The Industrial Testing Process

Transcription

1 The Industrial Testing Process Rhoda Gindi (978)

2 Three Types of Cleaning Parts Cleaning Cleaning parts during and after manufacturing in metal working or tooling industries Gross Cleaning Applications Precision Cleaning Cleaning parts during and after manufacturing in Semi Conductor and Medical Sectors Critical Cleaning Applications 2

3 Review Current System Contacted by company with cleaning related issue Gather background information on process SSL Test Request form Serve/Manufacturers_Parts_Cleaning/Test_Request_Form Material of parts to be cleaned Contaminants Current Solvent or other alternatives tested Available Equipment Operating conditions (time, temp, conc.) 3

4 Review Current System On-Site visit Complete Test Request form Gather samples and SDS Contaminants Current Solvent Dirty Parts Identify possible adjustments to process 4

5 Identifying an Alternative The cleaner must be assessed for Ability to remove the contaminants Compatibility with the surfaces to be cleaned Works with equipment that will be used The alternative should be safe for the worker and the environment 5

6 Alternative Selection Process is challenging Thousands of products Different information from different vendors What is right for some may not work for others Need for an easier selection method Independent analysis of products Objective operating conditions Process specific final evaluations 6

7 Keys to Success I. Product Selection Process Helps to scope project more efficiently Determine substrate surface/ chemical cleaner reactivity issues Review lab Safety Screening Scores ousing TURI s CleanerSolutions Database for cleaning alternatives ( database selection process based on past performance and safety considerations II. Temperature and Concentration Trials Chemical field may be narrowed/changed from Phase I Follow chemical manufacturer s recommendations for both parameters Equalize time Minimize same-source agitation* *chemical comparison tool; minimal use of mechanical energy; first round of scientific trials; gravimetric analysis IV. Actual Product Cleaning Trials Geometries and sizes of parts important to cleaning efficiency Duplicate optimal Phase III cleaning conditions Duplicate optimal Phase III cleanliness testing V. Pilot Plant / Scale-up Feasibility Trials Obtain input from employees that will be working on new process Identify areas concerns Arrange for lab loaning of equipment for further on-site testing Follow up lab work based on client feedback III. Mechanical Energy Trials Number of chemical cleaner candidates further decreases from Phase II Application-specific Economically-sensitive Space-limiting Conduct comprehensive EHS profiles of top performing products scientific study; may employ a variety of analytical tools for cleanliness evaluation 7

8 Testing an Alternative Phase 1 Use of CleanerSolutions TURI Lab Database of Testing Used to identify safer and effective products Safety Screening Scores VOC, ODP, GWP, HMIS/NFPA, ph Matching Performance Contaminant, substrate, equipment, current solvent 8

9 Testing an Alternative Phase 2 Initial laboratory evaluation of alternatives Using basic operating conditions Minimal concentration Short times Little agitation Using coupons matching part substrate Using supplied contaminants Compare with current solvent (if possible) 9

10 Testing an Alternative Phase 3 Advanced lab evaluation of alternatives Using client specific operating conditions Moderate concentration (if necessary) Times Appropriate agitation (match current equipment) Using coupons matching part substrate Using supplied contaminants Compare with current solvent (if possible) Determine if there are any health risks that the screening does not address TURI s Pollution Prevention Options Analysis System - P2OAYSys 10

11 Testing an Alternative Phase 4 Pilot cleaning in lab setting Using client specific operating conditions Using client supplied parts Compare with current solvent (if possible) Send/bring parts to client for assessment 11

12 Testing an Alternative Phase 5 Pilot testing at facility Using best alternative cleaning products Using operating conditions from lab piloting Modify conditions if necessary Set up piloting off-line from current system Compare pilot cleaned parts with current system for parts from the same manufacturing lot Get end user input for performance 12

13 Case Study A Company A is manufacturer of a wide variety of orifice hardware : Parts diameter range from 0.01 in 0.75 in Were using TCE to remove machining oils from parts 13

14 Testing protocol for Case study A We identify four products Lab evaluated the three alternatives on the client s soil using coupons. The results are recorded. Three of the alternative has an over 90% removal of contaminate from the coupons. Client choose one of the three products to conduct a thorough pilot. Client is piloting a study using the products in their facility Based on these results, actual client parts were cleaned and returned to client for inspection. 14

15 Case Study B Company B is manufacturer of ballerina shoes : They are using TCE to clean grease, adhesive and pen markings from fabric ballerina shoes 15

16 Testing protocol for Case study B We identify four Alternatives The lab evaluated the four alternatives on the client s actual samples of fabrics.the results are recorded. The alternatives did not remove any of the contaminates from the fabrics Client decided to try the alternatives on their own. A report was sent to the clients with our findings. 16

17 Case Study C Company C is manufacturer of Curved Brass large parts : They are using TCE to clean printing ink overrun. 17

18 Testing protocol for Case study C We identify four products The lab evaluated the four alternatives on the client s soil using coupons. The results are recorded. The alternative has an over 90% removal of contaminate from the coupons. Client choose one of the three products to conduct a thorough pilot. Client is piloting a study using the products in their facility Based on these results, actual client parts were cleaned and returned to client for inspection. 18

19 Questions? Contact: Rhoda Gindi (978)