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The Consequences of Implementing Statistical Process Control

Description: This study evaluated the changes which occur in manufacturing organizations in the plastic molding industry which implement statistical process control (SPC). The study evaluated changes in product quality, consistency, cost, changes in employee attitudes, and changes in the organization structure which occur after the implementation of SPC. The study was conducted in two phases. Phase 1 consisted of an exploratory field study of a single manufacturing company. Phase 2 consisted of a field survey of three manufacturing companies in the same industry. An unexpected opportunity to evaluate the differences in effects of successful and unsuccessful SPC implementations occurred during the field survey. One plant, whose management assessed their SPC program as being unsuccessful, reported no economic or quality benefits from SPC. Neither did this plant report any changes in the attitudes or behavior of their employees. Neither of these findings was surprising since this plant was the only one of the four study plants which implemented SPC as a quality control program with no participation from the production department. The three plants whose management assessed their SPC programs as being successful reported reduced product variation and a decrease in the proportion of defective product produced as a result of SPC. No consistent evidence was found concerning a reduction in the material required per product resulting from SPC. No consistent evidence was found linking changes in employee attitudes and behavior to the implementation of SPC. The field study found a significant change in the employees1 attitudes toward management but no change in their attitudes toward the company. The field survey found no evidence of change in either dimension. Evidence was found for a change to a more organic structure during SPC training and to a more mechanistic structure during SPC implementation. The final form of the organization was more organic than ...
Date: August 1990
Creator: Sower, Victor E.
Partner: UNT Libraries

An Adaptive System for Process Control

Description: Abstract: Researchers at the U.S. Bureau of Mines (USBM) have developed adaptive process control systems in which genetic algorithms (GA's) are used to augment fuzzy logic controllers (FLC's). GA's are search algorithms that rapidly locate near-optimum solutions to a wide spectrum of problems by loosely modeling the search procedures of natural genetics. FLC's are rule-based systems that efficiently manipulate a problem environment by modeling the "rule-of-thumb" strategy used in human decisionmaking. Together, GA's and FLC's include all of the capabilities necessary to produce powerful, efficient, and robust adaptive control systems. To perform efficiently, such control systems require a cont element to manipulate the problem environment, an analysis element to recognize changes in the problem environment, and an adaptive element to adjust to the changes in the problem environment. The control system also employs a computer simulation of the problem environment. Details of an overall adaptive control system are discussed. A specific laboratory acid-base pH system is used to demonstrate the ideas presented; all results are from the physical laboratory system and not from a computer simulation.
Date: 1995
Creator: Karr, Charles L.; Gentry, E. J. & Stanley, D. A.
Partner: UNT Libraries Government Documents Department

Statistical process control (SPC) for coordinate measurement machines

Description: The application of process capability analysis, using designed experiments, and gage capability studies as they apply to coordinate measurement machine (CMM) uncertainty analysis and control will be demonstrated. The use of control standards in designed experiments, and the use of range charts and moving range charts to separate measurement error into it's discrete components will be discussed. The method used to monitor and analyze the components of repeatability and reproducibility will be presented with specific emphasis on how to use control charts to determine and monitor CMM performance and capability, and stay within your uncertainty assumptions.
Date: January 4, 2000
Creator: Escher, R. N.
Partner: UNT Libraries Government Documents Department

Proceedings of the 1981 Symposium on Instrumentation and Control for Fossil-Energy Processes: June 8-10, 1981 Sheraton-Palace Hotel, San Francisco, California

Description: Compiled proceedings of the fifth Symposium on Instrumentation and Control for Fossil-Energy Processes, covering process control involved in the conversion of fossil fuels into synthetic fuels.
Date: January 1982
Creator: Argonne National Laboratory
Partner: UNT Libraries Government Documents Department


Description: We summarize the ECL2 workshop on electron cloud clearing, which was held at CERN in early March 2007, and highlight a number of novel ideas for electron cloud suppression, such as continuous clearing electrodes based on enamel, slotted structures, and electrete inserts.
Date: April 9, 2007
Creator: FISCHER,W.
Partner: UNT Libraries Government Documents Department

Adaptive control of femtosecond pulse propagation in optical fibers

Description: We present an adaptive control loop that synthesizes fs-pulses that are self-correcting for higher order nonlinear effects when launched in a conventional single-mode fiber, nearly preserving the initial (t{approx}200 fs) pulse duration.
Date: January 1, 2001
Creator: Omenetto, F. G. (Fiorenzo G.); Taylor, Antoinette J.,; Moores, M. D. (Mark D.) & Reitze, David H.
Partner: UNT Libraries Government Documents Department

Project B: Improved Liquid Steel Feed For Slab Casters

Description: This report describes the completion of the development of an electromagnetic valve to control liquid steel flow for improved liquid steel feeding for slab casters. Achievements result from a joint research effort between Westinghouse Science and Technology Center, North American Refractories and U.S. Steel. This effort is part of the American Iron and Steel Institute's (AISI) Advanced Process Control Program, a collaboration between the U.S. Department of Energy (DOE) and fifteen North American steel makers.
Date: October 1, 1998
Creator: Isaacson, Brent S.; Slepian, Mike & Richter, Thomas
Partner: UNT Libraries Government Documents Department

Emerging standards with application to accelerator safety systems

Description: This paper addresses international standards which can be applied to the requirements for accelerator personnel safety systems. Particular emphasis is given to standards which specify requirements for safety interlock systems which employ programmable electronic subsystems. The work draws on methodologies currently under development for the medical, process control, and nuclear industries.
Date: August 1, 1997
Creator: Mahoney, K.L. & Robertson, H.P.
Partner: UNT Libraries Government Documents Department

Process Control System Cyber Security Standards - An Overview

Description: The use of cyber security standards can greatly assist in the protection of process control systems by providing guidelines and requirements for the implementation of computer-controlled systems. These standards are most effective when the engineers and operators, using the standards, understand what each standard addresses. This paper provides an overview of several standards that deal with the cyber security of process measurements and control systems.
Date: May 1, 2006
Creator: Evans, Robert P.
Partner: UNT Libraries Government Documents Department

Help for the Developers of Control System Cyber Security Standards

Description: A Catalog of Control Systems Security: Recommendations for Standards Developers (Catalog), aimed at assisting organizations to facilitate the development and implementation of control system cyber security standards, has been developed. This catalog contains requirements that can help protect control systems from cyber attacks and can be applied to the Critical Infrastructures and Key Resources of the United States and other nations. The requirements contained in the catalog are a compilation of practices or various industry bodies used to increase the security of control systems from both physical and cyber attacks. They should be viewed as a collection of recommendations to be considered and judiciously employed, as appropriate, when reviewing and developing cyber security standards for control systems. The recommendations in the Catalog are intended to be broad enough to provide any industry using control systems the flexibility needed to develop sound cyber security standards specific to their individual security requirements.
Date: May 1, 2008
Creator: Evans, Robert P.
Partner: UNT Libraries Government Documents Department

Study of the State-of-the-Art of Instrumentation for Process Control and Safety in Large-Scale Coal Gasification, Liquefaction, and Fluidized-Bed Combustion Systems

Description: A study has been carried out to determine the state-of-the-art of instrumentation which is available for process control and safety in planned demonstration and commercial scale coal gasification, liquefaction, and fluidized-bed combustion systems. The study identified available instrumentation which will perform satisfactorily in these systems and pinpointed deficiencies for which instruments must be developed. The identified deficiencies fall into the same few categories for all processes considered. These categories are presented with associated physical parameters found in the various processes studied. Development of instruments to meet these deficiencies is recommended along with development of control valves and optimal control schemes in order to assure the possibility of automatic control of the large scale coal conversion and combustion systems.
Date: 1976
Creator: O'Fallon, N. M.; Beyerlein, R. A.; Managan, W. W.; Karplus, H. B. & Mulcahe, T. P.
Partner: UNT Libraries Government Documents Department

Photovoltaic Cz Silicon Module Improvements; Final Subcontract Report, 9 November 1995 - 8 November 1998

Description: This report describes work that focused on reducing the cost per watt of Cz silicon photovoltaic modules under Siemens Solar Industries' (SSI) DOE/NREL Photovoltaic Manufacturing Technology (PVMaT) 4A subcontract. SSI researchers deployed new module designs, realized improvements in yield of more than 25%, and implemented statistical process control (SPC). They have described yield improvements in detail and reported on the deployment of SPC in critical process steps. The sum of all improvements resulted in a greater than 17% cost per watt reduction in manufacturing.
Date: June 17, 1999
Creator: Jester, T. L.
Partner: UNT Libraries Government Documents Department


Description: Significant savings are being realized from the consolidated tritium gas-processing operations at the Savannah River Site. However, the trade-off is some reduction of operational flexibility due to decreased storage capacity for process and waste gases. Savannah River National Laboratory researchers are developing an integrated process gas model for tritium processing using Aspen Custom Modeler{trademark} (ACM) software. The modeling involves fully characterizing process flow streams (gas composition, quantity), frequency of batch transfers, and availability of equipment in the flow stream. The model provides a valuable engineering tool to identify flow bottlenecks, thereby enabling adjustments to be made to improve process operations.
Date: August 30, 2007
Creator: Hang, T & Anita Poore, A
Partner: UNT Libraries Government Documents Department


Description: Modern weld controllers typically use current to control the weld process. SRS uses a legacy voltage control method. This task was undertaken to determine if the improvements in the weld control equipment could be implemented to provide improvements to the process control. The constant current mode of operation will reduce weld variability by about a factor of 4. The constant voltage welds were slightly hotter than the constant current welds of the same nominal current. The control mode did not appear to adversely affect the weld quality, but appropriate current ranges need to be established and a qualification methodology for both welding and shunt calibrations needs to be developed and documented.
Date: October 11, 2005
Creator: Korinko, P; STANLEY, S & HOWARD, H
Partner: UNT Libraries Government Documents Department

Object Oriented Run Control for the CEBAF Data Acquisition System

Description: After an extensive evaluation, the Eiffel object oriented language has been selected for the design and implementation of the run control portion of the CEBAF Data Acquisition System. The OSF/Motif graphical user interface toolkit and Data Views process control system have been incorporated into this framework. We discuss the evaluation process, the status of the implementation and the lessons learned, particularly in the use of object oriented techniques.
Date: January 1, 1991
Creator: Quarrie, David; Jastrzembski, Edward; Heyes, William & Watson, William
Partner: UNT Libraries Government Documents Department

Update on specifications for NIF ignition targets and their rollup into an error budget

Description: Targets intended to produce ignition on NIF are being simulated and the simulations are used to set specifications for target fabrication. Recent design work has focused on designs that assume only 1.0 MJ of laser energy instead of the previous 1.6 MJ. To perform with less laser energy, the hohlraum has been redesigned to be more efficient than previously, and the capsules are slightly smaller. The main-line hohlraum design now has a SiO2 foam fill, a wall of U-Dy-Au, and shields mounted between the capsule and the laser entrance holes. Two capsule designs are being considered. One has a graded doped Be(Cu) ablator, and the other graded doped CH(Ge). Both can perform acceptably with recently demonstrated ice layer quality, and with recently demonstrated outer surface roughness. Smoothness of the internal interfaces may be an issue for the Be(Cu) design, and it may be necessary either to polish partially coated shells or to improve process control so that the internal layers are smoother. Complete tables of specifications are being prepared for both targets, to be completed this fiscal year. All the specifications are being rolled together into an error budget indicating adequate margin for ignition with the new designs.
Date: July 11, 2005
Creator: Haan, S W; Herrmann, M C; Amendt, P A; Callahan, D A; Dittrich, T R; Edwards, M J et al.
Partner: UNT Libraries Government Documents Department

A Built for Purpose Micro-Hole Coiled Tubing Rig (MCTR)

Description: This report will serve as the final report on the work performed from the contract period October 2005 thru April 2007. The project 'A Built for Purpose Microhole Coiled Tubing Rig (MCTR)' purpose was to upgrade an existing state-of-the-art Coiled Tubing Drilling Rig to a Microhole Coiled Tubing Rig (MCTR) capable of meeting the specifications and tasks of the Department of Energy. The individual tasks outlined to meet the Department of Energy's specifications are: (1) Concept and development of lubricator and tool deployment system; (2) Concept and development of process control and data acquisition; (3) Concept and development of safety and efficiency improvements; and (4) Final unit integration and testing. The end result of the MCTR upgrade has produced a unit capable of meeting the following requirements: (1) Capable of handling 1-inch through 2-3/8-inch coiled tubing (Currently dressed for 2-3/8-inch coiled tubing and capable of running up to 3-1/2-inch coiled tubing); (2) Capable of drilling and casing surface, intermediate, production and liner hole intervals; (3) Capable of drilling with coiled tubing and has all controls and installation piping for a top drive; (4) Rig is capable of running 7-5/8-inch range 2 casing; and (5) Capable of drilling 5,000 ft true vertical depth (TVD) and 6,000 ft true measured depth (TMD).
Date: September 30, 2007
Creator: Patton, Bart
Partner: UNT Libraries Government Documents Department