“ 18 1080 870 210 19% Capacity 8HR = 1080x8 = 8640 Trolley booking 8HR = 845x8=6760 Rework 8HR = 230x8=1880 Rework %= 21% Average PBD/8HR = 33 Mints 33x18=594 Actual production capacity = 6166 Tubes CONV#3 Size Tubes / HR Trolley Booting Rework Rework% 2.50-17BR 18 1080 820 260 24% Capacity 8HR = 1080x8=8640 Trolley Booking 8HR = 820x8 =6560 Rework 8HR = 260x8 = 2080 Rework% = 24% AVR PBD/8HR = 33MIN = 33x18 = 594 Actual prod capacity = 5966 CONV#4 Size Tubes / HR Trolley Booking Rework Rework% 2.50-18BR 18 1080 806 274 25% Capacity 8HR = 1080x8=8640 Trolley Booking = 806x8=6448 Rework 8HR = 274x8=2192 Rework% = 25% AVR PBD/8HR = 33MIN = 33x18=594 Actual prod capacity = 5854 CONV#5
xii. Total time lose /HR = 15.18 xiii. Reworks = 15.18x18=273 xv. Actual progress= 806x8=6454 xvi. Rework% = 25% (g) Summary – Time and Motion (Conveyor # 1-6) Conveyor Reworks Production Remarks #1 35% 4184 #2 30% 6016 #3 33% 5736 #4 34.9% 5616 #5 35% 5594 #6 25% 6454 32.15% 33600 (h) Electrical Capacity of Extrusion Section Ser Make & Type Made Size Motor RPM i. Warming Roll #1 Dailan 22’’x60’’ 95 KW (128 HP) 980 ii. Warming Roll #2 Dailan 22’’x60’’ 110 KW (147.5 HP) 730 iii. Warming Roll#3 iv. Feeding Roll #1 Taiwan 16’’x44’’ 40.2 KW (50 HP) 725 v. Feeding Roll #2 Taiwan 16’’x44’’ 40.2 KW (50 HP) 725 vi. Feeding Roll #3 Taiwan 16’’x44’’ 40.2 KW (50 HP) 725 vii. Refining #1 Taiwan 6’’ 75 KW (101 HP) 1480 viii. Refining #2 8’’ 75 KW (101 HP) 1428 ix. Refining #3 One 8’’ 90-108 KW (144.7 HP) 1480 X Extruder#1 Seyen Taiwan 6” (134HP) 1428 Xi Extruder#2 Yuan king Taiwan 6” 45KW (60HP) 1470 Xii Extruder#3 Kayton Taiwan 6” 45-50KW (67HP)
Xiii Extruder#4 Kayton Taiwan 6” 55KW (78HP) 980 Xiv Extruder#5 Kayton Taiwan 6” 45-52KW 70HP Xv Extruder#6 Kayton Taiwan 6” 45KW 60HP 1470 Xvi Soapstoner#1 to 6(inside dusting) 1/2HP*6=3HP Xvii Soapstoner#1 to 6(outside dusting) 1/2HP*6=3HP Xviii Nozzle pasting 3HP Xix Colour mixer 1HP Xx Refining conveyors 3HP Xxi Refining hydraulic motors 6.6HP Xxii Dust collectors 6HP Xxiii Conveyor drive motors 1 to 6 30HP xxiv Conveyor hydraulic pumps 3HP Xxv Conveyor air blower motors 6HP Xxvi Feeding conveyors motors 9HP Xxvii Vacuum pump motors 13.2HP
adjusted. Nozzle should be proper manufactured VI Nozzel base damage of wet pasted nozzle Over pasted nozzle . Unbalanced nozzle fixer pressure . Excess use of wiping swap solution Nozzle out problem Rework /re pasted nozzle Excessive powder inside the nozzle base Nozzle should be proper dry Nozzle should be properly pasted(1~2 coated). Nozzle fixer pressure should be balanced. Proper use of wiping swap. Nozzle out problem controlled by proper maintenance work. Avoid to use poor edges nozzle Nozzle fixing area should be proper clean VII Foreign Matrial If foreign particles like dust ,stone, hard compound, iron piece are in green tube then this fault occur. irregularity of changing in refining mesh More care full during green tube extrusion. Refining mesh should be change after 10 ~ 15 minutes VIII. Joint Gap variation in green tube both edges. Splicer dies up down/improper dies setting If operator not set green tube into splicer dies then this fault occur Less die hardness & low butting pressure Unequal buffing of dies Dies damaged at corner area Width should be same both end Splicer dies should be set properly Operator should fully trained. Die hardness should be within standard range (72 ~ 74) Butting should be normal Die should be OK at corner area
Improper anvil adjustment with respect to dies Proper adjustment with respect to dies IX Joint Thin Thickness variation. in tubes folders Unequal dies weight High butting pressure Improper splice die setting. Untrained operator Thickness should be same both end Dies weight should be equal Butting pressure should be within Splicer dies should be set properly Operator should fully trained. X. Joint leak Under size green tube Due to thickness variation in folders. Splicer dies are not proper clean. any rubber particle between dies then this fault occur. Green tube width should in specification. Thickness should be same both end Splicer dies should be properly cleaned. Operator should be fully trained. XI Body Thin tube width should in specification. Thickness should be same both ends. Splicer dies should be properly cleaned. Operator should be fully trained. Green tube thickness should be standard range. .Inside steam pressure should with in standard range(90~110psi) .No any hard particle in green tube .Pressman should be fully trained. Green tube width should be match with flat width. XII Nozzle Thin Excess nozzle holder pressure (unbalanced holder pressure) If nozzle punched not in centre. Due to shortage of inside steam Nozzle fixer pressure should be properly balanced. Nozzle should be punched in center.