This project aimed to reduce paste usage and costs on Backing Line 4 by improving the calendar roll, backing roll, and installing new measurement tools. Goals included installing a new nip station, controlling paste temperature to manage viscosity, and using a Terahertz thickness gauge to eliminate destructive testing. The project achieved a cost savings of $1.7 million annually within one month by installing temporary new rolls. Controlling paste temperature and installing the gauge were ongoing. Success criteria included reducing paste usage and providing real-time thickness measurements for better process control.

1. CO-INNOVATION
INNOVATION PROJECT BL4 Calendar Roll, Backing Roll and Coating Station Improvement 2012.doc Page 1 of 3
INNOVATION PROJECT(BL4 Calendar Roll and TeraHartz)
1.1 Project Overview and Status
Project Title: Backing Line 4 Calendar Roll, Backing Roll & Nip
Station Improvement (CEA 3524)
Project Maturity:
(Highlight as required)
P1/2/3Project Status: (Highlight as required) Completed
Project start date: 2/15/2012 Estimated completion date: 9/2013, 1/23/2014
Project Number: CEA 3524 Project Leader: Ray Shen
Related project(s): Department: Project engineering
Location: LaGrange Sponsor(s) (if any):
Project objective: (One-liner elevator pitch):
Reduce paste usage on Backing Line 4.
Reduce non-destructive thickness test of
backing.
Size of the problem or opportunity - summary:
(Including time frame and location)
Planned revenue: $
Planned cost saving: $2,900,000/yr. ROI > 1 yr.
Actual saving: $1,700,000/yr. ROI < 1 Month
Contribution to Mission Zero (%): No
Project abstract: (<100 words: What is it? Why do we need it? How much will it cost?)
Progress updates (One or two lines on status and next steps to be completed at regular intervals. Click 'edit' to add)
Goal #1- Purchase and install a nip station with calendar roll and backing roll. A set of
temporary calendar roll and backing roll are included so they can be used in the short term.
Status: Completed. Installed temporary new calendar roll and backing roll in July 2012.
Actual cost saving: $1,700,000/yr. New nip station is not economically justifiable (remove
from project at this time).
Goal #2 - Paste viscosity will be tempered by controlling temperature of delivery pipe.
Status: On going. Complete design in Jan. Secure quote in Feb. Place equipment order in
Mar. Installation in Jun. /Jul. Startup in July.
Goal #3 - A thickness measurement device will detect total add-on (was to measure paste
thickness and close-loop control the gap between the calendar roll and backing roll.).
Status: Installed THz & Training on 1/23/14. Await verification test result. Identified
Terahertz as best of class in gauge scanner. Evaluate vendor financial stability in Jan.,
2013.
All files are in Maint. Drive and Engrg. Drive.
How does the project align with our strategy? (Which Vector or enabler does it support?)

2. CO-INNOVATION
INNOVATION PROJECT BL4 Calendar Roll, Backing Roll and Coating Station Improvement 2012.doc Page 2 of 3
Project key words/Primary focus area: Calendar, Backing, Roll, Paste, Plastisol, Gauge, Scanner, Beta,
Coater, Coating, Cost Reduction, Temperature, Viscosity, TeraHertz.
1.2 Problem or opportunity definition
Problem/opportunity summary (One-liner on the basic need): Cost Reduction ($/sq. yd.) - Reduce plastisol
purchase.
Why is it a problem (or opportunity) and what is the size of the problem (or opportunity)?
1. Old calendar roll and backing roll were not strong enough for our process. We have been using
addition paste to over-come bow/gap between the rolls.
2. Ambient temperature change changes viscosity of paste. Operators do additional weight check and
adjust coater more when the temperatures change. If we can temper the temperature (range), we
can control viscosity (range).
3. Existing paste thickness test requires labor, finished goods, and time (delay result).
4. Lack of paste process control and process understanding.
Intellectual Property (Has patents/design rights/trademarks/copyright work been initiated? N/A
1.3 Size of the problem or opportunity - further information
Total addressable market / total potential savings:
Calendar/backing roll saving is $715M (7/16/12 to 12/16/12) YTD. Annualized saving is
$1,690M.
The expected saving of the project is approximately $2,900M per year. A 6.65 oz./sq. yd.
thick paste improvement is equal to approximately $2.9MM annual saving (2012 based).
Contribution to Mission Zero (%): (And rationale) ([Energy Efficiency][Renewable Energy][Waste Elimination][Water
Intake][Recycled Materials])
What are the criteria for success?
Goal #1 – Creation of a process capable of delivering an even paste add-on for first station
that is within the current spec of +/- 1 oz./sq. yd. Reduction of total paste add-
on.
Goal #2 – Control paste temperature at 85 F +/- 2 F. Control delivered paste viscosity.
Goal #3 – Elimination of destructive weight checks.
What does success look like? (Including who stands to benefit and how)
Everyone will benefit from reducing amount of raw material usage. It reduces the
amount of materials consumed in manufacturing our product that has a positive LCA
impact and reduces the cost of manufacturing the product.
Controlling paste temperature/viscosity will reduce process variation and will benefit both
the operations and technical teams. It is also expected to simplify the process of starting
the line in the mornings because there will no longer be a need to clear out the paste
delivery pipes.
Installing a gauge scanner will provide real time total add-on information allowing for
better control of add on, and eliminates the waste (material and time) of the current
destructive weight checks.

3. CO-INNOVATION
INNOVATION PROJECT BL4 Calendar Roll, Backing Roll and Coating Station Improvement 2012.doc Page 3 of 3
1.4 Gap analysis
What existing whole or partial solutions exist at Interface or externally?
1. Gauge scanning systems are in use by Interface Europe on some processes.
2. Paste oz. per sq. yd. is currently lower in Asia Pacific than in US but due to material
and process speed differences, there is not a technical advantage to use TeraHertz
(http://www.autocontroltech.com). It does show that the product can perform
satisfactorily at the lower weight.
How are others solving this problem today? Is there any Interface experience relevant to solving this problem? Have
there been past attempts that can be learned from.
1. A Beta Gauge was used previously on BL4 but was set up to measure a layer of PVC applied to
the carpet. The variation in the previous processes made this difficult to use and it was not a
reliable measure. Other divisions of the company have beta gauges in use but have found it that
even with before and after measurements, that reliability can be an issue.
2. Paste heating was tried previously on BL4 and in Shanghai facility. In both instances, the paste
began to cure inside the tank/pipes when wall temperature reaches 110 F. This has helped us to
investigate using a jacketed pipe with temperature controlled water loop to controlling paste
temperature. However, this concept is economically unfeasible.
1.5 Leadership, core team, networks & resources
Project Leader(s):
Ray Shen
Technical champion(s): Tim Mitchell, Zah,
Secondary leader(s): Pat Briggs, Chris Gleaton.
Team Members: Please provide details of the wider team or expert network, including details of
recruitment, briefing, current relationship and know-how:
Production – Dale Bowen, Tripp Skinner, BL4 operators.
Maint. – Chris Gleaton, Steve Miles,
Technical – Tim Mitchell.
R&D – C. H. Zah, James Wood, James White.
Project – Eddie Bradley, Pat Briggs, Walter Monk
EHS – Steve Decker, Byron Parker
Finance – Kerry Gibson
Purchasing – Sherri Bernasconi, Terri Landreth
External Project Partner(s) (if any): (Please provide details, summarise their role, level of involvement and whether
the relationship is past, present or future)
N/A