Full development process improvement

Nevertheless the euphoric optimism where these materials were allowed a huge potential in material applications has given way to a more realistic view. Nanocomposites are not a universal solution for reinforced materials. Their full potential can only be realised if every step in the added value chain is taken into account during the whole development process. From todays perspective nanocomposite materials with an improved thermal flammability resistance or improved barrier properties have the best chances to fulfil these requirements. 

As discussed earlier, many FR qualification tests for wires and cables, according to applicable standards, require testing on a fully fabricated article. However, to conduct research toward new materials for use in wire and cable applications, it is often desirable to obtain directional information in the early stages by conducting laboratory-scale tests that are capable of discerning improvements in FR characteristics of materials. Later in the product development process, optimization, validation, and qualification must nevertheless be conducted on full-scale articles and equipment. 

The development of a qualified down-scale model of a process module is integral to the approach of process validation using bench-scale experiments, as described earlier. We have developed down-scale models of process steps ranging from various types of process chromatography for protein purification to separation by precipitation and filtration. These down-scale models have been utilized to evaluate the effects of relevant process parameters on product-quality attributes. The normal logical sequence of process development, of course, is bench scale to pilot scale to full scale. However, for many plasma protein purification processes, a reverse order needs to be followed. As licensed full-scale processes already exist, the full-scale process steps need to be scaled down to construct small process models in order to evaluate the robustness of process parameters on the product without impacting full-scale production. These models can also be utilized to evaluate process changes, improvements, and optimizations easily and economically. 

Many other iron catalyst compositions have been examined experimentally as the styrene process has developed." Chromium was replaced or combined with a wide range of other oxide promoters, such as copper oxide, zinc oxide, vanadium pentoxide, thoria, tungsten oxide, molybdena, ceria, and alkaline earth oxides. At the time, none was used in any full-scale process but some were later found to give good performances in improved plants. 

A failure modes and effects analysis is a systematic analytical technique for identifying potential failures in a design or a process, assessing the probability of occurrence and likely effect, and determining the measures needed to eliminate, contain, or control the effects. Action taken on the basis of an FMEA will improve safety, performance, reliability, maintainability and reduce costs. The outputs are essential to balanced and effective quality plans for both development and production as it will help focus the controls upon those products, processes, and characteristics that are at risk. It is not the intention here to give a full appreciation of the FMEA technique and readers are advised to consult other texts. 

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