most reliable method of revealing microbial contamination of grafts. We obtained 100 % sensitivity by doubling tissue controls, while maintaining high specificity (77 %).

Lightweight, Room-Temperature CO2 Gas Sensor Based on Rare-Earth Metal-Free Composites—An Impedance Study

PubMed Central

2017-01-01

We report a light, flexible, and low-power poly(ionic liquid)/alumina composite CO2 sensor. We monitor the direct-current resistance changes as a function of CO2 concentration and relative humidity and demonstrate fast and reversible sensing kinetics. Moreover, on the basis of the alternating-current impedance measurements we propose a sensing mechanism related to proton conduction and gas diffusion. The findings presented herein will promote the development of organic/inorganic composite CO2 gas sensors. In the future, such sensors will be useful for numerous practical applications ranging from indoor air quality control to the monitoring of manufacturing processes. PMID:28726384

Melt-Pool Temperature and Size Measurement During Direct Laser Sintering

DOE Office of Scientific and Technical Information (OSTI.GOV)

List, III, Frederick Alyious; Dinwiddie, Ralph Barton; Carver, Keith

2017-08-01

Additive manufacturing has demonstrated the ability to fabricate complex geometries and components not possible with conventional casting and machining. In many cases, industry has demonstrated the ability to fabricate complex geometries with improved efficiency and performance. However, qualification and certification of processes is challenging, leaving companies to focus on certification of material though design allowable based approaches. This significantly reduces the business case for additive manufacturing. Therefore, real time monitoring of the melt pool can be used to detect the development of flaws, such as porosity or un-sintered powder and aid in the certification process. Characteristics of the melt poolmore » in the Direct Laser Sintering (DLS) process is also of great interest to modelers who are developing simulation models needed to improve and perfect the DLS process. Such models could provide a means to rapidly develop the optimum processing parameters for new alloy powders and optimize processing parameters for specific part geometries. Stratonics’ ThermaViz system will be integrated with the Renishaw DLS system in order to demonstrate its ability to measure melt pool size, shape and temperature. These results will be compared with data from an existing IR camera to determine the best approach for the determination of these critical parameters.« less

Bivalent rLP2086 (Trumenba®): Development of a well-characterized vaccine through commercialization.

PubMed

Sunasara, Khurram; Cundy, John; Srinivasan, Sriram; Evans, Brad; Sun, Weiqiang; Cook, Scott; Bortell, Eric; Farley, John; Griffin, Daniel; Bailey Piatchek, Michele; Arch-Douglas, Katherine

2018-05-24

The phrase "Process is the Product" is often applied to biologics, including multicomponent vaccines composed of complex components that evade complete characterization. Vaccine production processes must be defined and locked early in the development cycle to ensure consistent quality of the vaccine throughout scale-up, clinical studies, and commercialization. This approach of front-loading the development work helped facilitate the accelerated approval of the Biologic License Application for the well-characterized vaccine bivalent rLP2086 (Trumenba®, Pfizer Inc) in 2014 under Breakthrough Therapy Designation. Bivalent rLP2086 contains two rLP2086 antigens and is licensed for the prevention of meningococcal meningitis disease caused by Neisseria meningitidis serogroup B in individuals 10-25years of age in the United States. This paper discusses the development of the manufacturing process of the two antigens for the purpose of making it amenable to any manufacturing facility. For the journey to commercialization, the operating model used to manage this highly accelerated program led to a framework that ensured "right the first time" execution, robust process characterization, and proactive process monitoring. This framework enabled quick problem identification and proactive resolutions, resulting in a robust control strategy for the commercial process. Copyright © 2017 Elsevier Ltd. All rights reserved.

A QRM Discussion of Microbial Contamination of Non-sterile Drug Products, Using FDA and EMA Warning Letters Recorded between 2008 and 2016.

PubMed

Santos, Ana M C; Doria, Mara S; Meirinhos-Soares, Luís; Almeida, António J; Menezes, José C

2018-01-01

Microbial quality control of non-sterile drug products has been a concern to regulatory agencies and the pharmaceutical industry since the 1960s. Despite being an old challenge to companies, microbial contamination still affects a high number of manufacturers of non-sterile products. Consequences go well beyond the obvious direct costs related to batch rejections or product recalls, as human lives and a company's reputation are significantly impacted if such events occur. To better manage risk and establish effective mitigation strategies, it is necessary to understand the microbial hazards involved in non-sterile drug products manufacturing, be able to evaluate their potential impact on final product quality, and apply mitigation actions. Herein we discuss the most likely root causes involved in microbial contaminations referenced in warning letters issued by US health authorities and non-compliance reports issued by European health authorities over a period of several years. The quality risk management tools proposed were applied to the data gathered from those databases, and a generic risk ranking was provided based on a panel of non-sterile drug product manufacturers that was assembled and given the opportunity to perform the risk assessments. That panel identified gaps and defined potential mitigation actions, based on their own experience of potential risks expected for their processes. Major findings clearly indicate that the manufacturers affected by the warning letters should focus their attention on process improvements and microbial control strategies, especially those related to microbial analysis and raw material quality control. Additionally, the WLs considered frequently referred to failures in quality-related issues, which indicates that the quality commitment should be reinforced at most companies to avoid microbiological contaminations. LAY ABSTRACT: Microbial contamination of drug products affects the quality of non-sterile drug products produced by numerous manufacturers, representing a major risk to patients. It is necessary to understand the microbial hazards involved in the manufacturing process and evaluate their impact on final product quality so that effective prevention strategies can be implemented. A risk-based classification of most likely root causes for microbial contamination found in the warning letters issued by the US Food and Drug Administration and the European Medicines Agency is proposed. To validate the likely root causes extracted from the warning letters, a subject matter expert panel made of several manufacturers was formed and consulted. A quality risk management approach to assess microbiological contamination of non-sterile drug products is proposed for the identification of microbial hazards involved in the manufacturing process. To enable ranking of microbial contamination risks, quality risk management metrics related to criticality and overall risk were applied. The results showed that manufacturers of non-sterile drug products should improve their microbial control strategy, with special attention to quality controls of raw materials, primary containers, and closures. Besides that, they should invest in a more robust quality system and culture. As a start, manufacturers may consider investigating their specific microbiological risks, adressing their sites' own microbial ecology, type of manufacturing processes, and dosage form characteristics, as these may lead to increased contamination risks. Authorities should allow and enforce innovative, more comprehensive, and more effective approaches to in-process contamination monitoring and controls. © PDA, Inc. 2018.

Amine control for DUV lithography: identifying hidden sources

NASA Astrophysics Data System (ADS)

Kishkovich, Oleg P.; Larson, Carl E.

2000-06-01

The impact of airborne basic molecular contamination (MB) on the performance of chemically amplified (CA) resist systems has been a long standing problem. Low ppb levels of MB may be sufficient for robust 0.25 micrometer lithography with today's advanced CA resist systems combined with adequate chemical air filtration. However, with minimum CD targets heading below 150 nm, the introduction of new resist chemistries for Next Generation Lithography, and the trend towards thinner resists, the impact of MB at low and sub-ppb levels again becomes a critical manufacturing issue. Maximizing process control at aggressive feature sizes requires that the level of MB be maintained below a certain limit, which depends on such parameters as the sensitivity of the CA resist, the type of production tools, product mix, and process characteristics. Three approaches have been identified to reduce the susceptibility of CA resists to MB: effective chemical air filtration, modifications to resist chemistry/processing and cleanroom protocols involving MB monitoring and removal of MB sources from the fab. The final MB concentration depends on the effectiveness of filtration resources and on the total pollution originating from different sources in and out of the cleanroom. There are many well-documented sources of MB. Among these are: ambient air; polluted exhaust from other manufacturing areas re-entering the cleanroom through make-up air handlers; manufacturing process chemicals containing volatile molecular bases; certain cleanroom construction materials, such as paint and ceiling tiles; and volatile, humidifier system boiler additives (corrosion inhibitors), such as morpholine, cyclohexylamine, and dimethylaminoethanol. However, there is also an indeterminate number of other 'hidden' pollution sources, which are neither obvious nor well-documented. None of these sources are new, but they had little impact on earlier semiconductor manufacturing processes because the contamination levels are low enough that they were tolerable. The purpose of this article is to investigate some of these frequently overlooked sources of basic molecular contamination and to thereby increase the reader's awareness of their potential risks.

Scientific and Technological Foundations for Scaling Production of Nanostructured Metals

NASA Astrophysics Data System (ADS)

Lowe, Terry C.; Davis, Casey F.; Rovira, Peter M.; Hayne, Mathew L.; Campbell, Gordon S.; Grzenia, Joel E.; Stock, Paige J.; Meagher, Rilee C.; Rack, Henry J.

2017-05-01

Severe Plastic Deformation (SPD) has been explored in a wide range of metals and alloys. However, there are only a few industrial scale implementations of SPD for commercial alloys. To demonstrate and evolve technology for producing ultrafine grain metals by SPD, a Nanostructured Metals Manufacturing Testbed (NMMT) has been established in Golden, Colorado. Machines for research scale and pilot scale Equal Channel Angular Pressing-Conform (ECAP-C) technology have been configured in the NMMT to systematically evaluate and evolve SPD processing and advance the foundational science and technology for manufacturing. We highlight the scientific and technological areas that are critical for scale up of continuous SPD of aluminum, copper, magnesium, titanium, and iron-based alloys. Key areas that we will address in this presentation include the need for comprehensive analysis of starting microstructures, data on operating deformation mechanisms, high pressure thermodynamics and phase transformation kinetics, tribological behaviors, temperature dependence of lubricant properties, adaptation of tolerances and shear intensity to match viscoplastic behaviors, real-time process monitoring, and mechanics of billet/tooling interactions.

Carded Tow Real-Time Color Assessment: A Spectral Camera-Based System.

PubMed

Furferi, Rocco; Governi, Lapo; Volpe, Yary; Carfagni, Monica

2016-08-31

One of the most important parameters to be controlled during the production of textile yarns obtained by mixing pre-colored fibers, is the color correspondence between the manufactured yarn and a given reference, usually provided by a designer or a customer. Obtaining yarns from raw pre-colored fibers is a complex manufacturing process entailing a number of steps such as laboratory sampling, color recipe corrections, blowing, carding and spinning. Carding process is the one devoted to transform a "fuzzy mass" of tufted fibers into a regular mass of untwisted fibers, named "tow". During this process, unfortunately, the correspondence between the color of the tow and the target one cannot be assured, thus leading to yarns whose color differs from the one used for reference. To solve this issue, the main aim of this work is to provide a system able to perform a spectral camera-based real-time measurement of a carded tow, to assess its color correspondence with a reference carded fabric and, at the same time, to monitor the overall quality of the tow during the carding process. Tested against a number of differently colored carded fabrics, the proposed system proved its effectiveness in reliably assessing color correspondence in real-time.

Drop-on-Demand System for Manufacturing of Melt-based Solid Oral Dosage: Effect of Critical Process Parameters on Product Quality.

PubMed

Içten, Elçin; Giridhar, Arun; Nagy, Zoltan K; Reklaitis, Gintaras V

2016-04-01

The features of a drop-on-demand-based system developed for the manufacture of melt-based pharmaceuticals have been previously reported. In this paper, a supervisory control system, which is designed to ensure reproducible production of high quality of melt-based solid oral dosages, is presented. This control system enables the production of individual dosage forms with the desired critical quality attributes: amount of active ingredient and drug morphology by monitoring and controlling critical process parameters, such as drop size and product and process temperatures. The effects of these process parameters on the final product quality are investigated, and the properties of the produced dosage forms characterized using various techniques, such as Raman spectroscopy, optical microscopy, and dissolution testing. A crystallization temperature control strategy, including controlled temperature cycles, is presented to tailor the crystallization behavior of drug deposits and to achieve consistent drug morphology. This control strategy can be used to achieve the desired bioavailability of the drug by mitigating variations in the dissolution profiles. The supervisor control strategy enables the application of the drop-on-demand system to the production of individualized dosage required for personalized drug regimens.

76 FR 9809 - Notice of a Federal Advisory Committee Meeting Manufactured Housing Consensus Committee

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-22

..., including regulations specifying the permissible scope and conduct of monitoring in accordance with... Manufactured Housing Program Office Review Log of Proposals Call for Committee Reports Proposals Subcommittees...

Optical Metrology for CIGS Solar Cell Manufacturing and its Cost Implications

NASA Astrophysics Data System (ADS)

Sunkoju, Sravan Kumar

Solar energy is a promising source of renewable energy which can meet the demand for clean energy in near future with advances in research in the field of photovoltaics and cost reduction by commercialization. Availability of a non-contact, in-line, real time robust process control strategies can greatly aid in reducing the gap between cell and module efficiencies, thereby leading to cost-effective large-scale manufacturing of high efficiency CIGS solar cells. In order to achieve proper process monitoring and control for the deposition of the functional layers of CuIn1-xGaxSe 2 (CIGS) based thin film solar cell, optical techniques such as spectroscopic reflectometry and polarimetry are advantageous because they can be set up in an unobtrusive manner in the manufacturing line, and collect data in-line and in-situ. The use of these techniques requires accurate optical models that correctly represent the properties of the layers being deposited. In this study, Spectroscopic ellipsometry (SE) has been applied for the characterization of each individual stage of CIGS layers deposited using the 3-stage co-evaporation process along with the other functional layers. Dielectric functions have been determined for the energy range from 0.7 eV to 5.1 eV. Critical-point line-shape analysis was used in this study to determine the critical point energies of the CIGS based layers. To control the compositional and thickness uniformity of all the functional layers during the fabrication of CIGS solar cells over large areas, multilayer photovoltaics (PV) stack optical models were developed with the help of extracted dielectric functions. In this study, mapping capability of RC2 spectroscopic ellipsometer was used to map all the functional layer thicknesses of a CIGS solar cell in order to probe the spatial non-uniformities that can affect the performance of a cell. The optical functions for each of the stages of CIGS 3-stage deposition process along with buffer layer and transparent conducting oxide (TCO) bi-layer, thus derived were used in a fiber optic-based spectroscopic reflectometry optical monitoring system installed in the pilot line at the PVMC's Halfmoon facility. Results obtained from this study show that the use of regular fiber optics, instead of polarization-maintaining fiber optics, is sufficient for the purpose of process monitoring. Also, the technique does not need to be used "in-situ", but the measurements can be taken in-line, and are applicable to a variety of deposition techniques used for different functional layers deposited on rigid or flexible substrates. In addition, effect of Cu concentration on the CIGS optical properties has been studied. Mixed CIGS/Cu2-xSe phase was observed at the surface at the end of the second stage of 3-stage deposition process, under Cu-rich conditions. A significant change in optical behavior of CIGS due to Cu2-xSe at the surface was observed under Cu-rich conditions, which can be used as end-point detection method to move from 2nd stage to 3rd stage in the deposition process. Developed optical functions were applied to in-line reflectance measurements not only to identify the Cu2-xSe phase at the surface but also to measure the thickness of the mixed CIGS/Cu2-xSe layer. This spectroscopic reflectometry based in-line process control technique can be used for end-point detection as well as to control thickness during the preparation of large area CIGS films. These results can assist in the development of optical process-control tools for the manufacturing of high quality CIGS based photovoltaic cells, increasing the uptime and yield of the production line. Finally, to understand the cost implications, low cost potential of two different deposition technologies has been studied on both rigid and flexible substrates with the help of cost analysis. Cost advantages of employing a contactless optics based process control technique have been investigated in order to achieve a low cost of < 0.5 $/W for CIGS module production. Based on cost analysis, one of the best strategies for achieving the low cost targets would be increasing manufacturing throughput, using roll-to-roll thin-film module manufacturing, with co-evaporation and chemical bath deposition processes for absorber and buffer layer respectively, while applying a low-cost process control technique such as spectroscopic reflectometry to improve module efficiencies and maintain high yield.

21 CFR 26.15 - Monitoring continued equivalence.

Code of Federal Regulations, 2014 CFR

2014-04-01

... COMMUNITY Specific Sector Provisions for Pharmaceutical Good Manufacturing Practices § 26.15 Monitoring continued equivalence. Monitoring activities for the purpose of maintaining equivalence shall include review... 21 Food and Drugs 1 2014-04-01 2014-04-01 false Monitoring continued equivalence. 26.15 Section 26...

24 CFR 3282.452 - Participation in monitoring.

Code of Federal Regulations, 2010 CFR

2010-04-01

.... Where a State wishes to carry out monitoring activities it shall do so in coordination with the... 24 Housing and Urban Development 5 2010-04-01 2010-04-01 false Participation in monitoring. 3282... HOUSING AND URBAN DEVELOPMENT MANUFACTURED HOME PROCEDURAL AND ENFORCEMENT REGULATIONS Monitoring of...

21 CFR 26.15 - Monitoring continued equivalence.

Code of Federal Regulations, 2013 CFR

2013-04-01

... COMMUNITY Specific Sector Provisions for Pharmaceutical Good Manufacturing Practices § 26.15 Monitoring continued equivalence. Monitoring activities for the purpose of maintaining equivalence shall include review... 21 Food and Drugs 1 2013-04-01 2013-04-01 false Monitoring continued equivalence. 26.15 Section 26...

24 CFR 3282.452 - Participation in monitoring.

Code of Federal Regulations, 2011 CFR

2011-04-01

.... Where a State wishes to carry out monitoring activities it shall do so in coordination with the... 24 Housing and Urban Development 5 2011-04-01 2011-04-01 false Participation in monitoring. 3282... HOUSING AND URBAN DEVELOPMENT MANUFACTURED HOME PROCEDURAL AND ENFORCEMENT REGULATIONS Monitoring of...

24 CFR 3282.452 - Participation in monitoring.

Code of Federal Regulations, 2013 CFR

2013-04-01

.... Where a State wishes to carry out monitoring activities it shall do so in coordination with the... 24 Housing and Urban Development 5 2013-04-01 2013-04-01 false Participation in monitoring. 3282... HOUSING AND URBAN DEVELOPMENT MANUFACTURED HOME PROCEDURAL AND ENFORCEMENT REGULATIONS Monitoring of...

24 CFR 3282.452 - Participation in monitoring.

Code of Federal Regulations, 2014 CFR

2014-04-01

.... Where a State wishes to carry out monitoring activities it shall do so in coordination with the... 24 Housing and Urban Development 5 2014-04-01 2014-04-01 false Participation in monitoring. 3282... HOUSING AND URBAN DEVELOPMENT MANUFACTURED HOME PROCEDURAL AND ENFORCEMENT REGULATIONS Monitoring of...

24 CFR 3282.452 - Participation in monitoring.

Code of Federal Regulations, 2012 CFR

2012-04-01

.... Where a State wishes to carry out monitoring activities it shall do so in coordination with the... 24 Housing and Urban Development 5 2012-04-01 2012-04-01 false Participation in monitoring. 3282... HOUSING AND URBAN DEVELOPMENT MANUFACTURED HOME PROCEDURAL AND ENFORCEMENT REGULATIONS Monitoring of...

21 CFR 26.15 - Monitoring continued equivalence.

Code of Federal Regulations, 2012 CFR

2012-04-01

... COMMUNITY Specific Sector Provisions for Pharmaceutical Good Manufacturing Practices § 26.15 Monitoring continued equivalence. Monitoring activities for the purpose of maintaining equivalence shall include review... 21 Food and Drugs 1 2012-04-01 2012-04-01 false Monitoring continued equivalence. 26.15 Section 26...

40 CFR 63.751 - Monitoring requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

...) National Emission Standards for Aerospace Manufacturing and Rework Facilities § 63.751 Monitoring... specific monitoring procedures; (ii) Set the operating parameter value, or range of values, that... monitoring data. (1) The data may be recorded in reduced or nonreduced form (e.g., parts per million (ppm...

40 CFR 63.751 - Monitoring requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

...) National Emission Standards for Aerospace Manufacturing and Rework Facilities § 63.751 Monitoring... specific monitoring procedures; (ii) Set the operating parameter value, or range of values, that... monitoring data. (1) The data may be recorded in reduced or nonreduced form (e.g., parts per million (ppm...

40 CFR 63.751 - Monitoring requirements.

Code of Federal Regulations, 2014 CFR

2014-07-01

...) National Emission Standards for Aerospace Manufacturing and Rework Facilities § 63.751 Monitoring... specific monitoring procedures; (ii) Set the operating parameter value, or range of values, that... monitoring data. (1) The data may be recorded in reduced or nonreduced form (e.g., parts per million (ppm...

40 CFR 63.751 - Monitoring requirements.

Code of Federal Regulations, 2012 CFR

2012-07-01

...) National Emission Standards for Aerospace Manufacturing and Rework Facilities § 63.751 Monitoring... specific monitoring procedures; (ii) Set the operating parameter value, or range of values, that... monitoring data. (1) The data may be recorded in reduced or nonreduced form (e.g., parts per million (ppm...

40 CFR 63.751 - Monitoring requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

...) National Emission Standards for Aerospace Manufacturing and Rework Facilities § 63.751 Monitoring... specific monitoring procedures; (ii) Set the operating parameter value, or range of values, that... monitoring data. (1) The data may be recorded in reduced or nonreduced form (e.g., parts per million (ppm...

Auditing radiation sterilization facilities

NASA Astrophysics Data System (ADS)

Beck, Jeffrey A.

The diversity of radiation sterilization systems available today places renewed emphasis on the need for thorough Quality Assurance audits of these facilities. Evaluating compliance with Good Manufacturing Practices is an obvious requirement, but an effective audit must also evaluate installation and performance qualification programs (validation_, and process control and monitoring procedures in detail. The present paper describes general standards that radiation sterilization operations should meet in each of these key areas, and provides basic guidance for conducting QA audits of these facilities.

Computer-aided design of polymers and composites

NASA Technical Reports Server (NTRS)

Kaelble, D. H.

1985-01-01

This book on computer-aided design of polymers and composites introduces and discusses the subject from the viewpoint of atomic and molecular models. Thus, the origins of stiffness, strength, extensibility, and fracture toughness in composite materials can be analyzed directly in terms of chemical composition and molecular structure. Aspects of polymer composite reliability are considered along with characterization techniques for composite reliability, relations between atomic and molecular properties, computer aided design and manufacture, polymer CAD/CAM models, and composite CAD/CAM models. Attention is given to multiphase structural adhesives, fibrous composite reliability, metal joint reliability, polymer physical states and transitions, chemical quality assurance, processability testing, cure monitoring and management, nondestructive evaluation (NDE), surface NDE, elementary properties, ionic-covalent bonding, molecular analysis, acid-base interactions, the manufacturing science, and peel mechanics.

Innovative applications of artificial intelligence

NASA Astrophysics Data System (ADS)

Schorr, Herbert; Rappaport, Alain

Papers concerning applications of artificial intelligence are presented, covering applications in aerospace technology, banking and finance, biotechnology, emergency services, law, media planning, music, the military, operations management, personnel management, retail packaging, and manufacturing assembly and design. Specific topics include Space Shuttle telemetry monitoring, an intelligent training system for Space Shuttle flight controllers, an expert system for the diagnostics of manufacturing equipment, a logistics management system, a cooling systems design assistant, and a knowledge-based integrated circuit design critic. Additional topics include a hydraulic circuit design assistant, the use of a connector assembly specification expert system to harness detailed assembly process knowledge, a mixed initiative approach to airlift planning, naval battle management decision aids, an inventory simulation tool, a peptide synthesis expert system, and a system for planning the discharging and loading of container ships.

Design and manufacture of super-multilayer optical filters based on PARMS technology

NASA Astrophysics Data System (ADS)

Lü, Shaobo; Wang, Ruisheng; Ma, Jing; Jiang, Chao; Mu, Jiali; Zhao, Shuaifeng; Yin, Xiaojun

2018-04-01

Three multilayer interference optical filters, including a UV band-pass, a VIS dual-band-pass and a notch filter, were designed by using Ta2O5, Nb2O5, Al2O3 and SiO2 as high- and low-index materials. During the design of the coating process, a hybrid optical monitoring and RATE-controlled layer thickness control scheme was adopted. The coating process was simulated by using the optical monitoring system (OMS) Simulator, and the simulation result indicated that the layer thickness can be controlled within an error of less than ±0.1%. The three filters were manufactured on a plasma-assisted reactive magnetic sputtering (PARMS) coating machine. The measurements indicate that for the UV band-pass filter, the peak transmittance is higher than 95% and the blocking density is better than OD6 in the 300-1100 nm region, whereas for the dual-band-pass filter, the center wavelength positioning accuracy of the two passbands are less than ±2 nm, the peak transmittance is higher than 95% and blocking density is better than OD6 in the 300-950 nm region. Finally, for the notch filter, the minimum transmittance rates are >90% and >94% in the visible and near infrared, respectively, and the blocking density is better than OD5.5 at 808 nm.

15 CFR 400.33 - Restrictions on manufacturing and processing activity.

Code of Federal Regulations, 2010 CFR

2010-01-01

...-TRADE ZONES BOARD Manufacturing and Processing Activity-Reviews § 400.33 Restrictions on manufacturing and processing activity. (a) In general. In approving manufacturing or processing activity for a zone... 15 Commerce and Foreign Trade 2 2010-01-01 2010-01-01 false Restrictions on manufacturing and...

21 CFR 1005.25 - Service of process on manufacturers.

Code of Federal Regulations, 2010 CFR

2010-04-01

... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Service of process on manufacturers. 1005.25....25 Service of process on manufacturers. (a) Every manufacturer of electronic products, prior to... United States as the manufacturer's agent upon whom service of all processes, notices, orders, decisions...

Monitoring the quality of welding based on welding current and ste analysis

NASA Astrophysics Data System (ADS)

Mazlan, Afidatusshimah; Daniyal, Hamdan; Izzani Mohamed, Amir; Ishak, Mahadzir; Hadi, Amran Abdul

2017-10-01

Qualities of welding play an important part in industry especially in manufacturing field. Post-welding non-destructive test is one of the importance process to ensure the quality of welding but it is time consuming and costly. To reduce the chance of defects, online monitoring had been utilized by continuously sense some of welding parameters and predict welding quality. One of the parameters is welding current, which is rich of information but lack of study focus on extract them at signal analysis level. This paper presents the analysis of welding current using Short Time Energy (STE) signal processing to quantify the pattern of the current. GMAW set with carbon steel specimens are used in this experimental study with high-bandwidth and high sampling rate oscilloscope capturing the welding current. The results indicate welding current as signatures have high correlation with the welding process. Continue with STE analysis, the value below 5000 is declare as good welding, meanwhile the STE value more than 6000 is contained defect.

On-line monitoring of fluid bed granulation by photometric imaging.

PubMed

Soppela, Ira; Antikainen, Osmo; Sandler, Niklas; Yliruusi, Jouko

2014-11-01

This paper introduces and discusses a photometric surface imaging approach for on-line monitoring of fluid bed granulation. Five granule batches consisting of paracetamol and varying amounts of lactose and microcrystalline cellulose were manufactured with an instrumented fluid bed granulator. Photometric images and NIR spectra were continuously captured on-line and particle size information was extracted from them. Also key process parameters were recorded. The images provided direct real-time information on the growth, attrition and packing behaviour of the batches. Moreover, decreasing image brightness in the drying phase was found to indicate granule drying. The changes observed in the image data were also linked to the moisture and temperature profiles of the processes. Combined with complementary process analytical tools, photometric imaging opens up possibilities for improved real-time evaluation fluid bed granulation. Furthermore, images can give valuable insight into the behaviour of excipients or formulations during product development. Copyright © 2014 Elsevier B.V. All rights reserved.

Study of an ultrasound-based process analytical tool for homogenization of nanoparticulate pharmaceutical vehicles.

PubMed

Cavegn, Martin; Douglas, Ryan; Akkermans, Guy; Kuentz, Martin

2011-08-01

There are currently no adequate process analyzers for nanoparticulate viscosity enhancers. This article aims to evaluate ultrasonic resonator technology as a monitoring tool for homogenization of nanoparticulate gels. Aqueous dispersions of colloidal microcrystalline cellulose (MCC) and a mixture of clay particles with xanthan gum were compared with colloidal silicon dioxide in oil. The processing was conducted using a laboratory-scale homogenizing vessel. The study investigated first the homogenization kinetics of the different systems to focus then on process factors in the case of colloidal MCC. Moreover, rheological properties were analyzed offline to assess the structure of the resulting gels. Results showed the suitability of ultrasound velocimetry to monitor the homogenization process. The obtained data were fitted using a novel heuristic model. It was possible to identify characteristic homogenization times for each formulation. The subsequent study of the process factors demonstrated that ultrasonic process analysis was equally sensitive as offline rheological measurements in detecting subtle manufacturing changes. It can be concluded that the ultrasonic method was able to successfully assess homogenization of nanoparticulate viscosity enhancers. This novel technique can become a vital tool for development and production of pharmaceutical suspensions in the future. Copyright © 2011 Wiley-Liss, Inc.

On the monitoring and implications of growing damages caused by manufacturing defects in composite structures

NASA Astrophysics Data System (ADS)

Schagerl, M.; Viechtbauer, C.; Hörrmann, S.

2015-07-01

Damage tolerance is a classical safety concept for the design of aircraft structures. Basically, this approach considers possible damages in the structure, predicts the damage growth under applied loading conditions and predicts the following decrease of the structural strength. As a fundamental result the damage tolerance approach yields the maximum inspection interval, which is the time a damage grows from a detectable to a critical level. The above formulation of the damage tolerance safety concept targets on metallic structures where the damage is typically a simple fatigue crack. Fiber-reinforced polymers show a much more complex damage behavior, such as delaminationsin laminated composites. Moreover, progressive damage in composites is often initiated by manufacturing defects. The complex manufacturing processes for composite structures almost certainly yield parts with defects, e.g. pores in the matrix or undulations of fibers. From such defects growing damages may start after a certain time of operation. The demand to simplify or even avoid the inspection of composite structures has therefore led to a comeback of the traditional safe-life safety concept. The aim of the so-called safe-life flaw tolerance concept is a structure that is capable of carrying the static loads during operation, despite significant damages and after a representative fatigue load spectrum. A structure with this property does not need to be inspected, respectively monitored at all during its service life. However, its load carrying capability is thereby not fully utilized. This article presents the possible refinement of the state-of-the-art safe-life flaw tolerance concept for composite structures towards a damage tolerance approach considering also the influence of manufacturing defects on damage initiation and growth. Based on fundamental physical relations and experimental observations the challenges when developing damage growth and residual strength curves are discussed.

A quality by design study applied to an industrial pharmaceutical fluid bed granulation.

PubMed

Lourenço, Vera; Lochmann, Dirk; Reich, Gabriele; Menezes, José C; Herdling, Thorsten; Schewitz, Jens

2012-06-01

The pharmaceutical industry is encouraged within Quality by Design (QbD) to apply science-based manufacturing principles to assure quality not only of new but also of existing processes. This paper presents how QbD principles can be applied to an existing industrial pharmaceutical fluid bed granulation (FBG) process. A three-step approach is presented as follows: (1) implementation of Process Analytical Technology (PAT) monitoring tools at the industrial scale process, combined with multivariate data analysis (MVDA) of process and PAT data to increase the process knowledge; (2) execution of scaled-down designed experiments at a pilot scale, with adequate PAT monitoring tools, to investigate the process response to intended changes in Critical Process Parameters (CPPs); and finally (3) the definition of a process Design Space (DS) linking CPPs to Critical to Quality Attributes (CQAs), within which product quality is ensured by design, and after scale-up enabling its use at the industrial process scale. The proposed approach was developed for an existing industrial process. Through enhanced process knowledge established a significant reduction in product CQAs, variability already within quality specifications ranges was achieved by a better choice of CPPs values. The results of such step-wise development and implementation are described. Copyright © 2012 Elsevier B.V. All rights reserved.

A Simple Approach for Monitoring Business Service Time Variation

PubMed Central

2014-01-01

Control charts are effective tools for signal detection in both manufacturing processes and service processes. Much of the data in service industries comes from processes having nonnormal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, are not appropriately used here. In this paper, we propose a new asymmetric EWMA variance chart (EWMA-AV chart) and an asymmetric EWMA mean chart (EWMA-AM chart) based on two simple statistics to monitor process variance and mean shifts simultaneously. Further, we explore the sampling properties of the new monitoring statistics and calculate the average run lengths when using both the EWMA-AV chart and the EWMA-AM chart. The performance of the EWMA-AV and EWMA-AM charts and that of some existing variance and mean charts are compared. A numerical example involving nonnormal service times from the service system of a bank branch in Taiwan is used to illustrate the applications of the EWMA-AV and EWMA-AM charts and to compare them with the existing variance (or standard deviation) and mean charts. The proposed EWMA-AV chart and EWMA-AM charts show superior detection performance compared to the existing variance and mean charts. The EWMA-AV chart and EWMA-AM chart are thus recommended. PMID:24895647

A simple approach for monitoring business service time variation.

PubMed

Yang, Su-Fen; Arnold, Barry C

2014-01-01

Control charts are effective tools for signal detection in both manufacturing processes and service processes. Much of the data in service industries comes from processes having nonnormal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, are not appropriately used here. In this paper, we propose a new asymmetric EWMA variance chart (EWMA-AV chart) and an asymmetric EWMA mean chart (EWMA-AM chart) based on two simple statistics to monitor process variance and mean shifts simultaneously. Further, we explore the sampling properties of the new monitoring statistics and calculate the average run lengths when using both the EWMA-AV chart and the EWMA-AM chart. The performance of the EWMA-AV and EWMA-AM charts and that of some existing variance and mean charts are compared. A numerical example involving nonnormal service times from the service system of a bank branch in Taiwan is used to illustrate the applications of the EWMA-AV and EWMA-AM charts and to compare them with the existing variance (or standard deviation) and mean charts. The proposed EWMA-AV chart and EWMA-AM charts show superior detection performance compared to the existing variance and mean charts. The EWMA-AV chart and EWMA-AM chart are thus recommended.

Quality management of manufacturing process based on manufacturing execution system

NASA Astrophysics Data System (ADS)

Zhang, Jian; Jiang, Yang; Jiang, Weizhuo

2017-04-01

Quality control elements in manufacturing process are elaborated. And the approach of quality management of manufacturing process based on manufacturing execution system (MES) is discussed. The functions of MES for a microcircuit production line are introduced conclusively.

Estimation of tool wear during CNC milling using neural network-based sensor fusion

NASA Astrophysics Data System (ADS)

Ghosh, N.; Ravi, Y. B.; Patra, A.; Mukhopadhyay, S.; Paul, S.; Mohanty, A. R.; Chattopadhyay, A. B.

2007-01-01

Cutting tool wear degrades the product quality in manufacturing processes. Monitoring tool wear value online is therefore needed to prevent degradation in machining quality. Unfortunately there is no direct way of measuring the tool wear online. Therefore one has to adopt an indirect method wherein the tool wear is estimated from several sensors measuring related process variables. In this work, a neural network-based sensor fusion model has been developed for tool condition monitoring (TCM). Features extracted from a number of machining zone signals, namely cutting forces, spindle vibration, spindle current, and sound pressure level have been fused to estimate the average flank wear of the main cutting edge. Novel strategies such as, signal level segmentation for temporal registration, feature space filtering, outlier removal, and estimation space filtering have been proposed. The proposed approach has been validated by both laboratory and industrial implementations.

A Three-Step Resolution-Reconfigurable Hazardous Multi-Gas Sensor Interface for Wireless Air-Quality Monitoring Applications.

PubMed

Choi, Subin; Park, Kyeonghwan; Lee, Seungwook; Lim, Yeongjin; Oh, Byungjoo; Chae, Hee Young; Park, Chan Sam; Shin, Heugjoo; Kim, Jae Joon

2018-03-02

This paper presents a resolution-reconfigurable wide-range resistive sensor readout interface for wireless multi-gas monitoring applications that displays results on a smartphone. Three types of sensing resolutions were selected to minimize processing power consumption, and a dual-mode front-end structure was proposed to support the detection of a variety of hazardous gases with wide range of characteristic resistance. The readout integrated circuit (ROIC) was fabricated in a 0.18 μm CMOS process to provide three reconfigurable data conversions that correspond to a low-power resistance-to-digital converter (RDC), a 12-bit successive approximation register (SAR) analog-to-digital converter (ADC), and a 16-bit delta-sigma modulator. For functional feasibility, a wireless sensor system prototype that included in-house microelectromechanical (MEMS) sensing devices and commercial device products was manufactured and experimentally verified to detect a variety of hazardous gases.

Qualification of a Quantitative Method for Monitoring Aspartate Isomerization of a Monoclonal Antibody by Focused Peptide Mapping.

PubMed

Cao, Mingyan; Mo, Wenjun David; Shannon, Anthony; Wei, Ziping; Washabaugh, Michael; Cash, Patricia

Aspartate (Asp) isomerization is a common post-translational modification of recombinant therapeutic proteins that can occur during manufacturing, storage, or administration. Asp isomerization in the complementarity-determining regions of a monoclonal antibody may affect the target binding and thus a sufficiently robust quality control method for routine monitoring is desirable. In this work, we utilized a liquid chromatography-mass spectrometry (LC/MS)-based approach to identify the Asp isomerization in the complementarity-determining regions of a therapeutic monoclonal antibody. To quantitate the site-specific Asp isomerization of the monoclonal antibody, a UV detection-based quantitation assay utilizing the same LC platform was developed. The assay was qualified and implemented for routine monitoring of this product-specific modification. Compared with existing methods, this analytical paradigm is applicable to identify Asp isomerization (or other modifications) and subsequently develop a rapid, sufficiently robust quality control method for routine site-specific monitoring and quantitation to ensure product quality. This approach first identifies and locates a product-related impurity (a critical quality attribute) caused by isomerization, deamidation, oxidation, or other post-translational modifications, and then utilizes synthetic peptides and MS to assist the development of a LC-UV-based chromatographic method that separates and quantifies the product-related impurities by UV peaks. The established LC-UV method has acceptable peak specificity, precision, linearity, and accuracy; it can be validated and used in a good manufacturing practice environment for lot release and stability testing. Aspartate isomerization is a common post-translational modification of recombinant proteins during manufacture process and storage. Isomerization in the complementarity-determining regions (CDRs) of a monoclonal antibody A (mAb-A) has been detected and has been shown to have impact on the binding affinity to the antigen. In this work, we utilized a mass spectrometry-based peptide mapping approach to detect and quantitate the Asp isomerization in the CDRs of mAb-A. To routinely monitor the CDR isomerization of mAb-A, a focused peptide mapping method utilizing reversed phase chromatographic separation and UV detection has been developed and qualified. This approach is generally applicable to monitor isomerization and other post-translational modifications of proteins in a specific and high-throughput mode to ensure product quality. © PDA, Inc. 2016.

Redox Liquid Phase Exfoliation of Layered Transition Metal Dichalcogenides (Postprint)

DTIC Science & Technology

2016-12-29

RESEARCH LABORATORY MATERIALS AND MANUFACTURING DIRECTORATE WRIGHT-PATTERSON AIR FORCE BASE, OH 45433-7750 AIR FORCE MATERIEL COMMAND UNITED...ADDRESS(ES) 10. SPONSORING/MONITORING AGENCY ACRONYM(S) Air Force Research Laboratory Materials and Manufacturing Directorate Wright...Bultman, Adam Waite, Ming-Siao Hsiao, Richard A. Vaia* Materials and Manufacturing Directorate, Air Force Research Laboratory, Wright-Patterson AFB, Ohio

An Overview of Cloud Implementation in the Manufacturing Process Life Cycle

NASA Astrophysics Data System (ADS)

Kassim, Noordiana; Yusof, Yusri; Hakim Mohamad, Mahmod Abd; Omar, Abdul Halim; Roslan, Rosfuzah; Aryanie Bahrudin, Ida; Ali, Mohd Hatta Mohamed

2017-08-01

The advancement of information and communication technology (ICT) has changed the structure and functions of various sectors and it has also started to play a significant role in modern manufacturing in terms of computerized machining and cloud manufacturing. It is important for industries to keep up with the current trend of ICT for them to be able survive and be competitive. Cloud manufacturing is an approach that wanted to realize a real-world manufacturing processes that will apply the basic concept from the field of Cloud computing to the manufacturing domain called Cloud-based manufacturing (CBM) or cloud manufacturing (CM). Cloud manufacturing has been recognized as a new paradigm for manufacturing businesses. In cloud manufacturing, manufacturing companies need to support flexible and scalable business processes in the shop floor as well as the software itself. This paper provides an insight or overview on the implementation of cloud manufacturing in the modern manufacturing processes and at the same times analyses the requirements needed regarding process enactment for Cloud manufacturing and at the same time proposing a STEP-NC concept that can function as a tool to support the cloud manufacturing concept.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simpson, L.

ITN Energy Systems, Inc., and Global Solar Energy, Inc., with the assistance of NREL's PV Manufacturing R&D program, have continued the advancement of CIGS production technology through the development of trajectory-oriented predictive/control models, fault-tolerance control, control-platform development, in-situ sensors, and process improvements. Modeling activities to date include the development of physics-based and empirical models for CIGS and sputter-deposition processing, implementation of model-based control, and application of predictive models to the construction of new evaporation sources and for control. Model-based control is enabled through implementation of reduced or empirical models into a control platform. Reliability improvement activities include implementation of preventivemore » maintenance schedules; detection of failed sensors/equipment and reconfiguration to continue processing; and systematic development of fault prevention and reconfiguration strategies for the full range of CIGS PV production deposition processes. In-situ sensor development activities have resulted in improved control and indicated the potential for enhanced process status monitoring and control of the deposition processes. Substantial process improvements have been made, including significant improvement in CIGS uniformity, thickness control, efficiency, yield, and throughput. In large measure, these gains have been driven by process optimization, which, in turn, have been enabled by control and reliability improvements due to this PV Manufacturing R&D program. This has resulted in substantial improvements of flexible CIGS PV module performance and efficiency.« less

Three-dimensional printing (3DP) of neonatal head phantom for ultrasound: thermocouple embedding and simulation of bone.

PubMed

Gatto, Matteo; Memoli, Gianluca; Shaw, Adam; Sadhoo, Neelaksh; Gelat, Pierre; Harris, Russell A

2012-09-01

A neonatal head phantom, comprising of an ellipsoidal geometry and including a circular aperture for simulating the fontanel was designed and fabricated, in order to allow an objective assessment of thermal rise in tissues during trans-cranial ultrasonic scanning of pre-term neonates. The precise position of a series of thermocouples was determined on the basis of finite-element analysis, which identified crucial target points for the thermal monitoring within the phantom geometry. Three-Dimensional Printing (3DP) was employed for the manufacture of the skull phantom, which was subsequently filled with dedicated brain-mimic material. A novel 3DP material combination was found to be able to mimic the acoustic properties of neonatal skull bone. Similarly, variations of a standard recipe for tissue mimic were examined, until one was found to mimic the brain of an infant. A specific strategy was successfully pursued to embed a thermocouple within the 3DP skull phantom during the manufacturing process. An in-process machine vision system was used to assess the correct position of the deposited thermocouple inside the fabricated skull phantom. An external silicone-made skin-like covering completed the phantom and was manufactured through a Direct Rapid Tooling (DRT) technique. Copyright © 2011 IPEM. Published by Elsevier Ltd. All rights reserved.

SAMIS- STANDARD ASSEMBLY-LINE MANUFACTURING INDUSTRY SIMULATION

NASA Technical Reports Server (NTRS)

Chamberlain, R. G.

1994-01-01

The Standard Assembly-Line Manufacturing Industry Simulation (SAMIS) program was originally developed to model a hypothetical U. S. industry which manufactures silicon solar modules for use in electricity generation. The SAMIS program has now been generalized to the extent that it should be useful for simulating many different production-line manufacturing industries and companies. The most important capability of SAMIS is its ability to "simulate" an industry based on a model developed by the user with the aid of the SAMIS program. The results of the simulation are a set of financial reports which detail the requirements, including quantities and cost, of the companies and processes which comprise the industry. SAMIS provides a fair, consistent, and reliable means of comparing manufacturing processes being developed by numerous independent efforts. It can also be used to assess the industry-wide impact of changes in financial parameters, such as cost of resources and services, inflation rates, interest rates, tax policies, and required return on equity. Because of the large amount of data needed to describe an industry, a major portion of SAMIS is dedicated to data entry and maintenance. This activity in SAMIS is referred to as model management. Model management requires a significant amount of interaction through a system of "prompts" which make it possible for persons not familiar with computers, or the SAMIS program, to provide all of the data necessary to perform a simulation. SAMIS is written in TURBO PASCAL (version 2.0 required for compilation) and requires 10 meg of hard disk space, an 8087 coprocessor, and an IBM color graphics monitor. Executables and source code are provided. SAMIS was originally developed in 1978; the IBM PC version was developed in 1985. Release 6.1 was made available in 1986, and includes the PC-IPEG program.

Linear Temporal Logic (LTL) Based Monitoring of Smart Manufacturing Systems

PubMed Central

Heddy, Gerald; Huzaifa, Umer; Beling, Peter; Haimes, Yacov; Marvel, Jeremy; Weiss, Brian; LaViers, Amy

2017-01-01

The vision of Smart Manufacturing Systems (SMS) includes collaborative robots that can adapt to a range of scenarios. This vision requires a classification of multiple system behaviors, or sequences of movement, that can achieve the same high-level tasks. Likewise, this vision presents unique challenges regarding the management of environmental variables in concert with discrete, logic-based programming. Overcoming these challenges requires targeted performance and health monitoring of both the logical controller and the physical components of the robotic system. Prognostics and health management (PHM) defines a field of techniques and methods that enable condition-monitoring, diagnostics, and prognostics of physical elements, functional processes, overall systems, etc. PHM is warranted in this effort given that the controller is vulnerable to program changes, which propagate in unexpected ways, logical runtime exceptions, sensor failure, and even bit rot. The physical component’s health is affected by the wear and tear experienced by machines constantly in motion. The controller’s source of faults is inherently discrete, while the latter occurs in a manner that builds up continuously over time. Such a disconnect poses unique challenges for PHM. This paper presents a robotic monitoring system that captures and resolves this disconnect. This effort leverages supervisory robotic control and model checking with linear temporal logic (LTL), presenting them as a novel monitoring system for PHM. This methodology has been demonstrated in a MATLAB-based simulator for an industry inspired use-case in the context of PHM. Future work will use the methodology to develop adaptive, intelligent control strategies to evenly distribute wear on the joints of the robotic arms, maximizing the life of the system. PMID:28730154

Autonomous cloud based site monitoring through hydro geophysical data assimilation, processing and result delivery

NASA Astrophysics Data System (ADS)

Versteeg, R.; Johnson, D. V.; Rodzianko, A.; Zhou, H.; Dafflon, B.; Leger, E.; de Kleine, M.

2017-12-01

Understanding of processes in the shallow subsurface requires that geophysical, biogeochemical, hydrological and remote sensing datasets are assimilated, processed and interpreted. Multiple enabling software capabilities for process understanding have been developed by the science community. These include information models (ODM2), reactive transport modeling (PFLOTRAN, Modflow, CLM, Landlab), geophysical inversion (E4D, BERT), parameter estimation (PEST, DAKOTA), visualization (ViSiT, Paraview, D3, QGIS) as well as numerous tools written in python and R for petrophysical mapping, stochastic modeling, data analysis and so on. These capabilities use data collected using sensors and analytical tools developed by multiple manufacturers which produce many different measurements. While scientists obviously leverage tools, capabilities and lessons learned from one site at other sites, the current approach to site characterization and monitoring is very labor intensive and does not scale well. Our objective is to be able to monitor many (hundreds - thousands) of sites. This requires that monitoring can be done in a near time, affordable, auditable and essentially autonomous manner. For this we have developed a modular vertically integrated cloud based software framework which was designed from the ground up for effective site and process monitoring. This software framework (PAF - Predictive Assimilation Framework) is multitenant software and provides automation of data ingestion, processing and visualization of hydrological, geochemical and geophysical (ERT/DTS) data. The core organizational element of PAF is a project/user one in which capabilities available to users are controlled by a combination of available data and access permissions. All PAF capabilities are exposed through APIs, making it easy to quickly add new components. PAF is fully integrated with newly developed autonomous electrical geophysical hardware and thus allows for automation of electrical geophysical ingestion and processing and the ability for co analysis and visualization of the raw and processed data with other data of interest (e.g. soil temperature, soil moisture, precipitation). We will demonstrate current PAF capabilities and discuss future efforts.

40 CFR 723.175 - Chemical substances used in or for the manufacture or processing of instant photographic and peel...

Code of Federal Regulations, 2010 CFR

2010-07-01

... manufacture and processing in the special production area. All manufacturing, processing, and use operations... shape or design during manufacture, (ii) which has end use function(s) dependent in whole or in part... production area, the ambient air concentration of the new chemical substance during manufacture, processing...

Integrated Dynamic Process Planning and Scheduling in Flexible Manufacturing Systems via Autonomous Agents

NASA Astrophysics Data System (ADS)

Nejad, Hossein Tehrani Nik; Sugimura, Nobuhiro; Iwamura, Koji; Tanimizu, Yoshitaka

Process planning and scheduling are important manufacturing planning activities which deal with resource utilization and time span of manufacturing operations. The process plans and the schedules generated in the planning phase shall be modified in the execution phase due to the disturbances in the manufacturing systems. This paper deals with a multi-agent architecture of an integrated and dynamic system for process planning and scheduling for multi jobs. A negotiation protocol is discussed, in this paper, to generate the process plans and the schedules of the manufacturing resources and the individual jobs, dynamically and incrementally, based on the alternative manufacturing processes. The alternative manufacturing processes are presented by the process plan networks discussed in the previous paper, and the suitable process plans and schedules are searched and generated to cope with both the dynamic status and the disturbances of the manufacturing systems. We initiatively combine the heuristic search algorithms of the process plan networks with the negotiation protocols, in order to generate suitable process plans and schedules in the dynamic manufacturing environment. A simulation software has been developed to carry out case studies, aimed at verifying the performance of the proposed multi-agent architecture.

40 CFR 98.94 - Monitoring and QA/QC requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 40 Protection of Environment 21 2011-07-01 2011-07-01 false Monitoring and QA/QC requirements. 98... (CONTINUED) MANDATORY GREENHOUSE GAS REPORTING Electronics Manufacturing § 98.94 Monitoring and QA/QC requirements. (a) For calendar year 2011 monitoring, you may follow the provisions in paragraphs (a)(1) through...

40 CFR 98.94 - Monitoring and QA/QC requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 40 Protection of Environment 22 2013-07-01 2013-07-01 false Monitoring and QA/QC requirements. 98... (CONTINUED) MANDATORY GREENHOUSE GAS REPORTING Electronics Manufacturing § 98.94 Monitoring and QA/QC requirements. (a) For calendar year 2011 monitoring, you may follow the provisions in paragraphs (a)(1) through...

40 CFR 98.94 - Monitoring and QA/QC requirements.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 40 Protection of Environment 22 2012-07-01 2012-07-01 false Monitoring and QA/QC requirements. 98... (CONTINUED) MANDATORY GREENHOUSE GAS REPORTING Electronics Manufacturing § 98.94 Monitoring and QA/QC requirements. (a) For calendar year 2011 monitoring, you may follow the provisions in paragraphs (a)(1) through...

A processing centre for the CNES CE-GPS experimentation

NASA Technical Reports Server (NTRS)

Suard, Norbert; Durand, Jean-Claude

1994-01-01

CNES is involved in a GPS (Global Positioning System) geostationary overlay experimentation. The purpose of this experimentation is to test various new techniques in order to select the optimal station synchronization method, as well as the geostationary spacecraft orbitography method. These new techniques are needed to develop the Ranging GPS Integrity Channel services. The CNES experimentation includes three transmitting/receiving ground stations (manufactured by IN-SNEC), one INMARSAT 2 C/L band transponder and a processing center named STE (Station de Traitements de l'Experimentation). Not all the techniques to be tested are implemented, but the experimental system has to include several functions; part of the future system simulation functions, such as a servo-loop function, and in particular a data collection function providing for rapid monitoring of system operation, analysis of existing ground station processes, and several weeks of data coverage for other scientific studies. This paper discusses system architecture and some criteria used in its design, as well as the monitoring function, the approach used to develop a low-cost and short-life processing center in collaboration with a CNES sub-contractor (ATTDATAID), and some results.

Plant observation report and evaluation, Pennwalt Corporation, secondary and tertiary aliphatic monoamines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1980-08-27

A site visit was made to the amine manufacturing facility of the Pennwalt Corporation, Wyandotte, Michigan, to evaluate the facility in regard to the Secondary and Tertiary Aliphatic Monoamines Criteria Document. A total of 21 people were directly in contact with the amine production process. Two to four of the maintenance personnel may also come in contact with the process. Maintenance workers ran the risk of exposure not only to primary, secondary and tertiary amine compounds, but also to several other chemicals being used in the process. The processes used to unload raw materials are described, along with reactor operations,more » decanter and recycling operations, distillation operations, product storage and shipping. Medical monitoring at the facility included chest x-ray, respiratory function tests, sight screening, urinalysis, and back x-rays. Restricted and potentially hazardous area signs were clearly posted. Employees wore hard hats and safety glasses on the job as well as gloves, rubber boots, face shields, goggles, and respirators as necessary. Emergency procedures are described, including fire protection. Sanitation and personal hygiene are discussed, along with monitoring of the workplace conditions.« less

Fiber-optically sensorized composite wing

NASA Astrophysics Data System (ADS)

Costa, Joannes M.; Black, Richard J.; Moslehi, Behzad; Oblea, Levy; Patel, Rona; Sotoudeh, Vahid; Abouzeida, Essam; Quinones, Vladimir; Gowayed, Yasser; Soobramaney, Paul; Flowers, George

2014-04-01

Electromagnetic interference (EMI) immune and light-weight, fiber-optic sensor based Structural Health Monitoring (SHM) will find increasing application in aerospace structures ranging from aircraft wings to jet engine vanes. Intelligent Fiber Optic Systems Corporation (IFOS) has been developing multi-functional fiber Bragg grating (FBG) sensor systems including parallel processing FBG interrogators combined with advanced signal processing for SHM, structural state sensing and load monitoring applications. This paper reports work with Auburn University on embedding and testing FBG sensor arrays in a quarter scale model of a T38 composite wing. The wing was designed and manufactured using fabric reinforced polymer matrix composites. FBG sensors were embedded under the top layer of the composite. Their positions were chosen based on strain maps determined by finite element analysis. Static and dynamic testing confirmed expected response from the FBGs. The demonstrated technology has the potential to be further developed into an autonomous onboard system to perform load monitoring, SHM and Non-Destructive Evaluation (NDE) of composite aerospace structures (wings and rotorcraft blades). This platform technology could also be applied to flight testing of morphing and aero-elastic control surfaces.

Continuous Ultrasonic Inspection of Extruded Wood-Plastic Composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tucker, Brian J.; Bender, Donald A.

Nondestructive evaluation (NDE) techniques are needed for in-line monitoring of wood-plastic composite (WPC) quality during manufacturing for process control. Through-transmission ultrasonic inspection is useful in characterizing stiffness and detecting cracks and voids in a range of materials; however, little is documented about ultrasound propagation in WPC materials. The objectives of this research were to determine applicable ultrasonic transducer frequencies, coupling methods, configurations and placements for wave speed monitoring and web defect detection within an extrusion process; to quantify the effects of temperature on ultrasonic parameters; and to develop a prototype ultrasonic inspection system for a full-size extrusion line. An angledmore » beam, water-coupled ultrasonic inspection system using a pair of 50-kHz narrowband transducers was adequate for monitoring wave speed parallel to the extrusion direction. For locating internal web defects, water-coupled, 500-kHz broadband ultrasonic transducers were used in a through-thickness transmission setup. Temperature compensation factors were developed to adjust ultrasonic wave speed measurements. The prototype inspection system was demonstrated in a 55 mm conical twin-screw extrusion line.« less

Modelling and control for laser based welding processes: modern methods of process control to improve quality of laser-based joining methods

NASA Astrophysics Data System (ADS)

Zäh, Ralf-Kilian; Mosbach, Benedikt; Hollwich, Jan; Faupel, Benedikt

2017-02-01

To ensure the competitiveness of manufacturing companies it is indispensable to optimize their manufacturing processes. Slight variations of process parameters and machine settings have only marginally effects on the product quality. Therefore, the largest possible editing window is required. Such parameters are, for example, the movement of the laser beam across the component for the laser keyhole welding. That`s why it is necessary to keep the formation of welding seams within specified limits. Therefore, the quality of laser welding processes is ensured, by using post-process methods, like ultrasonic inspection, or special in-process methods. These in-process systems only achieve a simple evaluation which shows whether the weld seam is acceptable or not. Furthermore, in-process systems use no feedback for changing the control variables such as speed of the laser or adjustment of laser power. In this paper the research group presents current results of the research field of Online Monitoring, Online Controlling and Model predictive controlling in laser welding processes to increase the product quality. To record the characteristics of the welding process, tested online methods are used during the process. Based on the measurement data, a state space model is ascertained, which includes all the control variables of the system. Depending on simulation tools the model predictive controller (MPC) is designed for the model and integrated into an NI-Real-Time-System.

Industrial hygiene walk-through survey report of E. I. Dupont de Nemours and Company, Inc. , Chocolate Bayou Plant, Alvin, Texas

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fajen, J.M.

1985-05-01

A walkthrough survey of EI duPont deNemours and Company, Incorporated, Alvin, Texas was conducted in November, 1984. The purpose of the survey was to obtain information on the 1,3-butadiene monomer manufacturing process and the potential for exposure. The facility manufactured a crude product stream containing 1,3-butadiene as a coproduct of its ethylene process. The crude was refined to a 99.5% 1,3-butadiene product. The refining process occurred in a closed system, tightly maintained for economic, fire, and health-hazard reasons. The product was transferred by way of a pipeline to storage spheres for later transport off site. The facility used an open-loopmore » cylinder (bomb) technique for quality control sampling. All pumps were equipped with single mechanical seals, which were in the process of being replaced by tandem seals. Since 1962, the facility had experienced process changes and three changes of ownership. Because of these changes, records from previous owners of industrial hygiene monitoring were not available. Job titles identified as having potential exposure were processors, wage employee supervisors, production engineers, and laboratory technicians. The author concludes that a closed-loop manual quality-control sampling system should be installed to reduce exposure from this source.« less

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

NASA Astrophysics Data System (ADS)

Kumbhar, N. N.; Mulay, A. V.

2016-08-01

The Additive Manufacturing (AM) processes open the possibility to go directly from Computer-Aided Design (CAD) to a physical prototype. These prototypes are used as test models before it is finalized as well as sometimes as a final product. Additive Manufacturing has many advantages over the traditional process used to develop a product such as allowing early customer involvement in product development, complex shape generation and also save time as well as money. Additive manufacturing also possess some special challenges that are usually worth overcoming such as Poor Surface quality, Physical Properties and use of specific raw material for manufacturing. To improve the surface quality several attempts had been made by controlling various process parameters of Additive manufacturing and also applying different post processing techniques on components manufactured by Additive manufacturing. The main objective of this work is to document an extensive literature review in the general area of post processing techniques which are used in Additive manufacturing.

ENVIRONMENTAL TECHNOLOGY VERIFICATION REPORT ANR PIPELINE COMPANY PARAMETRIC EMISSIONS MONITORING SYSTEM (PEMS)

EPA Science Inventory

The Environmental Technology Verification report discusses the technology and performance of a gaseous-emissions monitoring system for large, natural-gas-fired internal combustion engines. The device tested is the Parametric Emissions Monitoring System (PEMS) manufactured by ANR ...

Energy index decomposition methodology at the plant level

NASA Astrophysics Data System (ADS)

Kumphai, Wisit

Scope and method of study. The dissertation explores the use of a high level energy intensity index as a facility-level energy performance monitoring indicator with a goal of developing a methodology for an economically based energy performance monitoring system that incorporates production information. The performance measure closely monitors energy usage, production quantity, and product mix and determines the production efficiency as a part of an ongoing process that would enable facility managers to keep track of and, in the future, be able to predict when to perform a recommissioning process. The study focuses on the use of the index decomposition methodology and explored several high level (industry, sector, and country levels) energy utilization indexes, namely, Additive Log Mean Divisia, Multiplicative Log Mean Divisia, and Additive Refined Laspeyres. One level of index decomposition is performed. The indexes are decomposed into Intensity and Product mix effects. These indexes are tested on a flow shop brick manufacturing plant model in three different climates in the United States. The indexes obtained are analyzed by fitting an ARIMA model and testing for dependency between the two decomposed indexes. Findings and conclusions. The results concluded that the Additive Refined Laspeyres index decomposition methodology is suitable to use on a flow shop, non air conditioned production environment as an energy performance monitoring indicator. It is likely that this research can be further expanded in to predicting when to perform a recommissioning process.

Field deployable processing methods for stay-in-place ultrasonic transducers

NASA Astrophysics Data System (ADS)

Malarich, Nathan; Lissenden, Cliff J.; Tittmann, Bernhard R.

2018-04-01

Condition monitoring provides key data for managing the operation and maintenance of mechanical equipment in the power generation, chemical processing, and manufacturing industries. Ultrasonic transducers provide active monitoring capabilities by wall thickness measurements, elastic property determination, crack detection, and other means. In many cases the components operate in harsh environments that may include high temperature, radiation, and hazardous chemicals. Thus, it is desirable to have permanently affixed ultrasonic transducers for condition monitoring in harsh environments. Spray-on transducers provide direct coupling between the active element and the substrate, and can be applied to curved surfaces. We describe a deposition methodology for ultrasonic transducers that can be applied in the field. First, piezoceramic powders mixed into a sol-gel are air-spray deposited onto the substrate. Powder constituents are selected based on the service environment in which the condition monitoring will be performed. Then the deposited coating is pyrolyzed and partially densified using an induction heating system with a custom work coil designed to match the substrate geometry. The next step, applying the electrodes, is more challenging than might be expected because of the porosity of the piezoelectric coating and the potential reactivity of elements in the adjacent layers. After connecting lead wires to the electrodes the transducer is poled and a protective coating can be applied prior to use. Processing of a PZT-bismuth titanate transducer on a large steel substrate is described along with alternate methods.

A Machine Vision Quality Control System for Industrial Acrylic Fibre Production

NASA Astrophysics Data System (ADS)

Heleno, Paulo; Davies, Roger; Correia, Bento A. Brázio; Dinis, João

2002-12-01

This paper describes the implementation of INFIBRA, a machine vision system used in the quality control of acrylic fibre production. The system was developed by INETI under a contract with a leading industrial manufacturer of acrylic fibres. It monitors several parameters of the acrylic production process. This paper presents, after a brief overview of the system, a detailed description of the machine vision algorithms developed to perform the inspection tasks unique to this system. Some of the results of online operation are also presented.

Development and validation of chromatographic methods (HPLC and GC) for the determination of the active components (benzocaine, tyrothricin and menthol) of a pharmaceutical preparation.

PubMed

Ortiz-Boyer, F; Tena, M T; Luque de Castro, M D; Valcárcel, M

1995-10-01

Methods are reported for the determination of tyrothricin and benzocaine by HPLC and menthol by GC in the analysis of throat lozenges (tablets) containing all three compounds. After optimization of the variables involved in both HPLC and GC the methods have been characterized and validated according to the guidelines of the Spanish Pharmacopoeia, and applied to both the monitoring of the manufacturing process and the quality control of the final product.

Collection, Measurement and Treatment of Microorganism Using Dielectrophoretic Micro Devices

NASA Astrophysics Data System (ADS)

Uchida, Satoshi

Constant monitoring of manufacturing processes has been essential in food industry because of global expansion of microbial infection. Micro-scale dielectrophoretic method is an attractive technique for direct operation and quantitative detection of bioparticles. The electrical system is capable of rapid and simple treatments corresponding to severe legal control for food safety. In this paper, newly developed techniques are reviewed for bacterial concentration, detection and sterilization using dielectrophoresis in a micro reactor. The perspective to an integrated micro device of those components is also discussed.

Manufacturing Methods for Process Effects on Aluminum Casting Allowables

DTIC Science & Technology

1985-03-01

silicon ingot (25% Si) 4 . Copper as copper shot 5. Manganese as aluminum manganese ingot (10% Mn) 6 . Titanium and boron as titanium -boron wire 7. Silver...in stock form 4 . Silver in granule form. 5. Manganese (10 percent) in button form 6 . 201 refining salt ( Titanium -Boron) Melt chemistry is adjusted to...FAFB, OH 45433 4 . PERFORIN41N ORGANIZATION REPORT NUMBER(S) 5. MONITORING ORGANIZATION REPORT NUMSER(S) NOR 85-119 AFWAL-TR-.84- 4 117 I 6 *. NAME OF

Using a Hierarchical Approach to Model Regional Source Sink Dynamics for Neotropical Nearctic Songbirds to Inform Management Practices on Department of Defense Installations

DTIC Science & Technology

2017-03-20

comparison with the more intensive demographic study . We found support for spatial variation in productivity at both location and station scales. At location...the larger intensive demographic monitoring study , we also fit a productivity model that included a covariate calculated for the 12 stations included...Reference herein to any specific commercial product , process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily

Intelligent Advanced Communications IP Telephony Feasibility for the U.S. Navy. Volume 1

DTIC Science & Technology

2007-10-01

Monitors Control and Bearer Designed by the There are no bearing Circuitry Health through Non - manufacture of the circuits to be testing in Selectable... controlled process, only replacing non -tactical end devices at first and then replacing tactical when the sailors and the commanding officers build up...looked at as an alternative to the touch screen in a non -software research . A complete review of development of voice is larger then this test bed can

Statistical Methods for Quality Control of Steel Coils Manufacturing Process using Generalized Linear Models

NASA Astrophysics Data System (ADS)

García-Díaz, J. Carlos

2009-11-01

Fault detection and diagnosis is an important problem in process engineering. Process equipments are subject to malfunctions during operation. Galvanized steel is a value added product, furnishing effective performance by combining the corrosion resistance of zinc with the strength and formability of steel. Fault detection and diagnosis is an important problem in continuous hot dip galvanizing and the increasingly stringent quality requirements in automotive industry has also demanded ongoing efforts in process control to make the process more robust. When faults occur, they change the relationship among these observed variables. This work compares different statistical regression models proposed in the literature for estimating the quality of galvanized steel coils on the basis of short time histories. Data for 26 batches were available. Five variables were selected for monitoring the process: the steel strip velocity, four bath temperatures and bath level. The entire data consisting of 48 galvanized steel coils was divided into sets. The first training data set was 25 conforming coils and the second data set was 23 nonconforming coils. Logistic regression is a modeling tool in which the dependent variable is categorical. In most applications, the dependent variable is binary. The results show that the logistic generalized linear models do provide good estimates of quality coils and can be useful for quality control in manufacturing process.

Advanced optical manufacturing digital integrated system

NASA Astrophysics Data System (ADS)

Tao, Yizheng; Li, Xinglan; Li, Wei; Tang, Dingyong

2012-10-01

It is necessarily to adapt development of advanced optical manufacturing technology with modern science technology development. To solved these problems which low of ration, ratio of finished product, repetition, consistent in big size and high precision in advanced optical component manufacturing. Applied business driven and method of Rational Unified Process, this paper has researched advanced optical manufacturing process flow, requirement of Advanced Optical Manufacturing integrated System, and put forward architecture and key technology of it. Designed Optical component core and Manufacturing process driven of Advanced Optical Manufacturing Digital Integrated System. the result displayed effective well, realized dynamic planning Manufacturing process, information integration improved ratio of production manufactory.

The microbiome as engineering tool: Manufacturing and trading between microorganisms.

PubMed

De Vrieze, Jo; Christiaens, Marlies E R; Verstraete, Willy

2017-10-25

The integration of microbial technologies within the framework of the water-energy nexus has been taking place for over a century, but these mixed microbial communities are considered hard to deal with 'black boxes'. Process steering is mainly based on avoiding process failure by monitoring conventional parameters, e.g., pH and temperature, which often leads to operation far below the intrinsic potential. Mixed microbial communities do not reflect a randomised individual mix, but an interacting microbiological entity. Advance monitoring to obtain effective engineering of the microbiome is achievable, and even crucial to obtain the desired performance and products. This can be achieved via a top-down or bottom-up approach. The top-down strategy is reflected in the microbial resource management concept that considers the microbial community as a well-structured network. This network can be monitored by means of molecular techniques that will allow the development of accurate and quick decision tools. In contrast, the bottom-up approach makes use of synthetic cultures that can be composed starting from defined axenic cultures, based on the requirements of the process under consideration. The success of both approaches depends on real-time monitoring and control. Of particular importance is the necessity to identify and characterise the key players in the process. These key players not only relate with the establishment of functional conversions, but also with the interaction between partner bacteria. This emphasises the importance of molecular (screening) techniques to obtain structural and functional insights, minimise energy input, and maximise product output by means of integrated microbiome processes. Copyright © 2017 Elsevier B.V. All rights reserved.

Evidence based vaccinology.

PubMed

Nalin, David R

2002-02-22

Evidence based vaccinology (EBV) is the identification and use of the best evidence in making and implementing decisions during all of the stages of the life of a vaccine, including pre-licensure vaccine development and post-licensure manufacture and research, and utilization of the vaccine for disease control. Vaccines, unlike most pharmaceuticals, are in a continuous process of development both before and after licensure. Changes in biologics manufacturing technology and changes that vaccines induce in population and disease biology lead to periodic review of regimens (and sometimes dosage) based on changing immunologic data or public perceptions relevant to vaccine safety and effectiveness. EBV includes the use of evidence based medicine (EBM) both in clinical trials and in national disease containment programs. The rationale for EBV is that the highest evidentiary standards are required to maintain a rigorous scientific basis of vaccine quality control in manufacture and to ensure valid determination of vaccine efficacy, field effectiveness and safety profiles (including post-licensure safety monitoring), cost-benefit analyses, and risk:benefit ratios. EBV is increasingly based on statistically validated, clearly defined laboratory, manufacturing, clinical and epidemiological research methods and procedures, codified as good laboratory practices (GLP), good manufacturing practices (GMP), good clinical research practices (GCRP) and in clinical and public health practice (good vaccination practices, GVP). Implementation demands many data-driven decisions made by a spectrum of specialists pre- and post-licensure, and is essential to maintaining public confidence in vaccines.

Manufacturing Process Selection of Composite Bicycle’s Crank Arm using Analytical Hierarchy Process (AHP)

NASA Astrophysics Data System (ADS)

Luqman, M.; Rosli, M. U.; Khor, C. Y.; Zambree, Shayfull; Jahidi, H.

2018-03-01

Crank arm is one of the important parts in a bicycle that is an expensive product due to the high cost of material and production process. This research is aimed to investigate the potential type of manufacturing process to fabricate composite bicycle crank arm and to describe an approach based on analytical hierarchy process (AHP) that assists decision makers or manufacturing engineers in determining the most suitable process to be employed in manufacturing of composite bicycle crank arm at the early stage of the product development process to reduce the production cost. There are four types of processes were considered, namely resin transfer molding (RTM), compression molding (CM), vacuum bag molding and filament winding (FW). The analysis ranks these four types of process for its suitability in the manufacturing of bicycle crank arm based on five main selection factors and 10 sub factors. Determining the right manufacturing process was performed based on AHP process steps. Consistency test was performed to make sure the judgements are consistent during the comparison. The results indicated that the compression molding was the most appropriate manufacturing process because it has the highest value (33.6%) among the other manufacturing processes.

Post-marketing surveillance and vigilance for medical devices: the European approach.

PubMed

Randall, H

2001-01-01

The extent to which the medical device manufacturers are responsible for actively monitoring the performance of their products after they have successfully passed the rigorous pre-market approval process has always been a matter of diverse opinion. Within Europe, the law is unhelpfully vague on this point. While there are some comparatively clear obligations for reporting incidents to the authorities (known as the 'vigilance system'), little detail is given on how diligently the manufacturer should try to find out about such incidents. In the early stages of the European Community Directives covering medical devices, there was much emphasis upon formulating guidance to help interpret the vigilance reporting requirements. It is, however, only recently that attention has turned to attempting to clarify what is expected from post-marketing surveillance (PMS) in its broader sense. This article discuses both the vigilance and PMS processes and outlines the currently available European, and particularly UK, guidance documents which are aimed at promoting a more level playing field across industry where these activities are concerned. In particular, it explains the principle differences between vigilance and post-marketing surveillance: the former being the reporting of adverse incidents by manufacturers to the regulatory authorities and their subsequent sharing of key incident data between each other; the latter being the process by which information on overall devise performance is captured, analysed and acted upon. Nevertheless, it is still a struggle to gain widespread appreciation that these two activities are not in fact one and the same.

Electrical conductivity and piezoresistive response of 3D printed thermoplastic polyurethane/multiwalled carbon nanotube composites

NASA Astrophysics Data System (ADS)

Hohimer, Cameron J.; Petrossian, Gayaneh; Ameli, Amir; Mo, Changki; Pötschke, Petra

2018-03-01

Additive manufacturing (AM) is an emerging field experiencing rapid growth. This paper presents a feasibility study of using fused-deposition modeling (FDM) techniques with smart materials to fabricate objects with sensing and actuating capabilities. The fabrication of objects with sensing typically requires the integration and assembly of multiple components. Incorporating sensing elements into a single FDM process has the potential to significantly simplify manufacturing. The integration of multiple materials, especially smart materials and those with multi-functional properties, into the FDM process is challenging and still requires further development. Previous works by the authors have demonstrated a good printability of thermoplastic polyurethane/multiwall carbon nanotubes (TPU/MWCNT) while maintaining conductivity and piezoresistive response. This research explores the effects of layer height, nozzle temperature, and bed temperature on the electrical conductivity and piezoresistive response of printed TPU/MWCNT nanocomposites. An impedance analyzer was used to determine the conductivity of printed samples under different printing conditions from 5Hz-13MHz. The samples were then tested under compression loads to measure the piezoresistive response. Results show the conductivity and piezoresistive response are only slightly affected by the print parameters and they can be largely considered independent of the print conditions within the examined ranges of print parameters. This behavior simplifies the printing process design for TPU/MWCNT complex structures. This work demonstrates the possibility of manufacturing embedded and multidirectional flexible strain sensors using an inexpensive and versatile method, with potential applications in soft robotics, flexible electronics, and health monitoring.

Heart Rate Monitors

NASA Technical Reports Server (NTRS)

1990-01-01

Under a NASA grant, Dr. Robert M. Davis and Dr. William M. Portnoy came up with a new type of electrocardiographic electrode that would enable long term use on astronauts. Their invention was an insulated capacitive electrode constructed of a thin dielectric film. NASA subsequently licensed the electrode technology to Richard Charnitski, inventor of the VersaClimber, who founded Heart Rate, Inc., to further develop and manufacture personal heart monitors and to produce exercise machines using the technology for the physical fitness, medical and home markets. Same technology is on both the Home and Institutional Model VersaClimbers. On the Home Model an infrared heart beat transmitter is worn under exercise clothing. Transmitted heart rate is used to control the work intensity on the VersaClimber using the heart rate as the speedometer of the exercise. This offers advantages to a full range of users from the cardiac rehab patient to the high level physical conditioning of elite athletes. The company manufactures and markets five models of the 1*2*3 HEART RATE monitors that are used wherever people exercise to accurately monitor their heart rate. Company is developing a talking heart rate monitor that works with portable headset radios. A version of the heart beat transmitter will be available to the manufacturers of other aerobic exercise machines.

Identification of ginsenoside markers from dry purified extract of Panax ginseng by a dereplication approach and UPLC-QTOF/MS analysis.

PubMed

Yang, Heejung; Lee, Dong Young; Kang, Kyo Bin; Kim, Jeom Yong; Kim, Sun Ok; Yoo, Young Hyo; Sung, Sang Hyun

2015-05-10

A dry purified extract of Panax ginseng (PEG) was prepared using a manufacturing process that includes column chromatography, acid hydrolysis, and an enzyme reaction. During the manufacturing process, the more polar ginsenosides were altered into less polar forms via cleavage of their sugar chains and structural modifications of the aglycones, such as hydroxylation and dehydroxylation. The structural changes of ginsenosides during the intermediate steps from dried ginseng extract (DGE) to PEG were monitored by ultra-performance liquid chromatography coupled with quadrupole time-of-flight mass spectroscopy (UPLC-QTOF/MS). 22 ginsenosides isolated from PEG were used as the reference standards for determining of unknown ginsenosides and further suggesting of the metabolic markers. The elution order of 22 ginsenosides based on the type of aglycones, and the location and number of sugar chains can be used for the structural elucidation of unknown ginsenosides. This information could be used in a dereplication process for quick and efficient identification of ginsenoside derivatives in ginseng preparations. A dereplication approach helped the identification of the metabolic markers in the UPLC-QTOF/MS chromatograms during the conversion process with multivariate analyses, including principal component analysis (PCA) and orthogonal partial least squares discriminant analysis (OPLS-DA) plots. These metabolic markers were identified by comparing with the dereplication information of the reference standards of 22 ginsenosides, or they were assigned using the pattern of the MS/MS fragmented ions. Consequently, the developed metabolic profiling approach using UPLC-QTOF/MS and multivariate analysis represents a new method for providing quality control as well as useful criteria for a similarity evaluation of the manufacturing process of ginseng preparations. Copyright © 2015 Elsevier B.V. All rights reserved.

Remote Diagnosis of the International Space Station Utilizing Telemetry Data

NASA Technical Reports Server (NTRS)

Deb, Somnath; Ghoshal, Sudipto; Malepati, Venkat; Domagala, Chuck; Patterson-Hine, Ann; Alena, Richard; Norvig, Peter (Technical Monitor)

2000-01-01

Modern systems such as fly-by-wire aircraft, nuclear power plants, manufacturing facilities, battlefields, etc., are all examples of highly connected network enabled systems. Many of these systems are also mission critical and need to be monitored round the clock. Such systems typically consist of embedded sensors in networked subsystems that can transmit data to central (or remote) monitoring stations. Moreover, many legacy are safety systems were originally not designed for real-time onboard diagnosis, but a critical and would benefit from such a solution. Embedding additional software or hardware in such systems is often considered too intrusive and introduces flight safety and validation concerns. Such systems can be equipped to transmit the sensor data to a remote-processing center for continuous health monitoring. At Qualtech Systems, we are developing a Remote Diagnosis Server (RDS) that can support multiple simultaneous diagnostic sessions from a variety of remote subsystems.

30 CFR 27.2 - Definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

... MINING PRODUCTS METHANE-MONITORING SYSTEMS General Provisions § 27.2 Definitions. As used in this part... designs, manufactures, or assembles and that seeks certification or preliminary testing of a methane-monitoring system or component. (c) Methane-monitoring system means a complete assembly of one or more...

40 CFR 461.3 - Monitoring and reporting requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 40 Protection of Environment 29 2010-07-01 2010-07-01 false Monitoring and reporting requirements. 461.3 Section 461.3 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS BATTERY MANUFACTURING POINT SOURCE CATEGORY General Provisions § 461.3 Monitoring...

40 CFR 461.3 - Monitoring and reporting requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 40 Protection of Environment 30 2011-07-01 2011-07-01 false Monitoring and reporting requirements. 461.3 Section 461.3 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS BATTERY MANUFACTURING POINT SOURCE CATEGORY General Provisions § 461.3 Monitoring...

An intelligent service matching method for mechanical equipment condition monitoring using the fibre Bragg grating sensor network

NASA Astrophysics Data System (ADS)

Zhang, Fan; Zhou, Zude; Liu, Quan; Xu, Wenjun

2017-02-01

Due to the advantages of being able to function under harsh environmental conditions and serving as a distributed condition information source in a networked monitoring system, the fibre Bragg grating (FBG) sensor network has attracted considerable attention for equipment online condition monitoring. To provide an overall conditional view of the mechanical equipment operation, a networked service-oriented condition monitoring framework based on FBG sensing is proposed, together with an intelligent matching method for supporting monitoring service management. In the novel framework, three classes of progressive service matching approaches, including service-chain knowledge database service matching, multi-objective constrained service matching and workflow-driven human-interactive service matching, are developed and integrated with an enhanced particle swarm optimisation (PSO) algorithm as well as a workflow-driven mechanism. Moreover, the manufacturing domain ontology, FBG sensor network structure and monitoring object are considered to facilitate the automatic matching of condition monitoring services to overcome the limitations of traditional service processing methods. The experimental results demonstrate that FBG monitoring services can be selected intelligently, and the developed condition monitoring system can be re-built rapidly as new equipment joins the framework. The effectiveness of the service matching method is also verified by implementing a prototype system together with its performance analysis.

Research on the full life cycle management system of smart electric energy meter

NASA Astrophysics Data System (ADS)

Chen, Xiangqun; Huang, Rui; Shen, Liman; Guo, Dingying; Xiong, Dezhi; Xiao, Xiangqi; Liu, Mouhai; Renheng, Xu

2018-02-01

At present, China’s smart electric energy meter life management is started from the procurement and acceptance. The related monitoring and management of the manufacturing sector has not yet been carried out. This article applies RFID technology and network cloud platform to full life cycle management system of smart electric energy meters, builds this full life cycle management system including design and manufacturing, process control, measurement and calibration testing, storage management, user acceptance, site operation, maintenance scrap and other aspects. Exploring smart electric energy meters on-line and off-line communication by the application of active RFID communication functions, and the actual functional application such as local data exchange and instrument calibration. This system provides technical supports on power demand side management and the improvement of smart electric energy meter reliability evaluation system.

Flow behavior in liquid molding

NASA Technical Reports Server (NTRS)

Hunston, D.; Phelan, F.; Parnas, R.

1992-01-01

The liquid molding (LM) process for manufacturing polymer composites with structural properties has the potential to significantly lower fabrication costs and increase production rates. LM includes both resin transfer molding and structural reaction injection molding. To achieve this potential, however, the underlying science base must be improved to facilitate effective process optimization and implementation of on-line process control. The National Institute of Standards and Technology (NIST) has a major program in LM that includes materials characterization, process simulation models, on-line process monitoring and control, and the fabrication of test specimens. The results of this program are applied to real parts through cooperative projects with industry. The key feature in the effort is a comprehensive and integrated approach to the processing science aspects of LM. This paper briefly outlines the NIST program and uses several examples to illustrate the work.

Can airborne ultrasound monitor bubble size in chocolate?

NASA Astrophysics Data System (ADS)

Watson, N.; Hazlehurst, T.; Povey, M.; Vieira, J.; Sundara, R.; Sandoz, J.-P.

2014-04-01

Aerated chocolate products consist of solid chocolate with the inclusion of bubbles and are a popular consumer product in many countries. The volume fraction and size distribution of the bubbles has an effect on their sensory properties and manufacturing cost. For these reasons it is important to have an online real time process monitoring system capable of measuring their bubble size distribution. As these products are eaten by consumers it is desirable that the monitoring system is non contact to avoid food contaminations. In this work we assess the feasibility of using an airborne ultrasound system to monitor the bubble size distribution in aerated chocolate bars. The experimental results from the airborne acoustic experiments were compared with theoretical results for known bubble size distributions using COMSOL Multiphysics. This combined experimental and theoretical approach is used to develop a greater understanding of how ultrasound propagates through aerated chocolate and to assess the feasibility of using airborne ultrasound to monitor bubble size distribution in these systems. The results indicated that a smaller bubble size distribution would result in an increase in attenuation through the product.

Development of Integrated Programs for Aerospace-vehicle Design (IPAD): Product manufacture interactions with the design process

NASA Technical Reports Server (NTRS)

Crowell, H. A.

1979-01-01

The product manufacturing interactions with the design process and the IPAD requirements to support the interactions are described. The data requirements supplied to manufacturing by design are identified and quantified. Trends in computer-aided manufacturing are discussed and the manufacturing process of the 1980's is anticipated.

Polysilicon planarization and plug recess etching in a decoupled plasma source chamber using two endpoint techniques

NASA Astrophysics Data System (ADS)

Kaplita, George A.; Schmitz, Stefan; Ranade, Rajiv; Mathad, Gangadhara S.

1999-09-01

The planarization and recessing of polysilicon to form a plug are processes of increasing importance in silicon IC fabrication. While this technology has been developed and applied to DRAM technology using Trench Storage Capacitors, the need for such processes in other IC applications (i.e. polysilicon studs) has increased. Both planarization and recess processes usually have stringent requirements on etch rate, recess uniformity, and selectivity to underlying films. Additionally, both processes generally must be isotropic, yet must not expand any seams that might be present in the polysilicon fill. These processes should also be insensitive to changes in exposed silicon area (pattern factor) on the wafer. A SF6 plasma process in a polysilicon DPS (Decoupled Plasma Source) reactor has demonstrated the capability of achieving the above process requirements for both planarization and recess etch. The SF6 process in the decoupled plasma source reactor exhibited less sensitivity to pattern factor than in other types of reactors. Control of these planarization and recess processes requires two endpoint systems to work sequentially in the same recipe: one for monitoring the endpoint when blanket polysilicon (100% Si loading) is being planarized and one for monitoring the recess depth while the plug is being recessed (less than 10% Si loading). The planarization process employs an optical emission endpoint system (OES). An interferometric endpoint system (IEP), capable of monitoring lateral interference, is used for determining the recess depth. The ability of using either or both systems is required to make these plug processes manufacturable. Measuring the recess depth resulting from the recess process can be difficult, costly and time- consuming. An Atomic Force Microscope (AFM) can greatly alleviate these problems and can serve as a critical tool in the development of recess processes.