Explosives Accessories Manufacturing Process Control Training

Objectives:
• Understand the scope and importance of explosives accessories in mining and construction.
• Identify key safety regulations and legal frameworks in South Africa.
• Recognize the role of process control in ensuring product quality.
• Describe the basic components of an explosives accessory.
• Outline the course structure and assessment criteria.

Topics:
• Overview of explosives accessories: detonators, boosters, connectors, and initiating systems.
• Legal framework: Explosives Act, SANS standards, and SAQA requirements.
• Introduction to process control principles.
• Safety culture and hazard awareness.
• Course roadmap and learning outcomes.

Objectives:
• Identify raw materials used in explosives accessories manufacturing.
• Understand quality assurance protocols for incoming materials.
• Apply sampling and testing methods for raw materials.
• Interpret material safety data sheets (MSDS).

Topics:
• Raw material types: PETN, RDX, lead azide, aluminium powder, and binders.
• Supplier qualification and incoming inspection.
• Testing methods: purity, particle size, moisture content.
• MSDS interpretation and handling precautions.
• Non-conforming material procedures.

Objectives:
• Describe the step-by-step assembly process of electric and non-electric detonators.
• Identify critical control points in detonator manufacturing.
• Understand the role of automation in assembly.
• Apply basic process monitoring techniques.

Topics:
• Detonator components: shell, base charge, primer, and fuse head.
• Assembly sequence: pressing, filling, and sealing.
• Automation vs manual assembly: benefits and risks.
• In-process inspection: crimp diameter, charge weight.
• Common defects and corrective actions.

Objectives:
• Explain the manufacturing process for boosters and connectors.
• Identify critical parameters affecting performance.
• Understand mixing and pressing techniques for explosives.
• Implement process control checks for boosters.

Topics:
• Booster design: shape, density, and explosive fill.
• Connector types: shock tube, detonating cord, and relays.
• Mixing and pressing of secondary explosives.
• Quality checks: density, detonation velocity.
• Handling and storage of intermediate products.

Objectives:
• Define process control and its application in explosives manufacturing.
• Identify key process variables: temperature, pressure, humidity.
• Understand control charts and statistical process control (SPC).
• Apply basic SPC tools to manufacturing data.

Topics:
• Process control vs quality control.
• Variable types: continuous and discrete.
• Control charts: X-bar, R, and p-charts.
• Process capability indices (Cp, Cpk).
• Practical exercise: constructing a control chart.

Objectives:
• Identify instruments used for measuring process parameters.
• Calibrate and maintain measurement devices.
• Understand data acquisition and logging.
• Troubleshoot common instrumentation issues.

Topics:
• Sensors: temperature, pressure, flow, and humidity.
• Calibration standards and traceability.
• Data loggers and SCADA interfaces.
• Error sources and uncertainty.
• Practical calibration exercise.

Objectives:
• Identify hazards specific to explosives accessories manufacturing.
• Apply hazard analysis techniques (HAZOP, FMEA).
• Understand safety interlocks and emergency shutdown systems.
• Develop risk mitigation strategies.

Topics:
• Hazard categories: mechanical, electrical, chemical, explosive.
• HAZOP methodology for process lines.
• Failure mode and effects analysis (FMEA).
• Safety instrumented systems (SIS).
• Emergency response procedures.

Objectives:
• Understand ISO 9001 requirements for process control.
• Document control and record keeping.
• Implement corrective and preventive actions (CAPA).
• Prepare for internal audits.

Topics:
• ISO 9001:2015 clauses relevant to manufacturing.
• Documented procedures and work instructions.
• CAPA process flow.
• Internal audit techniques.
• Non-conformance reporting.

Objectives:
• Implement batch tracking systems.
• Understand lot numbering and expiration dating.
• Apply traceability from raw material to finished product.
• Conduct mock recall exercises.

Topics:
• Batch record design.
• Lot numbering conventions.
• Traceability software and barcoding.
• Mock recall procedure.
• Regulatory requirements for traceability.

Objectives:
• Explain ESD risks in explosives manufacturing.
• Implement ESD control measures.
• Use ESD-safe tools and equipment.
• Monitor and verify ESD protection.

Topics:
• ESD fundamentals: generation and discharge.
• ESD-sensitive components.
• Grounding and bonding techniques.
• ESD-safe workstations and garments.
• Periodic ESD audits.

Objectives:
• Maintain cleanroom and controlled environment standards.
• Implement 5S methodology.
• Monitor temperature and humidity.
• Understand contamination prevention.

Topics:
• Cleanroom classifications (ISO 14644).
• 5S: Sort, Set in order, Shine, Standardize, Sustain.
• Environmental monitoring: temperature, humidity, particle count.
• Contamination sources and control.
• Housekeeping audits.

Objectives:
• Understand process validation stages (IQ, OQ, PQ).
• Implement change control procedures.
• Evaluate impact of process changes.
• Document validation activities.

Topics:
• Validation master plan.
• Installation qualification (IQ).
• Operational qualification (OQ).
• Performance qualification (PQ).
• Change control request forms.
• Revalidation triggers.

Objectives:
• Apply root cause analysis tools (5 Whys, fishbone).
• Identify common process deviations.
• Develop corrective action plans.
• Use data to drive troubleshooting.

Topics:
• Common defects: misfires, low output, premature initiation.
• 5 Whys technique.
• Fishbone (Ishikawa) diagram.
• Pareto analysis.
• Case studies: troubleshooting real incidents.

Objectives:
• Understand PLC and SCADA applications.
• Configure basic control loops.
• Monitor process parameters remotely.
• Troubleshoot automation faults.

Topics:
• PLC basics: inputs, outputs, ladder logic.
• SCADA overview: HMI, alarms, trends.
• PID control loops.
• Automated weighing and dosing systems.
• Hands-on simulation exercise.

Objectives:
• Understand regulatory requirements for explosives manufacturing.
• Prepare for external audits.
• Implement corrective actions from audit findings.
• Maintain compliance documentation.

Topics:
• Department of Mineral Resources and Energy (DMRE) requirements.
• SABS and SANS standards.
• Audit types: internal, customer, regulatory.
• Audit checklists and evidence.
• CAPA for audit findings.

Objectives:
• Apply lean principles to explosives manufacturing.
• Identify waste and implement improvements.
• Use Kaizen and Six Sigma tools.
• Measure improvement impact.

Topics:
• Lean: 8 wastes, value stream mapping.
• Kaizen events.
• Six Sigma: DMAIC methodology.
• Key performance indicators (KPIs).
• Case study: process improvement project.

Objectives:
• Demonstrate process control skills in a simulated environment.
• Complete a comprehensive practical assessment.
• Review key course concepts.
• Prepare for certification.

Topics:
• Simulated manufacturing scenario.
• Process monitoring and adjustment.
• Quality checks and documentation.
• Assessment feedback.
• Course summary and certification process.