Hot End Defect Reporting v/s

Cold End Defect Reporting

• Discuss good manufacturing practices in container glass for hot end reporting of glass defects v/s cold end reporting of glass defects

• Discuss heldware process• Discuss on Concepts • Benchmark and customize them to our process

Agenda

• Hot End Area – IS Machine From Gob cuts to Lehr exit Operator

Upkeep

• Cold End Area – From Cold End entry to Case packerCold end checker

Areas & Members

•Hot End Area-Lehr Entry Standard –e.g. 97% , Cold End Entry - 96%-Automatic defect identification equipment Standard

Sqzer(0.5%),OLT(1%),DPG(1%), CHD(1%),MCAL(1%),MNR(1%)- % Pack Operating Standard – e.g. 90%

- Hot end operator to do Set out every 1 hr.

- Critical , Major , Minor and check with AQL- Kicked out in the Hot end Reject (Hot End Reported Defect)- Communicated to the Cold End Checker & Upkeep- Upkeep will solve the defect, communicate to Cold end

checker and fill critical defect report

Hot End Area

No defect FoundDefect Found

•Cold End Area-Defect Communicated by Hot End operator-Check Last set out on sheet, computer-Check Lehr for ‘x’ no. Of bottles

- Critical , Major , Minor and check AQL- Kicked out in the MNR- Go for Audit @ the case packer; Audit ‘x’ no of cases/bulk

Cold End Area

No defect Foundafter ‘n’ times checkCommunicated to HE

Defect Found

No defect Foundzero Heldware

Defect FoundHeldware till loop is closedFill Critical Defect Report

•Cold End Area-Cold end set out every 1 hr.

- Critical , Major , Minor and check with AQL- Kicked out in the MNR; Cold End reported to Hot end- Go for Audit @ the case packer; Audit ‘x’ no of cases/bulk

Cold End Area

No defect FoundCommunicated to HEDefect Found

No defect Foundzero Heldware

Defect FoundHeldware till loop is closedFill Critical Defect Report

•Cold End Area-Will not take cavity out from MNR till ‘x’ no of bottles are checked and defect closed is confirmed-Qualify any equipment change-Run samples on Automatic detection equipment

•Hot End Area -Communicate to cold end on what was done to fix defect - Ask for qualification of any equipment change

Cold End Area

• Bottle counters–Gob Cuts,Lehr Entry, Cold End Entry, % Pack• Automatic Defect Identification and Rejection Machines• Mold No. Reader and Rejection• XPAR• SIL system & its Advantages• HER v/s CER• Critical Defect Report• Held ware concept• MIS for defects• Job On Job Off concept

•Bottle Code Identification•Automatic Weight Control & Recording of Weight•SOPs & TOPs – e.g. On New M reject for 20 cycles/Cold Mold

Concepts

• Bottle counters–Gob Cuts,Lehr Entry, Cold End Entry, %Pack

Concepts

Tank

I.S. Machines LehrCold End Inspection

Back Up TableCounters

•Automatic Defect Identification & Rejection Machines & LossesSqueezer- Std Loss – 0.5%Online thickness detector – zones 1,2,3,4 – Std Loss – 1-2%Dual Plug gauge – Std Loss – 0.5%Check Detector & Mold No. Reader - Std Loss – 2-3%Inexs – Std Loss 0.5%-1%

Std 97%

Std 96%

Std 92%

• XPAR- Using infrared variations to detect defects in glass containers

in the hot end before entering the LEHR- Thickness, Swab wear, Black spots, Stones, Bird swings

• SIL system & its Advantages- SILMOLD,SILQUAL,SILPROD,SILWARE all incorporated-Communication platform between HE & CE-Bottle counters history

- Automatic detection machine history- Machine/Section downtime history- Equipment history/hrs- Defects history

Concepts

• HER v/s CER• Critical Defect Report• Held ware concept & Recording

Concepts

Date:Time:

Shift:

Crew:

Tank:

Shop:

List of Critical Defects

Hot End Information

Y-Y Analysis for Defect

Cold End Information

No of Loads HeldNo of Bottles found on Lehr

Hot End Information

Upkeep Sign Supervisor Sign

Cold End Information

Checker Sign Supervisor Sign

HER V CER

• MIS Hot end• Job On Job Off concept• Bottle Code Identification• Automatic Weight Control & Recording of Weight• SOPs & TOPs – e.g. On New M reject for 20 cycles/Cold Mold• Qualification of equipment

Concepts