GOODYEAR Ballabgarh

REDUCTION OF WASTE FROM EXTRUSION IN TIRE MANUFACTURING PROCESS

Summer Project Presentation At GOODYEAR INDIA LIMITED, BALLABHGARH By

Abhrajit Sett 9920478411 abhrajit.sett@gmail.com

K J Somaiya Institute of Management Studies and Research Mumbai

1

A Global Company
Eastern Europe, Middle East, & Africa

North America

#1

#1
Asia

#2

Latin America

#1
Asia one of the fastest growing markets. Goodyear holds a # 2 position in market

Regional Rank

Goodyear Ballabhgarh
Plant Location : 28 km South of Delhi in Haryana state on National Highway No.2. Escorts, Maruti (Gurgaon), JCB, Yamaha, Honda (Greater Noida) 67 acre with 654,000 sq.ft of floor space Automotive tires started in 1961, presently producing 4100 Tires per day. Farm, Truck, LCV tires.

Major Industries in Area :

Area Manufacturing

: :

Products

Tire Building Process

Calendering

Banbury - Mixer

Curing

OEM Retail

Tire Building

Natural Rubber

Extrusion

Inspection Dispatch

Plant Layout

Project Approach

Project Definition Data collection Root Cause Analysis Actions suggested based on identified root causes Cost Benefit Analysis Key Learnings

Project Objective
DEFINITION The main objective of doing the project is to reduce the waste from extruder machine which produces tire treads so as to reduce scrap/rework costs and improve the productivity 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 the recommendations are under the purview of the organization.

ASSUMPTION The waste reduction was limited to material waste because the extrusion process bears slack. 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 shifts are expected to be of same pattern.

Extrusion Process

Compound storage area

EXTRUDER

Take away convey or

Skiver

Weighin g Convey or

Cap breakd own mill

Base feed mill

Gravity rollers

Declining Conveyo r

Scrap Marker

Base breakd own mill

Cap feed mill

Inclined convey or

Cooling Convey or

Cement Station

Defect Data
Types of defects in treads
54, 3% 7.8% 16% 51.3%
HIGH WEIGHT
LOW WEIGHT
Treads produced-12207 Treads rejected-1674

22.5%

LUMPS

TORNEDGE

OTHERS

Defect Data (sample for 24.5.2011)

Pareto Analysis
FINDINGS
More than 50% of the rejections are caused to low weight. High weight and lumps add up to almost 90% of the

rejections. 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.

Root Cause Analysis for Low Weight rejects

MAN
Feed break (M)
Die setting not proper Low weight

MATERIAL
Low Viscosity (M)
Low specific gravity (M) Running weight not properly set

Low weight
Line synchronization not proper Mechanical/Electrical stoppage (M) Waiting for compound Operating skills

MACHINE

METHOD

(M) Major reasons

Why-Why Analysis for Low weight rejects

Why #1

Low weight
Low viscosity
Compound milled for a long time at B.D. mill. Temperature at extruder head increased
No water circulation at extruder head

Why #2

Low specific gravity

Compoundin g not OK from Banbury Chemicals not mixed in proper quantity

Electrical stoppage s

Feedbrea k

Why #3

Compound stuck at mill guard of feed mill

Compound slipped from bite rollers

Why #4

Mill operator did not keep track of time

Material accumulated at top of millguard

Adequate distance from bite rollers not kept

Why #5

Operator negligence

Water valve closed

Scaling error in auto loading

Operator filed to notice accumulation

Bite-rollers not maintained

Why #6
Root Causes

Nonconformanc e of procedure

Calibration not done. Lack of audit

No line of sight less visibility

Audit not performed

Root Cause Analysis for High Weight rejects

MAN MATERIAL

Operating skills (Die setting)

High viscosity variation (M)

High weight
Line synchronization not proper Improper breakdown of compound at B.D. Mill (M) Wrong die tuning

MACHINE

METHOD

(M) Major reasons

Why-Why Analysis for High weight rejects

Why #1
High weight
Improper breakdown of compound

Why #2

High viscosity
Compound from Banbury was hard

Why #3

Compound milled for a lesser time

Why #4

Compound urgently needed at feed mill Feed mill running short of compound at extruder. Shortage of material. Planning improper.

Improper mixing at Banbury

Why #5

Mixing cycle not followed by operator

Why #6

SOP not in place

Root Cause Analysis for Lump rejects

MAN MATERIAL

Absenteeism Negligence (M)

Lumpy Compound (M) Viscosity variation (M)

Lumps
Temp/TCU Line stoppage (M) Waiting for compound Operating skills

MACHINE

METHOD

(M) Major reasons

Why-Why Analysis for Lump rejects

Why #1
Lumpy compound

Lumps

Why #2
Lumpy treads mixed at Banbury

Viscosity variation
Lumps formed at Banbury mixer

Line Stoppage

Why #3

Compound got lumpy in feed mill

Safety from the cooling tank

Why #4

Lumps not removed during segregation

Compound processed for a long time Orbit conveyor not used in cap side Operator not trained in orbit conveyor usage

Mill tailings waste added to mixer

Tread slipped from cooling tank to dancing roller

Why #5

Improper disposal of lumpy scrap

Mill tailings formed from mill guides

Less visibility for operator to see tread

Why #6

Improper disposal of lumpy treads

Lumpy treads not recorded

Housekeeping at mill guides not done

Process not standardized

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 tread to roller on time
Root Cause Less visibility for operator

Automated entry of lumpy treads count by operator at cementing station through push button
Root Cause Lumpy treads not recorded

Temp monitoring device at mill of Banbury to avoid excess heating of compound

Root Cause Lack of visibility in temp control

Actions / Opportunities
Implementation of Orbit conveyor at the cap & the base feed mills and train 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 Banbury mixer
Root Cause Improper disposal of lumpy treads

Scheduling of preventive maintenance at conveyor belt, skiver, motor to prevent untimely breakdown during running of batch
Root Cause Non conformance to procedure(maintenance)

Proper scheduling at Banbury to ensure there is enough compound. If not operator should inform supervisor at the starting of batch
Root Cause Shortage of material at B.D. mill

Actions / Opportunities
Censor installed at cap feed mill to indicate accumulation of material 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 towards the job they are doing & adhere to SOPs/specifications.
Root Cause Standard procedures not followed

Proper distance between the bite rollers should be maintained and its axis straightened so that rollers work properly.
Root Cause Safety and performance audit not conducted by plant

Cost Benefit Analysis

Cost of rejection in the previous state
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 Benefit Analysis

The rejection achieved after implementing some of the changes was from 13.71 to 7.06 % 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 of tread/month=206,095.44*1.69= Rs. 348,301

Therefore this project has potential to save = Rs.670,083.06 348,301

= 321,781.86 Rs/Month.

Key Learnings
Learned in detail about the steps/processes involved in tire manufacturing particularly producing treads in 10*10 extruder machine. Learned about the quality parameters which are responsible for the rejection of 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 the shop 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 another process.

Thank you