Download - The Apprentice_Abhrajit Sett_KJ SIMSR
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
1/24
GOODYEARBallabgarh
REDUCTION OF WASTE FROM EXTRUSION IN TIREMANUFACTURING PROCESS
Summer Project Presentation
At
GOODYEAR INDIA LIMITED,BALLABHGARH
By
Abhrajit Sett
K J Somaiya Institute of Management Studies and ResearchMumbai
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
2/24
#1North America
#1Latin America
#1
EasternEurope, MiddleEast, & Africa
Asia one of the fastestgrowing markets. Goodyear
holds a # 2 pos ition in market
#2
RegionalRank
A Global Company
Asia
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
3/24
Plant Location : 28 km South of Delhi in Haryanastate on National Highway No.2.
Major Industries in Area : Escorts, Maruti (Gurgaon), JCB, Yamaha,
Honda (Greater Noida)
Area : 67 acre with 654,000 sq.ft of floor space
Manufacturing : Automotive tires started in 1961,presently producing 4100 Tires per day.
Products : Farm, Truck, LCV tires.
Goodyear Ballabhgarh
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
4/24
Natural Rubber
Banbury - Mixer
Extrusion
Calendering
Tire Building
Curing
InspectionDispatch
OEMRetail
Tire Building Process
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
5/24
Plant Layout
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
6/24
Project Definition
Data collection
Root Cause Analysis Actions suggested based on identified root
causes
Cost Benefit Analysis Key Learnings
Project Approach
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
7/24
DEFINITION
The main objective of doing the project is to reduce the waste from extruder machinewhich produces tire treads so as to reduce scrap/rework costs and improve theproductivity of the plant.
SCOPE
The scope of the project includes study of extrusion waste that occurs in different
processes during tire making. Reduction of waste in other processes(particularly curing)was beyond the scope.
The scope is limited till the recommendation phase. The actual implementations of therecommendations are under the purview of the organization.
ASSUMPTION
The waste reduction was limited to material waste because the extrusion process bearsslack.
The bottleneck lies at the curing process so extrusion doesnt work at full capacity.
The defect data collected was only limited to 7 days in Shift A. The defects in other shiftsare expected to be of same pattern.
Project Objective
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
8/24
Compoundstorage area
Capbreakd
ownmill
Basebreakd
ownmill
Capfeedmill
Basefeedmill
EXTRUDER
Takeaway
conveyor
Gravityrollers
Inclinedconvey
or
CoolingConvey
or
DecliningConveyo
r
Skiver
Weighing
Conveyor
ScrapMarker
CementStation
Extrusion Process
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
9/24
51.3%
22.5%
16%
7.8%
54, 3%
Types of defects in treads
LOW WEIGHT
HIGH WEIGHT
LUMPS
TORNEDGE
OTHERS
Treads produced-12207Treads rejected-1674
Defect Data
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
10/24
Defect Data (sample for 24.5.2011)
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
11/24
Pareto Analysis
FINDINGS
More than 50% of the
rejections are caused to
low weight. High weight
and lumps add up to
almost 90% of therejections. In our analysis
lump rejection is being
considered because lump
rejections are completely
controllable up to 40%
whereas weight rejections
can be only be removed
up to 20% or below.
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
12/24
Low weight
MAN MATERIAL
MACHINE METHOD
Feed break (M) Low Viscosity (M)
Die setting not proper Low specific gravity (M)
Low weight Running weight not properly set
Line synchronization not proper Waiting for compound
Mechanical/Electrical Operating skillsstoppage (M)
Root Cause Analysis for Low Weight rejects
(M) Major reasons
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
13/24
Why-Why Analysis for Low weight rejects
Why #6
Why #5
Why #4
Why #3
Why #2
Why #1 Lowweight
Lowviscosity
Compound
milled for along time atB.D. mill.
Mill operatordid not keeptrack of time
Operatornegligence
Temperature
at extruderheadincreased
No watercirculation at
extruderhead
Water valveclosed
Non-conformanc
e ofprocedure
Lowspecificgravity
Compoundin
g not OKfromBanbury
Chemicalsnot mixed in
properquantity
Scaling error
in autoloading
Calibrationnot done.
Lack of audit
Electricalstoppage
s
Feedbreak
Compound
stuck at millguard of feedmill
Materialaccumulated
at top ofmillguard
Operator filed
to noticeaccumulation
No line ofsight less
visibility
Compoundslipped frombite rollers
Adequatedistance from
bite rollersnot kept
Bite-rollers
notmaintained
Audit notperformed
Root Causes
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
14/24
High weight
MAN MATERIAL
MACHINE METHOD
Operating skills High viscosity variation (M)(Die setting)
Line synchronization Improper breakdown ofnot proper compound at B.D. Mill (M)
Wrong die tuning
Root Cause Analysis for High Weight rejects
(M) Major reasons
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
15/24
Why-Why Analysis for High weight rejects
Why #6
Why #5
Why #4
Why #3
Why #2
Why #1 Highweight
Improperbreakdown
of compound
Compoundmilled for alesser time
Compoundurgently
needed atfeed mill
Feed millrunning shortof compoundat extruder.
Shortage ofmaterial.Planningimproper.
Highviscosity
Compound
fromBanbury was
hard
Impropermixing atBanbury
Mixing cyclenot followedby operator
SOP not inplace
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
16/24
Lumps
MAN MATERIAL
MACHINE METHOD
Absenteeism Lumpy Compound (M)
Negligence (M) Viscosity variation (M)
Temp/TCU Waiting for compound
Line stoppage (M) Operating skills
Root Cause Analysis for Lump rejects
(M) Major reasons
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
17/24
Why-Why Analysis for Lump rejects
Why #6
Why #5
Why #4
Why #3
Why #2
Why #1 Lumps
Lumpycompound
Lumpytreads mixedat Banbury
Lumps notremovedduring
segregation
Improperdisposal oflumpy scrap
Improperdisposal of
lumpy treads
Lumpytreads notrecorded
Compoundgot lumpy infeed mill
Compoundprocessedfor a long
time
Orbitconveyor notused in cap
side
Operator nottrained in orbit
conveyorusage
Lumps
formed atBanbury
mixer
Mill tailingswaste added
to mixer
Mill tailingsformed frommill guides
Housekeepingat mill guides
not done
Viscosityvariation
LineStoppage
Safety fromthe coolingtank
Tread slippedfrom cooling
tank todancing roller
Less visibilityfor operator to
see tread
Process notstandardized
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
18/24
Actions / Opportunities
Ensure Ok compound loaded on B.D. mill free from lumps
Root Cause - Operator negligence
Censor installed at declining conveyor so that operator loads treadto roller on time
Root Cause Less visibility for operator
Automated entry of lumpy treads count by operator at cementingstation through push button
Root Cause Lumpy treads not recorded
Temp monitoring device at mill of Banbury to avoid excess heatingof compound
Root Cause Lack of visibility in temp control
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
19/24
Actions / Opportunities
Implementation of Orbit conveyor at the cap & the base feed mills andtrain operator its function and usage.
Root Cause Lumps formed due to overheating as operator is not trained on its usage
Segregate lumps from lumpy treads before sending back to Banburymixer
Root Cause Improper disposal of lumpy treads
Scheduling of preventive maintenance at conveyor belt, skiver, motorto prevent untimely breakdown during running of batch
Root Cause Non conformance to procedure(maintenance)
Proper scheduling at Banbury to ensure there is enough compound. Ifnot operator should inform supervisor at the starting of batch
Root Cause Shortage of material at B.D. mill
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
20/24
Actions / Opportunities
Censor installed at cap feed mill to indicate accumulation ofmaterial at cap feed mill guard
Root Cause Less visibility for mill man
TCU leakages should be monitored frequently by the shift
supervisor. Root Cause Non-conformance to audits
Operator counseling to make them aware and responsible towardsthe job they are doing & adhere to SOPs/specifications.
Root Cause Standard procedures not followed
Proper distance between the bite rollers should be maintained andits axis straightened so that rollers work properly.
Root Cause Safety and performance audit not conducted by plant
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
21/24
Cost Benefit Analysis
Total no of treads rejected during 7 shifts =
1658 * 18.6 * 3/7 * 30 = 396498.85 KG
(No of rejects * Avg wt * No of shifts * No of days)
Total cost involved for treating one KG of tread
= Cost of Banbury + Cost of extruder
= 1.30+0.39=1.69 Rs/kg
Total cost of re-work per month: =396498.85 * 1.69 = Rs. 670, 083.06
Cost of rejection in the previous state
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
22/24
Cost Benefit Analysis
Treads rejected/day (After changes) =369.34 Nos
Treads rejected/month= 11080.4 Nos
Total loss of tread in terms of weight for 1 month
= 1080.4*18.60 (wt of 1 tread)=206,095.44 KG
New cost involved for rework oftread/month=206,095.44*1.69= Rs. 348,301
Therefore this project has potential tosave = Rs.670,083.06 348,301
= 321,781.86 Rs/Month.
The rejection achieved after implementing some of the changes was from 13.71 to 7.06 %
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
23/24
Key Learnings
Learned in detail about the steps/processes involved in tire manufacturingparticularly producing treads in 10*10 extruder machine.
Learned about the quality parameters which are responsible for the rejectionof tire treads.
Learned about the allocation of work, manpower, job scheduling & also
learned that how manpower is managed & handled on the shop floor. Undertook step-by-step approach using TQM tools to address the problem.
Practically saw the types of manufacturing waste being generated on theshop floor & how it impacts the productivity of the plant.
Learned about the interdependencies between various processes for this
project & how the impact of one process affects the output of anotherprocess.
-
8/3/2019 The Apprentice_Abhrajit Sett_KJ SIMSR
24/24
Thank you