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Opportunities in engineering products -Plastics industries
1. Sources for Technical Know –howSources for Technical Know –how
- Focus on Plastics Industries- Focus on Plastics Industries
Dr. K. Padmanabhan FIIPE, FIEDr. K. Padmanabhan FIIPE, FIE
ProfessorProfessor
Mechanical EngineeringMechanical Engineering
SVCE, Sri PerumbudurSVCE, Sri Perumbudur
2. ContentsContents
Plastics, Classifications, ConsumptionPlastics, Classifications, Consumption
Important Properties:Important Properties: Designer, Manufacturer, CustomerDesigner, Manufacturer, Customer
Materials and Manufacturing MethodsMaterials and Manufacturing Methods
Strategies for ImprovementStrategies for Improvement
Basic EconomicsBasic Economics
High Flying Projects- Case StudiesHigh Flying Projects- Case Studies
TANSTIA FNF Service CentreTANSTIA FNF Service Centre
3. ProductsProducts
Consumer ProductsConsumer Products
Engineering ProductsEngineering Products
Metal based productsMetal based products
Ceramic based productsCeramic based products
Polymer based productsPolymer based products
4. Polymer and PlasticPolymer and Plastic
A Plastic should be aA Plastic should be a
Solid in finished formSolid in finished form
Should be organic in structureShould be organic in structure
Must have been capable of flow atMust have been capable of flow at
some stage in processingsome stage in processing
(ASTM Definition)(ASTM Definition)
5. Focus on PlasticsFocus on Plastics
Plastics and Reinforced PlasticsPlastics and Reinforced Plastics
The Rising ImportanceThe Rising Importance
Present ConsumptionPresent Consumption
StatisticsStatistics
ScopeScope
8. Plastic ProductsPlastic Products
Commodity PlasticsCommodity Plastics
TypesTypes
ApplicationsApplications
Consumption and DemandConsumption and Demand
Engineering PlasticsEngineering Plastics
TypesTypes
ApplicationsApplications
Consumption and DemandConsumption and Demand
9. Plastic ProductsPlastic Products
Properties important to theProperties important to the
DesignerDesigner
ManufacturerManufacturer
Customer/ UserCustomer/ User
10. Design PropertiesDesign Properties
Strength, Stiffness, Toughness, Fatigue,Strength, Stiffness, Toughness, Fatigue,
Creep and ImpactCreep and Impact
Dimensions, Weight, TolerancesDimensions, Weight, Tolerances
Judicious use of drafts, radii, fillets, webs,Judicious use of drafts, radii, fillets, webs,
ribs, blends, chamfers and curves forribs, blends, chamfers and curves for
specific propertiesspecific properties
Ease of assembly, disassembly andEase of assembly, disassembly and
serviceservice
Aesthetics, colouring and texturingAesthetics, colouring and texturing
11. Manufacturing PropertiesManufacturing Properties
Forming temperature, Glass transition, MeltingForming temperature, Glass transition, Melting
point, Rate of solidificationpoint, Rate of solidification
Energy required to form, Whether batch processEnergy required to form, Whether batch process
possible? , Pressure requiredpossible? , Pressure required
Flow behaviour, Viscosity, Melt flow indexFlow behaviour, Viscosity, Melt flow index
Mouldability and Castability, WorkabilityMouldability and Castability, Workability
Fabrication of Complex Parts, TimeFabrication of Complex Parts, Time
Curing/Solidification Shrinkage in the MouldCuring/Solidification Shrinkage in the Mould
Materials properties, Availability, ToxicityMaterials properties, Availability, Toxicity
12. Customer/User RequirementsCustomer/User Requirements
Quality, Cost, Durability ( low moistureQuality, Cost, Durability ( low moisture
absorption), Reliability ( low degradation ofabsorption), Reliability ( low degradation of
properties with time)properties with time)
Efficiency : Better properties at lighterEfficiency : Better properties at lighter
weight and less money, Valueweight and less money, Value
Flexibility : Multi functionalityFlexibility : Multi functionality
Low maintenance costLow maintenance cost
Aesthetics, textures in DesignAesthetics, textures in Design
13. Material CostsMaterial Costs
An OverviewAn Overview
Commodity thermoplastics are the cheapest.Commodity thermoplastics are the cheapest.
Commodity thermosets are costlierCommodity thermosets are costlier
Entry level engineering thermoplastics areEntry level engineering thermoplastics are
cheaper than advanced engineeringcheaper than advanced engineering
thermoplasticsthermoplastics
High end blends, alloys and IPNs ofHigh end blends, alloys and IPNs of
thermoplastics and thermosets are expensivethermoplastics and thermosets are expensive
( used in aircrafts, marine industry, luxury /sports( used in aircrafts, marine industry, luxury /sports
cars, Sports equipment etc.)cars, Sports equipment etc.)
14. Manufacturing MethodsManufacturing Methods
For Plastics and Reinforced PlasticsFor Plastics and Reinforced Plastics
Calendaring, Autoclave vacuum bagging,Calendaring, Autoclave vacuum bagging,
Vacuum resin infusion moulding,Vacuum resin infusion moulding,
Reinforced reaction injection moulding,Reinforced reaction injection moulding,
Casting, Pultrusion, Extrusion, Hand layCasting, Pultrusion, Extrusion, Hand lay
up contact mouldingup contact moulding
21. Relative Margins in ManufacturingRelative Margins in Manufacturing
Injection moulding and compression mouldingInjection moulding and compression moulding
are efficient as batch fabrication is possibleare efficient as batch fabrication is possible
Extrusion is also efficientExtrusion is also efficient
Blow moulding, Thermoforming , Resin transferBlow moulding, Thermoforming , Resin transfer
moulding and Rotational moulding are alsomoulding and Rotational moulding are also
economicaleconomical
Room temperature thermosets and casting themRoom temperature thermosets and casting them
is cheapis cheap
Other techniques described are high endOther techniques described are high end
22. Choice of Manufacturing MethodChoice of Manufacturing Method
Shape, Size, Finish and Design complexityShape, Size, Finish and Design complexity
Desired mechanical propertiesDesired mechanical properties
Materials selectionMaterials selection
Batch processing requirementBatch processing requirement
Tooling, fixturing requiredTooling, fixturing required
Cost per pieceCost per piece
Demand and local availabilityDemand and local availability
Overall reliability and durability of the methodOverall reliability and durability of the method
SafetySafety
23. Plastics and StandardsPlastics and Standards
Raw Materials, semi finished and finishedRaw Materials, semi finished and finished
materials/productsmaterials/products
Processes, methodsProcesses, methods
Testing , specimen dimensionsTesting , specimen dimensions
Voluntary consensus standards, industryVoluntary consensus standards, industry
standards, company standardsstandards, company standards
Standards making bodiesStandards making bodies
ASTM, ASC, ISO,BIS,ISI, DIN….ASTM, ASC, ISO,BIS,ISI, DIN….
24. Design for ManufacturingDesign for Manufacturing
A practice for designing products, keepingA practice for designing products, keeping
manufacturing in mind.manufacturing in mind.
Minimise the number of parts through aMinimise the number of parts through a
more compliant designmore compliant design
Multifunctional partsMultifunctional parts
Minimize part variationsMinimize part variations
Ease of handling, assembly and repairEase of handling, assembly and repair
Optimum design for manufactureOptimum design for manufacture
25. Single Minute Exchange of DieSingle Minute Exchange of Die
A Japanese concept by Shigeo ShingoA Japanese concept by Shigeo Shingo
Quick change of die for a different partQuick change of die for a different part
Design for clampabilityDesign for clampability
Use of same machine for different partsUse of same machine for different parts
Switching Resins, transferring resins inSwitching Resins, transferring resins in
tankstanks
SMED reduces costsSMED reduces costs
26. Other Productivity StrategiesOther Productivity Strategies
Computer Aided Design, ManufacturingComputer Aided Design, Manufacturing
and Engineering (CAD/CAM/CAE)and Engineering (CAD/CAM/CAE)
Product design validation through finiteProduct design validation through finite
element analysiselement analysis
Feed back FEA results to design stagesFeed back FEA results to design stages
Iterative design process, avoid overIterative design process, avoid over
designdesign
Cost effective design optimizationCost effective design optimization
First attempt at production- to be aFirst attempt at production- to be a
success !success !
27. Estimated Cost of the ProjectEstimated Cost of the Project
Land and BuildingLand and Building
Plant and MachineryPlant and Machinery
Erection and CommissioningErection and Commissioning
Office EquipmentOffice Equipment
Pre-operative ExpensesPre-operative Expenses
Working Capital for Three MonthsWorking Capital for Three Months
Identification of Clients, CustomersIdentification of Clients, Customers
28. Basic EconomicsBasic Economics
Working CapitalWorking Capital
Cost of the ProjectCost of the Project
Net Profit Per YearNet Profit Per Year
Net Profit RatioNet Profit Ratio
Rate of Return on Total InvestmentRate of Return on Total Investment
Breakeven PointBreakeven Point
29. High Flying ProjectsHigh Flying Projects
High Returns/Profit ProjectsHigh Returns/Profit Projects
Compression moulded plastic goodsCompression moulded plastic goods
Blow moulded containersBlow moulded containers
FRP Products- Helmets and PanelsFRP Products- Helmets and Panels
Automatic injection moulded industrialAutomatic injection moulded industrial
componentscomponents
PTFE bushesPTFE bushes
Reprocessing of plasticsReprocessing of plastics
(contd…)(contd…)
30. High Flying ProjectsHigh Flying Projects
Keyboard switchesKeyboard switches
Plastic flash light torch casesPlastic flash light torch cases
Nylon zip fastenersNylon zip fasteners
Fevicol type adhesivesFevicol type adhesives
PET bottles from preformsPET bottles from preforms
Rigid PVC pipesRigid PVC pipes
PP/HDPE woven sacksPP/HDPE woven sacks
31. Present Status and FuturePresent Status and Future
Prospects of PlasticsProspects of Plastics
Production and demand patternProduction and demand pattern
Imports and exportsImports and exports
Application areasApplication areas
Electronics and telecommunication, Consumer goods,Electronics and telecommunication, Consumer goods,
Automobile industry, Structural Engineering, EnergyAutomobile industry, Structural Engineering, Energy
Sector, Sports and leisure, Medicine and MarineSector, Sports and leisure, Medicine and Marine
Scope for innovationScope for innovation
Manpower and employment potentialManpower and employment potential
Future prospectsFuture prospects
32. TANSTIA-FNF Service CentreTANSTIA-FNF Service Centre
www.tanstiafnf.comwww.tanstiafnf.com,, www.tanstia.org.inwww.tanstia.org.in
Tamil Nadu Small and Tiny IndustriesTamil Nadu Small and Tiny Industries
Association-Friedrich Naumann FoundationAssociation-Friedrich Naumann Foundation
(Germany) Service Centre, Estd 1992(Germany) Service Centre, Estd 1992
Situated at Guindy Indl. EstateSituated at Guindy Indl. Estate
Offers services in information, consultancy,Offers services in information, consultancy,
training programmes, seminars, studies andtraining programmes, seminars, studies and
publicationspublications
Assists to obtain subsidies, concessions andAssists to obtain subsidies, concessions and
benefits of various schemes by the governmentbenefits of various schemes by the government