Study of high-tech process furnace using inherently safer design strategies (I) temperature distribution model and process effect

High-tech industries, such as those producing semiconductor and TFT-LCD (Thin Film Transistor Liquid Crystal Display), have recently become the most important economic activities in Taiwan. Each of these industries has a complete chain of supply from raw material production, production pre-processing, product manufacturing, to waste handling. Any company in the chain is a critical component, since any accidents of fire, explosion, gas leakage, or power outage would cut off the supply chain, causing inability of continuous operation. In industries of semiconductor and TFT-LCD, great amounts of special gases and chemicals with many machinery equipments are used in the production processes. In cases of accidents or improper installation, this chain of supply, from raw material production, preproduction, product manufacturing, to waste handling materials and equipments may cause severe damages or incidents.This study used the existing model of the horizontal furnace to develop a simulation program. The simulation results were consistent with the existing model, and produced even slightly better results on temperature distribution and temperature sensitivity. The simulation model applied on a vertical furnace could provide data on furnace temperature control for industrial use. Meanwhile, this study also deduced actual temperature control and an ISD strategy, which are consistent with design strategy principles.The validation results on the proposed temperature distribution model suggested that the model can be applied in temperature distribution and sensitivity analysis to obtain adjustment and control models for various heating zones. In the case of a single tool, when processing reduction is 60 pieces, switching off the two heating zones can reduce 44% of power output, for a capacity utilization rate of 93.7% for the entire plant. The application of the proposed temperature control model can reduce power consumption by 121.4 kWh. In addition, with the same number of tools, facilities layouts in two cases have an area difference of 41.4775 m², thus shortening the evacuation time for operators. The experimental results proved that the proposed model has realized the ISD principles of intensification, attenuation, and limitation of effects.     

Ergonomics Oriented to Processes Becomes a Tool for Continuous Improvement

Abstract

A holistic view is essential for quality initiatives such as Total Quality Management (TQM), Standard No. ISO 9001:1994 (International Organization for Standardization [ISO], 1994), Concurrent Engineering, Business Reengineering, and Business Process Improvement. The challenge is knowing how to transition from this theoretical concept to implementation. The relationship between quality interest and anergonomics program will be the focus of this discussion. An ergonomics oriented improvement program includes (a) ergonomics or fitting the job to the person; (b) integration of operations management, safety engineering, medical management, and employees as co-owners of the process; (c) the emphasis of ergonomic precepts in the engineering of new processes and improvement of current processes; and (d) the emphasis of employees taking responsibility for their own well being and the improvement of their work environment. The parallel between the continuous improvement process delineated by the quality-system requirements in Standard No. ISO 9001:1994 (ISO, 1994) and the improvement contributions of ergonomics are very revealing (Getty, Abbott, & Getty, 1995). It is the contention of this approach that if the precepts of ergonomics were applied to the work environment, it would support the objective of world class quality and productivity, resulting in improved global competitiveness of businesses.     

A Model to Analyze Ergonomics Working Conditions

An ergonomics and safety model to assess and evaluate the most critical industrial improvement areas in a developing nation. This study was initiated and supported by a Fortune 500 Corporation interested in improving its global operations in developing nations. This initiative was also fully supported by an emerging nation that was concerned with its ergonomics and safety problems. The model was tested and validated in the emerging nation and the results were used to further enhance the model so that it can be implemented and adapted to other similar work environments. The model provides a practical methodology that analyzes and evaluates an emerging nation’s current work environments, suggests practical solutions, and recommends effective remedies.     

Anthropometry for Design for the Elderly

This paper presents anthropometric data on elderly people in Australia. Data were collected in the metropolitan city of Sydney, NSW, Australia. In all 171 elderly people (males and females, aged 65 years and above) took part in the study. Mean values, standard deviations, medians, range, and coefficients of variation for the various body dimensions were estimated. Correlation coefficients were also calculated to determine the relationship between different body dimensions for the elderly population. The mean stature of elderly Australian males and females were compared with populations from other countries. The paper discusses design implications for elderly people and provides several examples of application of the anthropometric data.     

Evaluation and Optimization of Handle Design Parameters of a Grass Trimming Machine

The grass trimming machine is a widely used agricultural machine for cutting grass by the roadside and in other areas in Malaysia. Hand-arm vibration (HAV) syndrome is very common among workers operating power tools and performing similar work for extended periods. Grass trimming involves the use of a motorized cutter spinning at high speed, resulting in high levels of HAV among its operators. The existing D-shape handle causes HAV-related stress and operational load in operators. This research proposes a new design of a handle of the grass trimming machine. When this new design was compared with the old one, it was found that the new handle resulted in 18% lower HAV. To find the lowest HAV, 3 critical parameters of the new handle (length, angle and material of the cap of the handle) were optimized using the Taguchi quality tool. Appropriately selected parameters of the new handle significantly reduced the occurrence of HAV among grass trimmers.     

Hand anthropometric study in northern Colombia

The main purpose of this study is to gather information about the dimensions of the northern Colombian (Caribbean region) population, focusing on the dimensions of the hand and comparing them with measurements from other regions. Thirty-two hand dimensions were chosen and 120 males and 86 females were measured. Results indicated that there were differences between the dimensions of the hand for men and women, showing that men are larger. Also, there was a comparison made between some measurements of other studies in different regions of Colombia, the USA, Chile, Jordan, Korea and Japan. The results indicated important physiological differences between regions in Colombia and across countries. It was therefore concluded that differences in anthropometric measurements must be included in the design and procurement of machinery and apparatus in order to avoid productivity loss, occupational injuries or illness.     

隧道型细水雾灭火系统在公路隧道的设计与应用

隧道火灾的防治一直是火灾科学研究的热点和难点.通过对公路隧道灭火技术的比较,指出细水雾灭火技术是适用于公路隧道消防保护的灭火技术.并在此基础上介绍了西欧一种新型的隧道型细水雾灭火系统,该系统采用模块化设计,每个保护区模块长18-20m,额定工作压力为1MPa,设计可靠、安装方便、维护成本低.在挪威Runehamar隧道开展了全尺寸实验,结果表明系统可成功控制和熄灭高达100MW的火灾.在全尺寸隧道火灾实验的基础上,进行了公路隧道内隧道型细水雾灭火系统的典型设计,为公路隧道细水雾灭火系统的应用及发展提供参考.     

A Two‐Decade Watershed Approach to Stream Restoration Log Jam Design and Stream Recovery Monitoring: Finney Creek,Washington

A federal, state, and private partnership leveraged resources and employed a long‐term, systematic approach to improve aquatic habitat degraded by decades of intensive forest management in Finney Creek, a tributary to the Skagit River of Northwest Washington State. After more than a decade of work to reduce sediment sources and the risk of landslides within the watershed, log jam installation commenced in 1999 and progressed downstream through 2010. Log jam design was adapted as experience was gained. A total of 181 log jams, including 60 floating log ballasted jams, were constructed along 12 km of channel. The goal was to alter hydraulic processes that affect aquatic habitat formation along 39 km of stream with emphasis on 18.5 km of lower Finney Creek. Aquatic habitat surveys over a five‐year period show an increase in the area of large pools and an accompanying increase in residual and maximum pool depth in the lower river reach. Channel cross sections show a generally deeper channel at the log jams, better channel definition in the gravel deposits at the head of the log jams, and improved riffle and thalweg development below the log jams. Stream temperature in the upper river decreased by 1.0°F in the first three years, and 1.1°F in the lowest treated reach over nine years. There is a trend of less stream heating over the restoration time period. Photo points show that riparian vegetation is recolonizing gravel bars.     

Modeling of Fluid Flow and Heat Transfer in a Copper Based Heat Sink Application

With the trend towards increasing the speed of processors in smaller sized of computers, there has been considerable interest in heat sink technologies with higher levels of performance and further miniaturization. This work addresses the fundamental heat transfer augmentation question of how to design a copper-based heat sink, when the overall dimensions of the bottom plate or fan are specified. A three-dimensional finite-volume model has been developed and applied to investigate flow and conjugate heat transfer in the copper-based heat sink. The model was produced with the commercial program FLUENT, which allows this nonlinear, highly turbulent problem to be simulated using the k-ε turbulence model. The theoretical model developed is validated by comparing the model predictions with available experimental data. The thermal performance and temperature distribution for the heat sink were analyzed and a procedure for optimizing the geometrical design parameters based on less space occupation and more efficient heat transfer coefficient is presented. Several design examples with different types of cooling methods and manufacturing processes have been analyzed. The reliability and effectiveness in heat spreading of those has been compared. It has been shown that the copper-based heat sink with louvered fins (case No.3) has an optimum design configuration.