Category: Manufacturing

Introduction

Cans are useful containers used in everyday life for packaging and storing beverages. Most manufacturers use aluminum as a raw material to manufacture beer and soft drink cans. For example, 95 percent of the cans manufactured in United States are from aluminum and amounts to 100 billion beverage cans in a single year. However, it is important to note that aluminum cans are not good in storing foodstuffs. In most cases, manufacturers prefer steel in manufacturing food cans. On the other hand, the inimitable properties of aluminum make it the best raw material for manufacturing cans for holding carbonated beverages. Additionally, the shiny aluminum walls make it one of the best decorating materials hence, attracting the attention of many consumers (Hosford & John, 1994, p.48).

History and Technical Description of Aluminum

The identification of aluminum dates back to 1782 as the metal widely recognized with stature in France. History asserts that in 1850s, many people preferred aluminum to gold and silver for manufacturing trinkets and eating utensils such as cups, plates and cooking pots. To crown it all, King Napoleon III became so much enthralled with military lightweight aluminum equipments and immediately sponsored its extraction. In ancient times, aluminum occurred in various places. Nevertheless, due to lack of expertise in the extraction process, aluminum remained elusive for a long period. As the most fascinated metal in 19^th century, aluminum became so expensive forcing many people to look for other alternatives. However, the period of technological advancements that started after the Second World War saw a breakthrough in the extraction of aluminum and easy smelting of aluminum. Eventually, exceedingly high prices of aluminum fell considerably paving its industrial exploitation.

Before the Second World War, manufacturers made beverage cans from steel. This is because many manufacturers could not afford the high price of aluminum. Besides, since the extraction of aluminum was limited due to lack of extraction expertise, many manufacturers of cans preferred the very available steel. For instance, during the Second World War, the U.S government used steel cans to transport beer to the soldiers involved in war overseas. This period saw large production of steel pipes, the production that continued even up after the end of the war. However, in 1958, the Adolph Coors Company became the first firm to create aluminum cans amid various difficulties in the manufacturing process. Nevertheless, the produced cans weighed less (198g) as compared to the usual cans that weigh 340g. Ironically, many people preferred the aluminum cans something that incited Coors and other metal companies to develop not only abundant aluminum cans, but also quality aluminum cans (Turner, 2001, pp. 20-27).

Other manufactures created steel cans with an aluminum crown as the new model of cans. It came out that this hybrid model of cans had distinct advantages compared to purely steel cans. For example, the aluminum top distorted the galvanic reaction occurring between beer and steel giving beer twofold shelf life as compared to the one stockpiled in purely steel cans. In addition, consumers found it easier to open the aluminum top by just a simple pull-tab. Most steel cans require a special opener prevalently known as “church opener” to remove the top lid. The struggle to remove this top lid forced firms like Schlitz Brewing Company to introduce aluminum tops making other brewing companies to follow suit. By the end of 1968, at least all brewing companies had their cans sealed with an aluminum top (Smith, 1988, pp. 8-34).

Two-piece drawing and wall ironing

The technique came into limelight in 1963 following Reynolds Metal Company’s successful fabrication. However, it is imperative to note that Coors was the first company to produce hybrid cans with top and bottom aluminum tops through impact-extrusion process. Immediately after their development, giant breweries such as Coca-Cola, PepsiCo, Coors and Hamms opted to store their beverages in these cans thus becoming the first beneficiaries. According to statistics, the number of aluminum cans used in United States increased from 500 million in 1965 to 8.5 billion in 1972 and the figure continued to swell even as many brewery firms opted for aluminum cans for storing carbonated beverages. Noticeably, the modern aluminum cans have very many disadvantages as compared to the old steel or steel-and-aluminum cans. For example, aluminum cans do not rust and lengthens shelf life. Moreover, aluminum cans chills speedily, are easy to salvage and its lustrous surface is quite arresting (Hosford & John, 1994, pp.48-53).

Raw Materials

As discussed in the sections above, aluminum is the main raw material for manufacturing cans. Nevertheless, aluminum occurs naturally as bauxite. After extraction, bauxite undergoes refinement in the factory and later on smelted to produce molten aluminum and cast into ingots. Manufacturers also mix small percentages of other metals to make aluminum cans. For instance, the bottom part of the aluminum can contain small amounts of other metals such as silicon, magnesium, manganese and copper. In most cases, manufacturers use recycled aluminum to manufacture aluminum cans. The ability to recycle aluminum easily makes it easier for manufacturing companies to recycle the used cans hence, sustainable development. In addition, the amount of energy used in smelting can is less as compared to the one of smelting bauxite (Alcoa Rigid Packaging, 2010, p.1).

Manufacturing Process

In most cases, the ordinary process of making aluminum beverage cans is drawing and ironing. The following procedure analyses all steps involved in manufacturing cans beginning with the cutting of blanks.

Cutting the blank

This procedure starts with the casted aluminum ingots. The casted aluminum ingots measures 76cm of 30 inches in thickness and appear as sheets of uniform thickness. Manufacturers will cut the sheet into circles (14 cm in diameter) popularly known as blanks, which will build the bottom and sides of the can. The top part of the can will form later due to the crystalline condition of the aluminum pane. It is important to note that during the cutting process, some pieces of aluminum sheet go to waste. Thus in order to minimize losses, manufacturers should make wide ingots that can produce two spread out rows, each comprising of seven blanks. By doing this, only 12 to 14 percent of the material goes to waste, and they can recycle later. Following the separation of blanks is to fold them to form a small cup that measure 4.45cm in radius.

Redrawing the cup

The succeeding step is to move the pinched diminutive cup into a subsequent device to continue the procedure. The sleeve of the second machine puts the cup in position such that immediately the punch lowers; it forms circular cups of diameter 6.6 cm. on the same note, the height of the cup roses from 3.3cm to 5.7cm. Next, the ironing rings will elongate and slender the cup walls to form the desired shape. After slandering and thinning, the cup now measures 5 inches or 13cm in height. Next, knock the bottom to bend inside in order to counteract the pressure exerted by the carbonated beverage. In addition, the manufacturer designs the bottom part in such a way that it appears thicker than the top part due to the pressure exerted by the carbonated beverage.

Trimming the ears

The third procedure of can manufacturing is trimming the ears. You realize that after successful drawing and ironing, the top of the cup appears wavy characterized by small ripples or “ears”. However, in a move aimed at controlling the development of “ears”, diverse aluminum companies who have studied this incident expansively control the rolling of aluminum sheet in order to manipulate the height of the ears. Nevertheless, due to trimming of the ears, some pieces of aluminum go to waste.

Embellishment

The producers do not need auxiliary concluding of the can for example, buffing up since the cup is shimmering and smooth following the above procedures. Habitually, after the cup has undergone trimming, the producers will clean and label it and then squeeze the top to form a neck and an out-ward flange where the lid will rest (Alcoa Rigid Packaging, 2010, p.1).

The lid

So far, we have discussed how aluminum builds the bottom and sides of aluminum beverage cans. The only remaining part is the lid, which covers the beverage stored in the can. Additionally, the procedure has also elaborated why we need a thicker material and an in-ward bulge at the bottom, that is, to contain the pressure exerted by carbonated beverages. Likewise, the lid ought to be strong and stiff, and even stronger and stiffer than the base. Thus, in order to make a stronger and stiffer lid, manufacturers mix aluminum with some alloys of magnesium and manganese, which results into a strong and stiff metal. In addition, the lid is normally thicker than the sides or bottom of the can. Next, the designers will cut the lid into circular pieces of diameter 5.3cm (2.1 inches). Clearly, we notice that the lid appears smaller as compared to the diameter of the walls (6.6cm or 2.6 inches). Subsequently, the manufacturers will then stretch the middle of the lid vaguely upwards before moving it to another machine for riveting. Up to this point, we have a riveted lid. The manufacturer will then bring in another piece of metal called a pull tub and insert it beneath the rivet. The next step is to score the lid so that when opening, the consumer will only pull the tab and leave the can open. The process of manufacturing an aluminum lead is almost over. The quality control division will have to check whether the cans have cracks or pinholes. Any can with pinholes or cracks becomes defective (Singh, 1993, 129-131).

Filling and seaming

The final stage of can manufacturing is filling and seaming. At this particular stage, we have a can with a neck and a complete lid. Next, the manufacturer will move the aluminum can, fix it tightly against the bench of the filling device, and pour the carbonated beverage inside. After filling, next is adding the lid and then bending the upper flange towards the lid completely seaming the aluminum can. We now have a complete aluminum beverage can ready for the market.

Byproducts and Alternatives

It goes without saying that during the drawing and ironing can manufacturing process, some aluminum materials get lost on the way. For instance, during the cutting of the blanks and trimming of the ears, several pieces of aluminum remain unused. Nevertheless, through recycling, manufacturers can join the small pieces together for the next process. In addition, used aluminum cans also undergo recycling for use in the next manufacturing process. Noticeably, the recycling of aluminum is vital to any can manufacturing industry, as the factory is able to save up to 95 percent of energy. This is on one of the advantages that make aluminum the best material for manufacturing cans as compared to steel or all-steel-and-aluminum cans, which seem hard to recycle.

Nevertheless, manufacturers have also come up with mechanisms of saving waste during the can manufacturing process for example, developing rigid sheets circumspectly managing the whole process to ensure minimal loses during cutting of “ears”. Furthermore, the reason why manufacturers design a smaller lid as compared to the sides is to minimize the huge loss of aluminum. Following the continued rising demand of aluminum cans, many manufacturers are studying ways of reducing the lid further to conserve more aluminum (Larson, 1993, pp. 30-31).

Conclusion

The rising demand of cans has forced manufacturers to increase the production of aluminum cans in order to curb this demand. Today, aluminum companies all over the world produce several billion cans each year for various uses such as storage of carbonated beverages (beer and soft drinks), and foodstuffs. Thus, in the wake of this growing demand of cans, the future production of cans chiefly depends on the designs that save energy, money and materials. Other incidents include designing cans with smaller lids and neck diameters to minimize losses. So far, aluminum cans enjoy much preference as compared to other cans as it doubles shelf life, does not rust, and is recyclable.

Reference List

Alcoa Rigid Packing. (2010). How aluminum cans are made. Web.

Hosford, F. & John, L. (1994). The Aluminum Beverage Can. Scientific American, 48-53

Larson, M. (1993). New Ideas Come In Cans. Packaging, 30-31.

Singh, S. (1993). Internal Gas Pressure on the Compression Strength of Beverage Cans and Plastic Bottles. Journal of Testing and Evaluation, 21(2), 129-131.

Smith, G. (1988). From Monopoly to Competition: The Transformations of Alcoa, 1888-1986. Cambridge University Press.

Turner, T. (2001). Can making for Can Fillers. Boca Raton: CRC Press.

Utah is a small population state with a big gang and graffiti problem. Most of the gangs live in the small towns and cities and for this reason, the authorities in such towns and cities must learn the best strategies to use in trying to eradicate the influence of gang members on the population. Criminal street gangs in Utah have been on increase within the recent past years.

Gangs first appeared in Europe and Mexico but no one is sure when and why they came to America. The first record of their appearance in America as early as 1783 when the American Revolution ended (Harness 2). They emerged from adolescent playgroups or a collective response to urban conditions. The migration of Mexicans from their country as a result of the Mexican revolution is also believed to have led to their moving to the southeast, thereby resulting in the emergence of the gangs. They came to existence due to the difficulties the Mexican youth encountered with the social adjustment to the lifestyle in America whose conditions were very poor in the Southwest.

In Utah, although there are various gangs to be found in the state, however, the largest number is in Salt Lake County. The underclass is composed of groups that veered from convectional, responsible behavior. They are characterized by poverty, crime, and illegitimacy. Affluent gangs also emerge from the east side of Salt Lake City, and also from other regions of the city (Pearson 84).

Pearson (86) asserts that many gangs in Utah are generally formed for social reasons. Also, they may go against what is required by laws of society to obtain resources though they may be considered the minority. Gangs may also form basis for violence against communities and individuals, and may capture both sex who emerge from poor, dysfunctional, or even broken homes; who could be school dropouts. Many of the gang members come from families headed by single mothers, and in which a father figure lacks.

Gangs have various levels of commitment that the members are required to manifest and in the case of Utah, there are four levels. The highest level of commitment entails the full-fledged members. Next, we have associate members. Then, there is the third group made up of the ‘Wanna-be’. They are afraid of committing violent acts but they are attracted to excitement and involvement. Finally, the ‘Hanging-out’ are not in gangs but just hang around gang members at shopping malls, gatherings etc. and may be recruited for membership later (Pearson 88).

In 2009, a survey was carried out in Utah to assess the impact of gangs in the state, and the extent to which it had spread. Threat assessment during that year showed that there was a huge growth of criminal gangs (Harness 5). Thanks to online networks and websites, gang members make use of graffiti. Criminal groups and bombing raid are also used by the gang members to promote the group’s activities.

Gangs’ presence is noticed everywhere in the state and many school districts are observed doing very little to reduce their influence and spread on and around public school property (Harness 6). They may also complain that they are not conversant with the gang related attire. Some gangs imitate logos of some sports teams, rap artists and musical groups. In Utah, gang members are predominantly Caucasians.

Several indicators show one has been involved in a gang. The following changes in child’s behavior are early warning signs; missing or dropping out of school, poor grades, changing of friends, changing of dressing mode, staying out at late night, having huge amounts of money, developing attitude and behavior problems etc.

Youths in Utah join gangs for different reason some of which I will discuss below. One reason is family tradition where one of the relatives belonged to a certain gang. The involvement of the youth will be just within the same gang as the other family member. Also lack of supervision and also involving themselves in abusive relationships, the youngster may be found in a gang affiliation. Excitement can also be a contributing factor since kids are adventurous, they may want to test thing and find the limit they can go up to (Cole 36 ).

Kids may feel unsafe due to various reasons such as the environment they are exposed to, thus they feel that they need protection. Due to this, they are made to believe that when they involve themselves with gangs, they will get the protection and avoid becoming targets of protection (Cole 37). Peer pressure may also lead to kids joining gangs where they seek for love, attention, support, protection or acceptance by the group being made to believe that what is missing in their lives will be provided in a gang.

Also, young stars may join a gang for financial gain due to the apparent ease of making huge amounts of money within a short time while applying very little effort. They fail in grasping the long-term effects of engaging in illegal behavior and tend to look at the short-term advantages. Finally, since kids like being noticed and appreciated for whom they are by parents, or teachers, failing to do that, may turn them to gangs. This is due to the appearance that gang members are powerful than other people and they are respected for their gang affiliation (Cole 38).

Psychological and structural explanations for crime are incorporated in the strain theory. The Strain theory involves the idea that gives results when people are unable to achieve their goals through genuine channels. In such cases, people may go for unlawful channels to achieve their goals or strike out at the origin of their disappointment in anger. When individuals fail to achieve their set goals they become frustrated and may end in yielding into unlawful acts (Agnew para.1). This theory has a direct resemblance of how gangs have been formed in Utah. The weakness with this theory is that it focuses on the social class and delinquency. It predicts that delinquency is concentrated in the lower class.

This is because the lower class individuals most of the time lack the means to achieve economic success. Also the other weakness with the theory is that, it assumes commitment to materialistic goals and also ignores the spontaneous crime. Finally, it finds it difficult to elaborate on the reason why some individuals who experienced strain did not turn to crime. The only strength with the theory is that it is a realistic reflection of word.

According to Scott (9) there are several ways to prevent gang formation. The first step is awareness and this can prevent a gang problem from developing in a community. Parents have more power to prevent gangs from establishing and also to prevent their children from joining them. The parents must learn how best to train their children on the importance of developing sound social skills. This is because once children possess these chances are that they are not likely to be involved in gangs. The good social behaviors include; honest communication, cooperation, personal responsibility, ability to make decisions, ability to give and receive unconditional love and community involvement (Nova Scotia 10).

Parents should also balance between love and discipline. They should spend time alone with each child to get to know each other better. In addition they make time for their family to eat together, make trips, and keep family traditions. Furthermore they should help their children to talk with them without fear of being punished. There is also the need for parents to assist their children learn how best to face peer influence. Limits should be set for children and teens since there is need for them to know what is expected of them and the consequences of not honoring. Finally, youth-meaning opportunities should be given and involve them in decision making, planning and implementation of family, school and community projects (Scott 11).

It is important to ensure that intervention programs are formed early so that children who are likely to join gangs are prevented from doing so. This is to help them make a positive early school adjustment (Pearson 11). Formation of recreation programs should be encouraged. These will attract gang members and different issues such sportsmanship, teamwork, etc., and will keep the gang members off the streets.

Work Cited

Agnew, Robert. A revised strain theory of delinquency. Social Forces, (1999): 64151- 167.

Cole, George and Smith, Christopher. Criminal justice in America. Stamford, CT Thomson Learning. Inc., USA, 2007. Print.

Harness, William. Gang facts and myths. 2006. Web.

Nova Scotia. Gang prevention: A resource guide on youth & gangs. 2007. Web.

Pearson, Dale. Young gang violence: community interventions, 2006. Web.

The life cycle of the newspaper is split into several phases. First, each paper is made of wood, is the main raw material for producing printed papers. The newspapers are specifically made of fresh fibers received from spruce trees that grow in forests of Germany, Sweden, and Canada (Axel Springer Verlag 8).

Second, the wood pulp is also necessary for the manufacturing process because it constitutes an important substance for yellowing newspapers. Third, the chemical pulp contains cellulose that is extracted from wood and is bleached (Axel Springer Verlag 9). Part of the raw materials involved in the production derives from vegetable matter, recycled newspaper, and cloth. The use of pine trees is also frequent because it contributes to the strength of the paper.

A certain percentage of newspaper’s materials involve the wood pulp from the sawmill, as well as recycled paper. The latter is heavily used by the newspaper manufacturers to handle the issue of environmental protection and deforestation (Axel Springer Verlag 9). The trees used in the production of paper industry are called “softwood.” Linen and cotton rags are also used for producing a newspaper with strong cardstock.

Newspapers are usually printed using mineral oil ink. Because newsprint does not include heating, there is the time needed for drying the ink, which is absorbed by the paper inner fibers and remains throughout the entire lifecycle of the paper. Inks are composed of four major elements – resins, pigments, solvents, and additives.

The black pigment derives from carbon black, binder, composed of oil and resin, and a variety of additives, including drying and chelating agents. Resins bind other components of the ink and form a film for binding the ink and the paper.

The substance can be composed of cellulose derivatives and such chemical substances as males, alkyds, phenolics, and formaldehyde. Cyclized rubber and chlorinated rubber are two major types used in printing production.

Further, solvents are applied in the ink production to keep the liquid from the printed surface (Print Ink Technology and Manufacture 2). Volatile solvents include such compositions as ethyl acetate, isopropanol, and methylated spirits. Finally, additives are necessary to alter the properties of the ink. They include cyclohexanone, aromatic distillates, butoxyethanol, methoxypropanol acetate, and butyrolactone (Print Ink Technology and Manufacture 3).

Aside from wood pulp, fresh fibers, recycled newspapers, and ink, electricity and transportation means belong to the list of raw materials. These raw products are used particularly in the recycling and waste management. For instance, to recycle newspaper, such elements as recycled fiber and fresh fiber as a part of the recovered paper are substantial for producing the paper.

Transportation of wood, paper fiber, and ink is also necessary to deliver the raw material to the manufacturing plant. Therefore, the producers should take care of a sufficient supply of gas for transport. Electricity is required at various stage of paper production – from wood processing to ink printing.

This raw material should not be underestimated while evaluating production costs. In particular, the energy input is also used in the chemical and mechanical process of producing ink and paper separately. Finally, the use of transportation gas and electricity is also used for proper was management.

About the above-present components of newspaper production, it should be concluded that this process is very sophisticated because it is composed of central and periphery raw materials.

The central one includes wood, which is necessary for producing paper, and black carbon for producing ink. The periphery materials involve gas and electricity that are vital for transporting wood and processing raw substances.

Works Cited

Axel Springer Verlag. A Life Cycle Assessment of the Production of a Daily Newspaper and a Weekly Magazine. 1998: 1-72. Web.

Print Ink Technology and Manufacture. n. d. Web.

Accident Causes

Following the accident that occurred on January 24 in Laser Tech Inc.’s manufacturing plant, the occupational health and safety team identified various factors that directly and indirectly caused the accident.

Direct Causes

The first direct cause of the accident was the inexperience of the crane operator and the injured worker. The crane operator was not qualified to handle the hoisting apparatus, and this made him ignore the critical safety procedures that are essential when moving heavy equipment. For instance, the crane operator acknowledged that he had injured his colleague, although he insisted that the other worker should not have been in the area.

A qualified and experienced crane operator would have stopped the hoisting process and warned the worker to move out of the dangerous zone. The injured worker was also inexperienced in working in such dangerous areas because he demonstrated unawareness of the risks involved in working around hoisting cranes. The worker should have been more careful to work in the designated areas and watched out for moving equipment. The worker also had only two months of experience of working in such environments.

The second direct cause of the accident was irresponsibility by the employees involved in the accident. The injured employee revealed his irresponsibility by failing to secure the steel sheets that were being hoisted by the crane. The employee was also working outside the designated area, and this exposed him directly to the injuries he sustained. In addition, the employee missed worked and refused to acknowledge this by signing the disciplinary notice. This shows the employees’ indifference to working in Laser Tech’s plant.

Indirect Causes

The primary indirect cause of the accident was unsafe working conditions. The company’s traveling crane had remained unmaintained for a long time, and this could have made the crane defective. The crane operator also pointed out that the warning alarm did not function, and this increased the risks of working near the crane. Finally, the company violated the OSHA regulations because it did not provide the injured worker with Laser Tech’s safety regulations.

Response and Remedial Measures

After an accident, the safety personnel must offer the injured workers first aid and immediately transfer them to the hospital. The occupational health and safety manager must then record the work-related accidents to prevent the recurrence of similar accidents in the future. The manager must indicate the cause of the accident, injuries sustained, and treatment offered. According to the OSHA inspection priorities, the safety manager should also inspect looming dangers and any safety complaints raised by the employees. The managers should randomly inspect and re-inspect all activities within the factory.

The first remedial measure to implement after the accident is repairing all the alarm systems in Laser Tech Inc.’s factory or installing new ones. The second measure is conducting the evaluation and maintenance of all the equipment in the factory. The third remedial measure is to ensure that all employees are qualified for their jobs. The fourth remedial measure is to ensure that all employees have the company’s safety regulations. Finally, the company should mark the danger-prone zones in the factory and punish the employees who ignore the safety regulations.

Recommendations

To prevent more accidents within the next three months, Laser Tech Inc. should implement the following recommendations.

1. Conducting frequent and regular maintenance activities to ensure that all equipment functions properly.
2. The company should train all its employees on health and safety practices at work.
3. Laser Tech Inc. should conduct regular risk assessments in its factory.
4. The company should re-evaluate the qualifications of its employees within the factory and offer refresher courses on a regular basis.
5. The company should train its employees on the appropriate procedures to follow during emergencies.

This work focuses on preparing a detailed and methodical project plan on furniture manufacturing in the UAE (Abu Dhabi) and attempts to come up with the best possible project management practices to ensure that the assignment is completed efficiently in the shortest possible time.

Background

Project Idea and Description

• The project idea is to start a furniture manufacturing business in the UAE (Abu Dhabi).
• Unlike its competitors, this business will offer its customers furniture at a low cost.
• The business will attempt to attract customers by allowing them to pay for (invest in) the quality of the furniture, not for the advertising campaign.
• It will be an online-based business; therefore, the costs would be significantly lower – customers would be able to place an order at any time from any location.
• The workshop will be situated in Abu Dhabi, and the main product line shall include everything necessary to furnish a home, office, or educational institute.
• Customers proximate to the workshop will be privileged as they are exempted from paying for the transportation cost.

Project Purpose and Justification

• A huge number of tourists visit Abu Dhabi annually, and hotels are compelled to refurbish their décor to attract them; consequently, there is a strong need for modern furniture in the market.
• This business aims to offer furniture with innovative design, made from leather, cardboard, nutshells, wood composites, eco-friendly plastic wood, and high-quality hardwood.
• Besides being a furniture manufacturer, an important purpose of the business will be to ensure environmental sustainability and low carbon emissions.
• For a competitive advantage, the items must be available at cheaper rates.

Project Objectives

The main objective of this project is to enable the customers of Abu Dhabi to access the best and the most contemporary forms of furniture at relatively lower cost.

• The company will engage with local community in order to ensure communal welfare as part of the company’s corporate social responsibility.
• The business will start to fully engage in corporate social responsibility from the second year of its operation.
• The entrepreneurs believe that ensuring environmental justice should be a key concern for every business entity; as a result, this furniture business would conduct an environmental impact assessment before starting the project.
• It will also make sure the operation is as eco-friendly as possible.
• The entrepreneurs have the intention of reaching the break-even point by the end of the first year of operation.
• In order to ensure that the business is cost-effective and operationally efficient, the owners would try to implement lean management techniques throughout all departments.
• These techniques must include a “just in time approach” and measures to ensure economies of scale.
• The business would try to undertake cost-effective advertising measures through social media, the corporate website, direct emails, and so on.

Project Initiation

Project Life Cycle

Project Charter

Requests for Proposal (RFP)

This furniture manufacturing company will seek proposals from the contractors to establish a unique outlet. In this case, the request for proposal shall describe the statement of work, requirements for participants, project objectives, evaluation and acceptance criteria, deliverables, items supplied by the owner, bid information, type of contract, payment terms, schedule, and so on.

Proposal

Contract

This furniture manufacturing company will set terms and conditions to sign a contract after May 18, 2017, and both parties must follow clauses to mitigate risks arising from misrepresentation, delays, changed materials specification, errors in price, natural disasters, non-compliance of privacy policy in case of online transaction, and security concerns.

Project Scope

Acceptance Criteria Analysis

• It will fulfill the legal requirements of the United Arab Emirates to obtain a commercial license from the Department of Economic Development.
• Assurance regarding workplace safety.
• Use of high-quality equipment and raw materials.
• It will avoid negative influence on the environment; so, it will achieve the level of ISO 14001 and ISO 18001 from the same authority.

Project Deliverables

• Organization of the workshop.
• Recruiting experienced employees.
• Launching a website successfully and ensuring online order placement system.
• Starting production of furniture.
• Processing the orders of the customers.

Customer Requirements

• Stylish furniture at reasonable prices.
• Customers seek furniture with environmentally suitable materials.
• Clients looking for comfortable furniture.
• Satisfaction of clients through products and service.

Stakeholder Management

• This furniture manufacturing company is committed to build long-term maximum value.
• Integrity and responsible actions strengthen its commercial performance.
• Members of support team communicate with employees by maintaining a regular two-way flow of information to motivate stakeholders.

Requests for Commercial and Environmental License

The Department of Economic Development is a license-issuing authority in the UAE; thus, a company applies for a license by meeting the legal criteria and paying the fees. Here, the fees include:

• Industrial license fees: AED 250.
• Environmental license fees: AED 250.
• Activity fees: Subject to activity type.
• Main product fees for permanent license: AED 1,000.
• Branch product fees for permanent license: AED 500.

Reserving the Trade Name

In order to reserve the trade name, this furniture manufacturing company must pay AED 40 to the Department of Economic Development.

Place Size for Manufactory

The main office will have an area of 10,000 m² and shall include –

Table 1. Place Size.

Project Planning

Scope of Work

Work Breakdown Structure (WBS)

Initial Risks

• Exhaust inexorable financial pressure to survive.
• Unsuitable temperature conditions may damage the raw materials.
• High accident rate is the primary risk in making hotel furniture.
• The extent of the noise causing hearing loss in employees.
• Threats of substitute products and bargaining power of buyers.
• Staff mistakes may cause financial loss.

Information System Development

Responsibility Assignment Matrix

Sequence of Activities (Milestones Schedule)

Table 3. Sequence of Activities.

Resource Plan

Table 4. Resource Plan.

Workers

The workers shall act in accordance with the preferences of the people of Abu Dhabi. Furthermore, they would implement the organization’s vision, control the furniture distribution channel, and supply inventory to increase sales and growth. A total of 50 workers, including a factory manager, two production managers, and five logistics personnel are needed.

Suppliers

The workshop will receive supplies of all the essential tools and materials for furniture manufacturing. It should coordinate with other third parties (Al Khaznah Tannery, Al Eskafi Leather Industries, Abaad Wood Industries, and Royal Wood Factory) to collect wood, leather, imitation leather, fabric, metal, and many other materials. In addition, the furniture manufacturing company will import wood from outside the country using the ports of Dubai or Abu Dhabi; in addition, it will also collect equipment and tools from suppliers in China, Italy, and Germany.

Preliminary Roles and Responsibilities

Chief Financial Officer Ameera Al Katheeri, Project Director and Head of Communications Mezna Al Mansoori, and Chief Industry Expert Eslah Al Hammadi are responsible to supply funds to implement the project; the CFO will control and monitor the financial system, the Project Director will analyze the employees’ performances, and the Chief Industry Expert will focus on overall operations management.

Quality Plan

In order to ensure quality, the furniture manufacturing company is committed to complete work in accordance with the specifications, maintain international standards, monitor project progress, evaluate performance of the employees,and deliver products on time; however, Eslah Al Hammadi is responsible for maintaining quality control.

SWOT Analysis

Table 5. SWOT Analysis of Furniture Manufacturing Company.

Regulatory Factors

In order to establish and operate a furniture manufacturing company in Abu Dhabi, the entrepreneurs will consider the domestic regulations of the area. The management team will collect a commercial license from the Department of Economic Development, and will strictly follow terms and conditions of the authority to operate the business, to open a new branch, to share profits or losses, and to ensure good governance.

Risks Management Matrix

Network Diagram

Financial Plan (Cost)

Yearly Rent

Table 7: Yearly Rent.

Salary and Fees

Table 8. Salary and Fees for Employees.

Estimated Budget and Funding

The group consists of three people who will equally invest from their savings accounts to establish the furniture manufacturing company; as a result, they all remain equal partners of the venture, and the distribution of equity investment will be the following:

Table 9. Funding for the project.

Table 10. Total Investment and Depreciation Costs.

Projected Income Statement for 3 Years

Table 11. Projected Income Statement for 3 Years.

Project Performing

• Engage highest efforts to attain project objectives.
• Step-by-step assessment of the progression and the remaining trend.
• Re-design necessary changes with narrow the gaps.
• Continuous monitoring and progress controlling with baseline analysis.
• Change management to ensure stakeholders’ satisfaction.

Project Closing Actions

• Assess the design, development, and testing processes.
• Compliance with completion criteria.
• Collect outstanding payment.
• Recognize and evaluate staff planning.
• Project implementation.
• Archive all acceptance documents.
• Assess lessons learned so far.

Conclusion & Lessons Learned

Throughout the implementation stage of the project, the closing phase is one of the most significant sessions for the team members, since at this stage the group will exchange their views and ideas with all the stakeholders and offer opportunities to improve the conditions further through attaining:

• Objectives of the project.
• Significance of project planning and success with outstanding outcomes.
• Clear assignment for eliminating the negative impact for future endeavors.
• Conceptualization of the VOC in selection.
• Benchmark for the continuous improvement process.

Over the years, there have been significant changes in enhancing productivity and sustainability in the manufacturing sector. Such kinds of studies are used to examine the various ways in which organizations can improve their level of productivity through the use of sustainable measures. The analysis is undertaken through undertaking manufacturing research and analysis. Through such research and analysis, it is easy to interpret the information obtained to understand the underlying issues influencing the organization’s success and provide measures that can be used to enhance its sustainability.

Productivity

Manufacturing productivity is defined as the output ratio to the inputs injected in the production process. Research on the aspect shows how a company can influence its production based on the amount of input injected, and it mainly emphasizes the quantity of the products produced (Stundziene & Saboniene, 2019). An organization’s main inputs are labor in terms of working hours, capital, and the different natural resources that are basic for the organization to produce a product unit (Stundziene & Saboniene, 2019). Due to the nature of activities linked to the productivity of the organization. In enhancing productivity among the staff working, organizations have adopted numerous approaches that effectively make the organization run smoothly and productively.

Researchers have identified numerous trends maintained by most manufacturing industries in recent years. One of the main trends includes adopting artificial intelligence in the manufacturing process. Since the organization’s management is continuously changing, members of Generation Z take critical roles in the manufacturing process (Hall, 2020). Since the generation is highly digitalized, the management of the production processes involves a highly computerized system that automatically checks the number of inputs injected in the production process controlling the level of information used in the production process and controlling the desired output. In addition, adaptability is another trend experienced in the production process. It has enabled the organizations to cope with the various changes like the emergence of Covid-19, which made most organizations be able to continue with their productivity irrespective of the changing economic conditions (Hall, 2020). The inclusion of generation Z in the workplace is another trend experienced as individuals have to put up with their traits.

Consumer good application

The table provides information about a good consumer application and its changes in the pasts six months. Residential utilities are the assigned consumer good which has experienced an almost constant production in the past six months. Both the estimate and the total index are almost the same, with a small margin of advancement. The highest index was recorded at 113.9 in February 2022 after seasonal adjustment, and the lowest index was recorded at 98.0 in December 2021 (Federal Reserve, 2022). Across the six months, the production of the product has experienced continuous changes, which is inconsistent.

During the six months, the residential utilities experienced a low growth rate. However, slightly higher than other products since most people remained indoors due to the fear caused by the coronavirus pandemic. The virus decreased economic activities across the globe as most individuals were focused on maintaining safety and recovering from the previous year linked to lockdowns. (Federal Reserve, 2022) This aspect made the industry experience a much higher index. Most people were indoors, avoiding public places. Consumer good has a slower growth rate than other industries like the food, tobacco products, and beverage industries, which recorded significant changes as they are essential to the consumers. The product is essential; that is why it recorded a higher index in the past six months.

Industrial/Business Good Application

The table provides information about commercial energy products and the various changes recorded in the last six months. In the past six months, the development of the product experienced an insignificant change, a range of 7.3 in the index, even though the index has been evenly distributed in the past six months (Federal Reserve, 2022). The industry is also perceived to experience a low growth rate as the industries had low activities since the pandemic made people shift to working from home to avoid contracting the coronavirus. In this case, the industry did not experience many activities that would make the index high as it is lower than the residential utilities. Individually, the industry has not changed drastically over the past six months, meaning that the activities were well regulated. The highest index is recorded in April 2022, meaning that commercial activities had started to resume due to the containment of the virus and the presence of the vaccines. Such a trend can only be explained by the economic activities experienced in the past six months resulting from the economic changes and containment measures to deal with the pandemic.

Sustainability

Sustainability in manufacturing is perceived as developing manufactured products under economically rational processes that regulate the negative environmental impacts. Sustainability aims to enhance the production of goods and services and maintain energy conservation and all-natural resources. Maintenance of sustainable working practices also enhances the safety of the employees, product, and community (Abubakr et al., 2020). In recent years, businesses have been adopting the concept of sustainability as a critical aspect of their operations and strategy. In the process, the companies pursue sustainability for numerous reasons. The reasons include operational efficiency, cost and waste reduction, consumer attraction, protection of brand reputation, consumer trust, long-term viability and success, and regulatory opportunities and constraints. Such factors push most products to be highly trusted and bring an excellent reputation to their consumers. Research shows that sustainability is a concept that most companies and industries have adopted, irrespective of their size or reputation (Ebrahim et al., 2019). The process is highly important as it has enabled most companies to enhance their performance and regulate their resources.

In addition, most companies and industries address the issue of sustainability as a formal, coordinated and integrated aspect that is considered part of the organization. The concept has also enhanced the focus of the level of competitiveness as it makes companies focus on the maintenance of competitive advantage (Ebrahim et al., 2019). Other organizations use innovation, strategic analysis, and scenario planning. Also, others have integrated sustainability into their business functions, enabling them to focus on long-term goals. Adopting sustainability as part of the organizational strategy has played a critical role in bringing different stakeholders together. The concept has enabled organizations to check their activities and ensure that they do not adversely affect people and the environment (Abubakr et al., 2020). Therefore, making a sustainability routine in everyday organizational activities has also enabled businesses to maintain high standards of ethics, which check the behaviors maintained by the staff and the entire organization when interacting with other organizations.

References

Abubakr, M., Abbas, A. T., Tomaz, I., Soliman, M. S., Luqman, M., & Hegab, H. (2020). Sustainable and smart manufacturing: An integrated approach. Sustainability, 12(6), 2280.

Ebrahim, Z., Ahmad, N. A., & Muhamad, M. R. (2019). A model for manufacturing sustainability in manufacturing operations. International Journal of Recent Technology and Engineering (IJRTE) ISSN, 2277-3878.

Federalreserve. (2022). The Fed – Industrial Production and Capacity Utilization – G.17. Federalreserve.gov.

Hall, J. (2020). 5 Productivity trends that are taking the lead right now. Forbes. Web.

Stundziene, A., & Saboniene, A. (2019). Tangible investment and labor productivity: Evidence from European manufacturing. Economic Research-Ekonomska Istraživanja, 32(1), 3519-3537.

Meat is generally considered an integral part of a healthy diet for people and carnivorous pets such as cats and dogs. However, there also exists a noteworthy vegetarian movement, with extreme members known as vegans. There is a variety of reasons why one may choose to forgo eating meat or animal-based products in general. Supposed health benefits or personal beliefs are usually considered the primary drivers for vegetarians, and vegans tend to base their position on disapproval of the animal cruelty that takes place on farms. However, their opinions are not taken into consideration often, possibly in part due to animal product suppliers exerting control to protect the status quo.

The Case Against Animal Product Producers

Like most businesses, farms are concerned with efficiency and maximizing profits by minimizing spending. This trend often means that the comfort and potentially well-being of the animals who are used are disregarded, and the treatment may be considered unethical from some standpoints. Meadows (2012) describes how chickens are killed en masse, female pigs are exploited and kept mostly immobile, and cows are killed when their milk production slows. While these practices are appropriate from a purely utilitarian perspective, most people would not enjoy witnessing them in person. As such, empathy plays a significant part in the case against supporting animal product producers, as doing so would reduce their profits and potentially compel them to create better conditions for their livestock.

Some people, mostly vegans, take a more radical stance and draw parallels between animals and humans. Spiegel (1988) begins her book by comparing racism and speciesism, or the tendency of modern humanity to show disdain for animals. She argues that the onset of industrial trends, spurred mostly by the rapid expansion of the European civilization, changed the view of animals from creatures to admire and honor to pests and livestock (Spiegel, 1988). Some people champion the idea that animals deserve the same, or similar, treatment as what humans receive, with specific rights that are enforced. The methods employed by many producers, particularly large-scale firms that benefit from efficiency improvements considerably, would be unethical, if not illegal, in such a situation.

The abuse perpetrated by meat, dairy, egg, and other suppliers that employ animals in their activities becomes still less justifiable as technology advances. Wurgaft (2019) discusses the concept of artificially growing meat for human consumption using samples collected from animals with minimal inconveniences for them. The idea is not yet viable for large-scale implementation, but if the costs can be reduced to a competitive level, the technology may render many meat producers obsolete. Animals can then be released to live their lives in relative freedom, though humanity will still likely have to care for them, as they are fully domesticated. With the emergence of viable alternatives, cruel methods will become morally unjustifiable.

Methods of Control

Humans are omnivores, and therefore, it is natural for them to include meat and other animal products in their diet. As such, the current position that views vegetarians, and vegans in particular, as oddities and outliers, appears justifiable. However, the moral questions of animal treatment remain valid, and many vegetarians would be satisfied if livestock were not abused throughout their lives. Necessity is a compelling counterpoint, as the unprecedented numbers of modern humanity demand that producers go to extremes to satisfy our need for food. However, there are also methods of control that are employed by businesses and governments to downplay or avoid the issue and maintain the status quo.

Throughout much of human history, meat consumption was viewed as a symbol of power, the victory of the hunter over the prey, or the success of a farmer. According to Ruby and Heine (2011), people associate omnivorous habits more masculine when compared to vegetarianism, even though vegetarians were seen as more virtuous. It is in the interest of marketers and other people who create societal narratives to maintain this image. Thus, popular culture expressions such as fast food advertisements and depictions of wealthy and successful men often emphasize meat consumption. By contrast, vegetarianism receives considerably less attention, both because members of the movement are a minority and because it is inconvenient to interested parties.

Animal products that may have been less ubiquitous in the past have become popular and irreplaceable through aggressive marketing. According to Guptill, Copelton, and Lucal (2017), milk is an example of this phenomenon, which is known as commodification. It was not especially popular in the United States before the 20th century, but then the government began promoting its production and consumption through a variety of methods. As a result, dairy products became prevalent throughout the national culture, leading to a dramatic increase in demand and the consequent need to match it for suppliers. This change became one of the two primary reasons why dairy production became industrial and possibly dehumanized.

The other cause is the government’s approach to farming, which favored some methods over others with damaging consequences. Guptill et al. (2017) refer to this outcome as the farm crisis, wherein smaller, local producers could not compete due to the restrictions placed on their practices by the government. Meanwhile, large firms with efficient, automated approaches that came at the cost of the animals’ comfort could operate freely and proceeded to saturate the market. As Guptill et al. (2017) note, the opposition to these policies did not result in significant changes, and the practices became normalized. Opponents of changes informed by morality can now refer to the non-viability of the classic farm as an argument.

This point leads to the final form of control employed by the industry and the government, cost. Traditional producers could not compete because their practices incurred higher expenses than those of their inhumane peers, forcing them to set non-competitive prices or forgo profits. The same logic will be correct if a firm switches to non-abusive methods today, as organic products show in the agricultural industry. As such, most animal product suppliers will not commit to the change because of its detriment to their business.

Conclusion

Many of the practices employed by modern animal product manufacturers may be considered abusive to animals. However, they justify themselves to the public by claiming that the methods are necessary, a claim that is valid to some degree. Traditional farming is non-viable in the U.S., though that may be a result of government policies, and advanced technologies such as artificial meat growth are not ready for the market. However, the industry is also responsible for facilitating abuse by promoting the consumption of meat and other animal products. It perpetuates the existing cultural connotations of eating specific products when they benefit its narrative and tries to increase the popularity of its less widespread offerings.

References

Guptill, A. E., Copelton, D. A., & Lucal, B. (2017). Food and society: Principles and paradoxes (2nd ed.). Malden, MA: Polity Press.

Meadows, T. (2012). Because they matter. In A. B. Harper (Ed.), Sistah vegan: Black female vegans speak on food, identity, health, and society. New York, NY: Lantern Books.

Ruby, M. B., & Heine, S. J. (2011). Meat, morals, and masculinity. Appetite, 56, 447-450.

Spiegel, M. (1988). The dreaded comparison: Human and animal slavery. Philadelphia, PA: New Society Publishers.

Wurgaft, B. A. (2019). Biotech Cockaigne of the vegan hopeful. The Hedgehog Review, 21(1), 52-61.

Problem

The research department of a household appliances manufacturing company has devised a bimetallic thermal sensor for a toaster. According to the research department, this new sensor will reduce the return of appliances with a year-full warranty by 2%-6%. To validate this claim, two groups of toasters were selected by the testing department: a group produced with new sensors and a group produced with old sensors. Both of these were exposed to a worth of wear of an average year. Of the 250 toasters manufactured with new sensors, 8 would be returned. Of the 250 toasters manufactured with old sensors, 17 would be returned. A statistical procedure is needed for the research department’s claim to be to verified or refuted.

Theory

Since one needs to verify or refute a hypothesis, it is only reasonable to resort to hypothesis testing for the solution to this problem. According to Casella and Berger (2021), a hypothesis is a population parameter statement. The purpose of hypothesis testing is to determine which of the two complementary hypotheses is true based on a population sample. These complementary hypotheses are referred to as the null hypothesis and the alternative hypothesis and are respectively designated as H₀ and H₁.

Z-Test Model

For solving this particular problem, one is to use the Z test model for differences in proportions. As per Schumacker (2017), the Z-test questions may include the difference between a one-sample percentage and a determinate population percentage or the difference in the proportion of populations between two independent groups. Other types of questions may be related to differences in the proportions of populations between related groups. Z-test statistics can provide answers to research questions related to a single percentage, percentage differences between independent groups, and dependent percentage differences.

Z-Test Assumptions

When it comes to Two Sample Z Proportion Hypothesis Tests, there are some assumptions about those. According to Hessing (n.d.), data is both populations’ simple random values, both populations follow the Gaussian Probability distribution, and samples are never dependent of one another. Moreover, as per Hessing (n.d.), two sample Z proportion tests have their hypotheses. The null hypothesis and the alternative hypothesis have been mentioned before. In addition to that, there are right-tailed and left-tailed hypotheses: this is when the difference between proportions of the population is greater or smaller than the expected difference, respectively.

Solution

The solution starts with the definition of the null and alternative hypotheses. Null hypothesis means the proportions are the same, and alternative means they are not. Old sensors returns = x₁ = 8, and new sensors returns = x₂ = 17. Old sensors = n₁ = 250, and new sensors = n₂ = 250. Old sensors return = p̂_₁=17/250= 0.068 = 6,8%, and new sensors return = p̂_₂=8/250 = 0.032 = 3.2%. First compute p₀ = x₁+x₂ /n₁+n₂ = 8+17/250+250=25/500=0.05 = 5%.

Then, for the final Z formula, a couple more figures are needed. First, there is p̂₁ – p̂₂ = 0.068 – 0.032 = 0.036. Then, there is p₀ * (1 – p₀ ) = 0.05 * (1 – 0.05) = 0.05 * 0.95 = 0.0475. Finally, there is (1/n₁) + (1/n₂) = (1/250) + (1/250) = 0.004 + 0.004 = 0.008. Therefore, Z = (0.036)/ SQRT ( (0.0475) * (0.008)). Z = (0.036)/ SQRT ( 0.00038)) = (0.036)/ (0.019493) = 1.84

Flowchart

A flowchart, a diagram depicting a process, workflow, or algorithm, can be used to show the process of solving a two-proportions Z-test. This particular flowchart shows the operations that were necessary to calculate the final percentage difference between the two groups. All one needed to know was the number of old sensors and new sensors, and the number of old sensors and new sensor returns, as well as the relevant formulas.

Summary

In conclusion, the percentage difference between the groups of old sensor and new sensor returns equals 1.84. It shows a significant difference between the two product lines: the proportions are not the same. Therefore, the null hypothesis is rejected. When it comes to the research department’s claim, it is refuted since 1.84 is less than 2, and 2 percent was the lower limit of expected results.

References

Casella, G., & Berger, R. L. (2021). Statistical inference. Cengage Learning.

Hessing, T. (n.d.). Two sample Z tests for proportions. Six Sigma Study Guide.

Schumacker, R. E. (2017). Learning statistics using R. SAGE Publications.

Introduction

This report presents a discussion on aluminum casting alloys. The report describes the source of materials in the manufacture of aluminum alloys, the manufacturing process, and the economic importance of the product. The engineering properties that make aluminum casting alloys preferred are also discussed in the report.

Sources of aluminum casting alloy materials

Processed aluminum is lightweight and can easily be transported to different destinations. However, aluminum is extracted from various materials. The method of extraction determines the type and source of raw materials. Aluminum alloy materials are classified into two sources: primary and secondary logs (Lumley, 2010). Primary sources of raw materials for aluminum casting alloys are naturally-occurring compounds. On the other hand, secondary sources of aluminum, which is often used in recycling, include scrap metal and prime.

Aluminum occurs naturally in the form of bauxite. Therefore, bauxite provides the most common and largest source of raw materials for manufacturing virgin aluminum. Five nations are prolific producers of bauxite. They include Australia, Brazil, China, and Guinea. Currently, Australia is the largest producer of bauxite, yielding 250% more bauxite than its closest rival. Apart from the production of virgin aluminum, which is expensive both to produce and sell, aluminum can also be processed from recycled materials (Lumley, 2010). Recycling aluminum is the most cost-effective way of retrieving the metal from scrap.

With minimal differences in the structural make-up of the recycled and virgin aluminum, the high demand for the metal has been met through the recycling process. According to Azom.com (2014)), it takes 14,000 kWh to produce 1 ton of aluminum from bauxite whereas only 700 kWh are required to recycle the same amount of aluminum from scrap metal. Therefore, the energy consumption aspect and concerns about the environment justify the use of recycled aluminum.

Engineering properties that make Aluminium Preferred

Aluminum is one of the most used non-ferrous metal in industrial and domestic applications. Aluminum facilitates the construction industry, transport sector, mechanical and electrical engineering, and design (Lumley, 2010). The metal is unique, in its engineering properties, which makes it preferable for use in various applications. The following are among the common engineering properties of aluminum:

1. Corrosion-resistant and durable – According to Higgins (2010), aluminum metal is very resistant to corrosion, which makes it durable than other metals. The thin oxide coating on aluminum provides protection from chemical decomposition.
2. Good conductors – Aluminium is an excellent electrical and thermal conductor. This makes it a good thermo-conductor and thus better in heavy industrial use.
3. Aluminum alloys often blend better with the base metal and exhibit the basic characteristics of aluminum. These alloys can be molded into many shapes and forms, and thus the multiplicity of application.
4. Excellent recyclability – Aluminium has excellent recycling capability and can be recycled many times over.
5. Aluminum casting alloys can be given an artificial oxide layer that is resistant to water, using the ELOXAL process (Timelli & Bonollo, 2013).

The engineering characteristics of aluminum, and the many applications through which the metal can be used made it recyclable since time immemorial. Aluminum parts and its alloys are highly recyclable because the metal is extremely well-suited for re-melting.

Production Process

The aluminum alloy casting process begins with the sourcing of raw materials from different suppliers. Aluminum naturally occurs in the form of bauxite, the primary raw material from which the metal is processed (Higgins, 2010).

The raw material, bauxite, is prepared for production by the removal of impurities. A chemical process results in the production of alumina (aluminum oxide). The alumina is then mixed with sodium hydroxide solution, and passed through steady steam under high pressure to dissolve the aluminum oxide (Bonlalum.com, 2014). A blast furnace is used in this process. The casting equipment, through which the bauxite is passed consists of the pre-heat oven, the recuperator, front-end loader, and furnaces. The following diagram simplifies the process of purifying bauxite into alumina:

Impurities are filtered from the solution-form aluminum oxide through the process of filtration and filtration. The hot liquid solution is then allowed to cool, forming crystals of hydrated aluminum oxide.

The alumina crystals are then washed with water and dried in long rotary kilns (Higgins, 2010). The final clean and dry aluminum oxide is a very fine, crystalline compound that looks like sugar crystals. Aluminum is extracted from aluminum oxide through electrolysis. The alumina solution is electrolyzed in molten fluorides to make fine aluminum. The electrolysis process takes place in reduction pots, which are found in aluminum extraction plants.

Through electrolysis, high-quality final aluminum is produced. The reduction process reduces aluminum oxide to aluminum, eliminating the oxygen element from the oxide. It is interesting to note that alumina consists of an almost equal amount of oxygen as the aluminum component. This implies that one can extract one pound of pure aluminum from double the amount of alumina.

Production of aluminum alloys

The first step in alloy production is the addition of agents in recommended proportions into the furnace. The primary agents used in the preparation of aluminum cast alloys are scrape, prime, and hardeners, these consists of the charge (Bonlalum.com, 2014). These two elements are often pre-heated before being added to the furnace because of the explosion may occur if they contain moisture. The second stage is the degassing or fluxing stage. Degassing is the elimination of hydrogen elements from the molten metal (Higgins, 2010). Impure elements such as lithium, sodium, and alkaline are forced to precipitate.

Lastly, hardeners are added to the mixture to strengthen the resultant alloy. Before adding hardeners, samples are taken for spectrometer analysis (Timelli & Bonollo, 2013). The analysis evaluates element concentration in an alloy through comparative wavelength intensity analysis. Silicone and magnesium are added to the molten metal to act as hardeners.

Economic consideration

According to Aluminum.org (2014), the aluminum industry accounts for more than $150 billion of the US Gross Domestic Product (GDP). The industry has many economic impacts to any country involved in the production of aluminum. The following are the financial contributions of aluminum:

1. Aluminum recycling produces significant value to the economy – apart from the increased value of production of virgin aluminum, recycling of the metal conserve energy by up to ninety percent savings.
2. Job creation – In regions or nations where the manufacture of aluminum is evident, more job opportunities are created for the population. Primary manufacturing factories, smelting, and alloy production create numerous job opportunities for the population.
3. Economic impact – the industry contributes towards the economic impact of the country by more than $60 billion. With suppliers and allied businesses, the overall contribution spills over $150 billion in economic impact (Aluminum.org, 2014).

Conclusion

This report has allowed us to discuss the subject of aluminum casting alloys. The report has established that aluminum casting alloys are better suited for use in many applications because of the positive characteristics of the metal. Recycling the metal is economically better than manufacturing virgin aluminum. There are many economic advantages of the metal, as discussed in this report.

References

Aluminum.org,. (2014). The Economic Impact of Aluminum: The Aluminum Association. Web.

Azom.com,. (2014). Aluminium – History, Sources, Properties, Forming and Products. Web.

Bonlalum.com,. (2014). Aluminum Casting Process – Casting Terminology. Web.

Higgins, R. A. (2010). Materials for engineers and technicians. London: Elsevier.

Lumley, R. (2010). Fundamentals of Aluminium Metallurgy (1st ed.). Burlington: Elsevier Science.

Timelli, G., & Bonollo, F. (2013). Quality mapping of aluminium alloy diecastings. Metallurgical Science and Tecnology, 26(1).

Abstract

Modern manufacturing industries depend on metals for their production. Understanding metal forming and other properties of the commonly used materials like copper, normalized steel (NS-Black) and work-hardened steel (WHS-Silver) could help in the determination of their critical functional phenomenon. The tensile experiment studied parameters like strain fracture, tensile strength, yield stress, and elasticity (Young’s modulus). Findings were helpful for assessing the yield stress obtained from the graphical representation of the experiment and the existing theoretical values to evaluate the proof stress.

Introduction

Production of semi-finished or finished metal material depends on forming properties of the metal selected for industrial application. Downstream production processes rely on the properties of the formed metal (Alexander & Brewer, 1963). Therefore, modification and alteration of microstructure by plastic deformation, heat treatment, or heating help in changing metal properties to a material amenable to product development as early described by Alexander and Brewer (1963). The behavior of copper, normalized steel (NS-Black) and work-hardened steel (WHS-Silver) under tensile load is an important functional phenomenon of a tensile experiment. Measurement of mechanical properties of the strain to fracture, the tensile strength, the yield stress, and the elasticity (Young’s modulus) provided information on their plasticity and fracture (figure 1 below). These results were helpful in examining how the mechanical properties were affected by stress. The finding showed that the discrepancy could have resulted from using the graphical representations to determine the yield stress. These results suggested that copper material was more ductile than steel material, which had a higher toughness. However, steel material exhibited a higher yield and tensile strength. These observations were necessary to distinguish brittle fracture and other features of ductility (Tarr, n.d).

Results and Calculations

Sample dimensions (mm)

Yielding stress

Normalised steel (NS-Black)

copper experiment

Work-hardened steel (WHS-silver)

Tensile strength

Normalised steel (NS-Black)

Copper experiment

Work hardened steel (WHS-Steel)

Ductility (strain-to-fracture)

Normalised steel (NS-Black)

Copper experiment

Work hardened steel (WHS-Steel)

Young modulus E

Normalised steel (NS-Black)

Copper experiment

Work hardened steel (WHS-Steel)

Yield strain

Normalised steel (NS-Black)

Copper experiment

Work hardened steel (WHS-Steel)

Graphical representation

Descriptions of graphs

Graphical representation of figures 2, 3, and 4 show the findings of the stress-strain relationship of the three materials studied. Copper reported 445MP, work hardened steel gave 508MPa, while normalised steel has 536MPa tensile stress. With a proof stress of 0.1%, copper material exhibited a gradual yield making it different from the other two materials. Calculated elasticity modulus for these materials based on yield stress gave 26 Gpa for normalise steel, 66 Gpa for copper and 21 Gpa for work-hardened steel. Besides, the finding on elongation showed that normalised steel elongated by 3.5% after the experimental procedure. Analysis of the cross-sectional area demonstrated that the steel recorded a decline of 53.1% at the location of the fracture. However, copper underwent elongation by 6.5% while the cross-sectional area decreased by 25.9% at the site of the fracture.

The finding on copper yielding stress depicted a discrepancy in the experimental value obtained and the values listed in the engineering material. For instance, the experiment procedure got 200MPa, which was different from the 60MPa value in the engineering procedure. Such discrepancies were attributed to the fact that the analysis predicted copper yielding stress. Since the proof stress was the main component for the prediction of copper yield stress, there is a high likelihood that it could have an adverse impact on the authenticity of yield stress (Tarr, n.d). The other source of errors could include the reading obtained from the machine. In this experiment, the machine was not calibrated as advised by the instructor. The discrepancy between the yield stresses could have occurred because the graphical representations were used to determine the yield stress. The graphical representation presented clear and well-defined values for the high carbon steel as opposed to those of copper material. Proof stress was not appropriate for deriving the benefits because using it would give more accurate values with high confidence.

Determination of material modulus based on experimental uni-axial tensile stress may not reflect actual values, for this reason, the modulus is best determined through the measurement of sample natural frequency using oscillation test. Evaluating experimental modulus of elasticity, it is apparent that values in the engineering material were higher than those obtained from the experiment by one order magnitude. The engineering material quoted 124GPa for copper and 200GPa for steel.

Conclusion

These findings showed that copper material was more ductile than the steel material; copper had the highest toughness while steel material had the highest yield and tensile strength. However, when comparing copper and steel with equal elastic modulus, steel exhibited superior characteristics of tensile strength and yield stress than copper. The theoretical and experimental modulus values gave the indication that these results had lower confidence for the future referencing in related studies. However, these findings elaborated the importance of considering proof stress concept in the tensile analysis.

References

Alexander, J.M., & Brewer, R.C. (1963). Manufacturing Properties of Materials. Amsterdam: Van Nostrand Rheinhold

Tarr, M. (n.d). Stress and its effect on Materials. Web.