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Statistical process control (SPC) is an important quality application that is used throughout industry and is composed of control charts. Most often, it is applied in the final stages of product manufacturing. However it would be beneficial to apply SPC throughout all stages of the manufacturing process such as the beginning stages. This report explores the fundamentals of SPC, applicable programs, important aspects of implementation, and specific examples of where SPC was beneficial. Important programs for SPC are general statistical software such as JMP and Minitab, and some programs are made specifically for SPC such as SPACE: statistical process and control environment. Advanced programs like SPACE are beneficial because they can easily assist with creating control charts and setting up rules, alarms and notifications, and reaction mechanisms. After the charts are set up it is important to apply rules to the charts to see when a system is running off target which indicates the need to troubleshoot and investigate. This makes the notification part an integral aspect as well because attention and awareness must be brought to out of control situations. The next important aspect is ensuring there is a reaction mechanism or plan on what to do in the event of an out of control situation and what to do to get the system running back on target. Setting up an SPC system takes time and practice and requires a lot of collaboration with experts who know more about the system or the quality side. Some of the more difficult parts of implementation is getting everyone on board and creating trainings and getting the appropriate personnel trained.
ContributorsSennavongsa, Christy (Author) / Raupp, Gregory (Thesis director) / Dai, Lenore (Committee member) / Materials Science and Engineering Program (Contributor) / Chemical Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
Mangura Mine in Zimbabwe has been operating under a traditional copper mining method for the past few decades. This mining method is referred to as the pyrometallurgical process. The process involves copper ore extraction, crushing, milling, floatation, concentrating and smelting. With the low copper grades reported at the mine, this multi-stage process is not highly effective to extract this metal. The energy, labor and other expenses incurred in pollution control, have been high. The mine is downsizing every year and it is expected to close in the foreseeable time horizon, even though they still have copper reserves at their property. This project was aimed at providing an effective approach to the future of extracting low grade copper through using a hydrometallurgical extraction process. The hydrometallurgical method is a multi-stage process involving the leaching of copper ore, solvent extraction and electrowinning. The economic viability of implementing a hydrometallurgical process for extracting copper was evaluated. The paper demonstrated the feasibility of the hydrometallurgical process in extracting low grade copper at the mine. A detailed extraction process was developed with the goal of recovering 2.9 million metric tons of copper per year with 99.9 wt.% minimum purity. The return on investment was estimated to be more than 200%. All the findings indicated that implementing a hydrometallurgical process should be the future of Mhangura Mine.
ContributorsMtemeri, Lincoln (Author) / Raupp, Gregory (Thesis director) / Taylor, David (Committee member) / Chemical Engineering Program (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2019-05