CONTROL PLAN FOR EXTRUSION OF TRUCK TREADS

PLAN/DO PROCESS OWNER: MANAGER - EXTRUSION CHECK ACT

Flow Chart

Indicators
freq of sample measure goal size ment Method of recording data

Corrective Actions
Procedure For Process Adjustment Procedure Criteria for For System decision Improvement making Responsibility for decision making

CTQ Production Move Prepare Top Cap Tread Key task - checks Sub Tread Key task - checks Undertread Key task - checks Polythene Film Key task - checks

Monitoring Standards

unit of measure

type of sensor

Who records & how

Damage Control

Compound A from Stock

Ensure that correct ID mark is there and that it has been passed in lab testing

Compound B from Stock

Ensure that correct ID mark is there and that it has been passed in lab testing

Compound C from Stock

Ensure that correct ID mark is there and that it has been passed in lab testing

From Stock

Ensure that the roll has been tested in lab for grammage, thickness & tensile trength

correct Rheometer Time for Rheome batch compound, duly passing & change in ter testing tested correct coding elasticity

100 gm

Rheo Graph; Scorch time on a control chart

Technician

Reject compound

Compound properties

Technician

Moved in front of the Mills for top cap

Moved in front of the Mills for Subtread

Moved in front of the undertread CF Exruder

Warmed on 3 mill setup Correct banking on mills to prevent overheating

Warmed on 2 mill setup

Fed to extruder through strips

Correct banking on mills to prevent overheating

Cold Water circulation in Mills

Flow 200 GPM at 18 Deg C

Flow GPM ; Deg Meter Twice Per C &Therm Shift ometer

Temp Chart (Run chart)

Process Controller Manual

Stop process if correct flow & temp not registered.

Restart process only after rectification

Analysis of frwquency of failures; if cost justified, install online monitoring of parameters.

Production Manager

Fed into Top Cap Twin Extruders (Y Box)

Ensure correct Hydraulic Pressure at the Y Box; Feed strip feed at controlled rate without jamming.

Fed into Sub Tread Extruder

Undertread calender

Feed strip feed at controlled rate without jamming

Ensure correct width

Undertread width

Process spec in Cm

Cm

Solenoid controll ed continuo Pneuma us tic knives

Process Control Chart Controller Manual

Stop process if width control device malfunctions

Restart process only after rectification

Production Manager

Joining of the Top Cap & Subtread after lickering

correct even lickering

visual

continuo us

no record

Leading Hand

stop line & adjust

check solution and lickering Tech device before start up

Consolidation through roller assembly

Correct consolidaton

Visual ; absenceof curlup

continuo us

no record

Leading Hand

Stop the line & adjust

Increase the pressure on the rollers

Create a data bank on pressure edges lifting needed for up each type of tread

Leading Hand

Embossing of Tread Code & Size, shift etc

On line weighing System

Weight of tread Kg per Mt +/Kg / Mt per metre 50 gm

Electron continuo ic Load us cell

Run chart

Automatic

Scrap for reuse

Only technological Adjust speed change is of extrusion possible - has and ratio of to be feed to speed prescribed by Chief Of Tech.

Weight going outsidelimit at the right COT extruder settings

Joing of Undertread & Consoldiation.

Beta Ray Equipment for film thickness

Thickness of strip

MM

MM

nuclear

continuo us

Run Chart

Automatic

Stop the line Adjust to rectify the calender nip system

Only technological change is Thickness Production in possible - has outside range charge to be prescribed by Chief Of Tech.

Polythene application to undertread

Clean, unwrinkled polythene

visual

begining of each roll

Checklist

Leading Hand

Stop & change the polythene roll

Buying Absence of specifications Production in contaminatio to be more charge n, wrinkles stringent.

Through Cooling Conveyor

Temp of water & flow should be even in the spray nzzles

Temp 16+/1Deg C

Deg C

Once Thermo every meter hour

Run Chart

Leading Hand

Slow down line & check water system ; if correction not possible, stop

Frequency of failures from the chart; Temp going review for out of lmits closed circuit system

Production in charge

Cutting KnifeLength Checking

1.Sharpness of cut; 2. correct Length

Visual + checking of length

Metres

once in 20 treads

Run chart

Traying Hand

Stop the line Engineering to rectify the crew to be system trained

Frequency of failures to determine change to alternative system

Variation in length

Traying hand

Length Checking Weighing

Weight Weight of tread. prescribed +/- Kg 200 gm

Physical Every weighin tread g

5 readings in 50 treads control chart

Traying Hand

Stop the line to rectify the system; sortout out of tolerance treads - strip components and reuse

Production, Engineering & Technology crew to be trained

Increase audit systems to Variation in create strict weight control

Production Manager

Storing for the next Internal Customer

EXTRUSION OF TRUCK TREADS

Mills In-line weighing

Twin Extruder with Y Box Top Cap

Lickering

Joining

Consolidation

Embossing

Sub tread Extruder Mills

Bins For Feeding

Joining & Consolidatio n

Polythene apply

Weigh Scale Cooling Cutting

Traying

Table-length checking Polythene Feeder Beta Ray Extruder Calender