Dinesh Goonarathne led a Six Sigma project to reduce defects in Alumex PLC's powder coating process. The project team measured a defect rate of 6.82% in June, which improved to 4.93% in July after analyzing root causes. Low and high micron thickness and water deposits were identified as main issues. Process controls like monitoring pretreatment chemical concentrations helped maintain the lower defect rate. This improved productivity, increasing profits by over 37 million LKR compared to June's performance.
This document describes a dye house project undertaken by Ocean Lanka to address production delays caused by long queue times at dye machines. The problem was analyzed and it was found that replacing existing dye machines with higher temperature, lower liquor ratio machines could help reduce queue times and water usage. The project aimed to install Fongs TEC3 high temperature dyeing machines to achieve shorter dye cycles, higher machine output, and reduced water consumption per unit of fabric dyed. This was expected to help Ocean Lanka meet production targets and improve on-time delivery performance.
Huntsman Advanced Materials produces a range of thermosetting composite resin systems for various manufacturing industries. They offer technical support and expertise to help customers optimize processes and develop customized solutions. Their product range includes resin formulations for wet layup, resin transfer molding, infusion, filament winding, and other composites manufacturing methods. Huntsman works with customers to select the best resin system for their needs, improve quality and performance, and accelerate time to market.
Custom Molds, Inc. is a father-son business that began focusing on molds and later expanded into plastic parts production. It faces issues with longer production times than promised and defective products due to bottlenecks. The document analyzes the mold and parts production processes and recommends reconfiguring machines and workflows between departments, especially mold fabrication, parts fabrication, and testing, to better match current needs and reduce inefficiencies. It also recommends the office focus orders on what can be completed on time and streamline design processes.
Custom Molds, Inc. was founded in 1987 and originally focused on custom mold fabrication but has since expanded into plastic parts manufacturing. The changing sales mix has created bottlenecks and quality issues. Alternatives were presented: continue as is, discontinue molds, or restructure. Clear recommendations included improving lead times through better scheduling and layout, eliminating a machinist, and revising the layout. Detailed next steps are to implement recommendations and continue process improvement.
This document provides information about Aberdeen Radiators, including their management team, facilities, markets, products, and services. They have over 40 years of experience in marine engineering and heat exchangers. Their facilities include two workshops for radiator fabrication, repair, and testing. They serve various onshore and offshore markets and have the capabilities to design, manufacture, overhaul, and repair different heat exchange equipment.
IRJET- Productivity Improvement Kaizen of XC-60 HousingIRJET Journal
1) The document discusses improvements made to the productivity and quality of an aluminum die casting process for an XC-60 housing component through the application of Kaizen methodology.
2) Major defects identified through analysis of 100 samples included dents, blackmarks, failures of M4 gauge tests and slider fits. Changes to dies, fixtures, and processes reduced rejection rates for these defects.
3) Additional changes such as a pneumatic slider cutting fixture and optimized sanding procedures increased productivity from 87 to 128 units and reduced cycle times from 71 to 48 minutes by addressing bottlenecks in machining and trimming operations.
This document describes a dye house project undertaken by Ocean Lanka to address production delays caused by long queue times at dye machines. The problem was analyzed and it was found that replacing existing dye machines with higher temperature, lower liquor ratio machines could help reduce queue times and water usage. The project aimed to install Fongs TEC3 high temperature dyeing machines to achieve shorter dye cycles, higher machine output, and reduced water consumption per unit of fabric dyed. This was expected to help Ocean Lanka meet production targets and improve on-time delivery performance.
Huntsman Advanced Materials produces a range of thermosetting composite resin systems for various manufacturing industries. They offer technical support and expertise to help customers optimize processes and develop customized solutions. Their product range includes resin formulations for wet layup, resin transfer molding, infusion, filament winding, and other composites manufacturing methods. Huntsman works with customers to select the best resin system for their needs, improve quality and performance, and accelerate time to market.
Custom Molds, Inc. is a father-son business that began focusing on molds and later expanded into plastic parts production. It faces issues with longer production times than promised and defective products due to bottlenecks. The document analyzes the mold and parts production processes and recommends reconfiguring machines and workflows between departments, especially mold fabrication, parts fabrication, and testing, to better match current needs and reduce inefficiencies. It also recommends the office focus orders on what can be completed on time and streamline design processes.
Custom Molds, Inc. was founded in 1987 and originally focused on custom mold fabrication but has since expanded into plastic parts manufacturing. The changing sales mix has created bottlenecks and quality issues. Alternatives were presented: continue as is, discontinue molds, or restructure. Clear recommendations included improving lead times through better scheduling and layout, eliminating a machinist, and revising the layout. Detailed next steps are to implement recommendations and continue process improvement.
This document provides information about Aberdeen Radiators, including their management team, facilities, markets, products, and services. They have over 40 years of experience in marine engineering and heat exchangers. Their facilities include two workshops for radiator fabrication, repair, and testing. They serve various onshore and offshore markets and have the capabilities to design, manufacture, overhaul, and repair different heat exchange equipment.
IRJET- Productivity Improvement Kaizen of XC-60 HousingIRJET Journal
1) The document discusses improvements made to the productivity and quality of an aluminum die casting process for an XC-60 housing component through the application of Kaizen methodology.
2) Major defects identified through analysis of 100 samples included dents, blackmarks, failures of M4 gauge tests and slider fits. Changes to dies, fixtures, and processes reduced rejection rates for these defects.
3) Additional changes such as a pneumatic slider cutting fixture and optimized sanding procedures increased productivity from 87 to 128 units and reduced cycle times from 71 to 48 minutes by addressing bottlenecks in machining and trimming operations.
The document discusses additive manufacturing (AM) at the Manufacturing Technology Centre (MTC). It outlines the MTC's goals of accelerating AM standardization, developing robust AM supply chains, and building confidence in AM. It describes various AM processes like binder jetting, powder bed fusion, and vat photopolymerization. The document also discusses benefits of AM like design freedom, mass customization, and reduced lead times. Finally, it provides examples of using AM for ceramic foundry filters and turbine blade casting cores.
Keywords: six sigma; foundry SMEs; small and medium-sized enterprises; design of experiments; DOE; measurement system analysis; MSA; failure mode and effects analysis; FMEA; non-conforming products; cost of poor quality; hypothesis testing; defects per million opportunities; DPMO; process capability; DMAICS; analysis of variance; ANOVA; India; make-to-order foundries; scrap reduction; productivity.
This talk by Clive Ayling, Managing Director, Meteor Inkjet Ltd, at the IMI InPrint USA conference, April 2017, highlights the key considerations in making the most important design decision for ink jet printing systems - printhead selection. Printheads are the highest cost system component and printer performance and output quality are dependent on printhead characteristics and specifications.
Learn the key parameters and methodology to make an informed printhead selection decision for your industrial ink jet system.
The document summarizes a final year project presentation on applying the SMED methodology to reduce changeover times at Yunus Textile Mills. The group analyzed changeover processes in four areas - singeing & desizing, bleaching, mercerizing, and printing. Through separating internal and external changeover elements and streamlining tasks, they were able to reduce average changeover times across the areas, in some cases by over 50%. For example, changeover time was reduced from 20.28 to 11.02 minutes in singeing & desizing and from 803 to 400 seconds in bleaching. The results indicate SMED is effective at reducing changeover waste at Yunus Textile Mills.
Improvement strategy by using ML and TM. A case study for solving cracking i...q-Maxim
1. The case study aimed to reduce cracking in steel castings produced via sand casting by optimizing process parameters.
2. In Phase 1, exploratory data analysis of over 6500 records identified furnace number, tap temperature, ladle temperature, and chemistry variables like C and Ni as most influential on cracking.
3. Linear regression and LASSO regression confirmed these findings and shortlisted key variables to focus on in subsequent experimentation and optimization.
1. Dicomol is a plastic molding company that has been operating for over 30 years, specializing in design, manufacturing, repair, and maintenance of plastic injection molds.
2. They have extensive experience and capabilities, including lasers welding, CNC machining, mold modifications, and production of parts.
3. Dicomol serves various industries such as automotive, appliances, IT, electrical, packaging, and more, with high-quality molds and services.
Indespa Industries is an aluminum casting foundry located in Coimbatore, India established in 1995. The foundry has a capacity of 3000 tons per year and facilities for gravity die casting and sand casting. It has ISO 9001:2008 certification and produces aluminum alloy components for automotive and industrial applications weighing from 0.08kg to 20kg. The document provides details on Indespa's facilities, processes, customers, quality systems and certifications.
This document provides a dissertation submitted by Kannan P for the degree of Master of Engineering in Mechanical Engineering with specialization in Lean Manufacturing. The dissertation focuses on improving productivity in the manufacturing division of a sheet metal industry located in Coimbatore, India. It involves analyzing the current production process through time studies, layout analysis, and identifying wastes. Based on the analysis, modifications are proposed to the layout and a scrap management system is developed to improve material utilization and reduce waste. The dissertation documents the methodology, analysis of the current state, proposed improvements and their implementation to enhance productivity in the sheet metal manufacturing process.
CAB Automotive is a privately owned company established in 2005 that develops and manufactures automotive interior solutions. It has 200 employees and a turnover of £18M in 2011. As a tier 1 supplier, CAB Automotive offers a wide range of interior products and processes to automotive manufacturers. It has the capabilities to cut, sew, trim, assemble, and integrate various materials like leather, carpet, and composites.
The 3D printing process builds a three-dimensional object from a computer-aided design model, usually by successively adding material layer by layer, which is why it is also called additive manufacturing,
Design and fabrication of working model of abrasive jet machineNirmaljit Singh
This document is a project report submitted by Jitesh Kumar for the partial fulfillment of a Master's degree in Mechanical Engineering. It discusses the design and fabrication of a working model of an Abrasive Jet Machine. The report includes sections on the components of an AJM, variables that influence the machining process, advantages and limitations, applications, and a literature review. It also provides details on the design of the major components of the machine being developed for this project.
Plast-Pro Solutions [Pune] are known to be among the most eminent organizations involved in offering a broad array of Mold flow CAE Capabilities, Mold Cooling Analysis and Optimization, Designing Services, Product Modeling Service and Plastic Filing Case.
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
IRJET- Controlling the Formation of Rust in the Rocker Panel using Cavity...IRJET Journal
This document discusses a study that aimed to prevent rust formation in the rocker panel of vehicles using cavity wax. The researchers used Deming's PDCA (plan-do-check-act) cycle to guide their methodology. In the plan stage, they selected a vehicle body and cut out the rocker panel. In the do stage, they applied cavity wax to the rocker panel using a pump. In the check stage, they evaluated if the wax was applied evenly. In the act stage, they identified areas for process improvement. The results showed that applying cavity wax to the rocker panel via this process helped prevent rust formation.
For the bioprocessing and biopharmaceutical professional, this presentation discusses the topic:
Is Standardization Possible in a Custom Single-use World.
Key learning objectives are:
1. Understand why single-use design processes can become protracted
2. Understand how standardization can help to shorten the design phase
3. Discuss the opportunities for standardization in single use
This presentation was first given as a live webinar by Guy Matthews to an audience of biopharmaceutical professionals from around the world in June 2016.
Guy Matthews has worked in the biopharm industry for the last 20 years during which he has been involved in many projects implementing single-use technology in bioprocessing. Guy now works as Market Development Manager for Parker domnick hunter where he is focused on bringing Parker's expertise in motion and control to bioprocessing.
This document provides an overview of 3D printing and tooling. It begins by stating the educational objectives and outcomes of the course, which are to understand the principles, methods, materials, possibilities, limitations and environmental effects of additive manufacturing technologies.
The document then covers the different units that will be taught, with the first unit providing an introduction to additive manufacturing. It discusses the history and need for additive manufacturing, provides a classification of the different technologies, and discusses how additive manufacturing is used in product development. It also introduces the different materials that can be used for additive manufacturing.
In closing, the document emphasizes that additive manufacturing enables both a design and industrial revolution across many industries such as aerospace, energy, automotive
PPT on GRP pipes and fittings - manufacturing and testinganoopmanoharan2
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and flexing/movement will have no effect. With both GRP and FRP materials, there is a 100% guarantee that it cannot rust or corrode
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and fl
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and flexing/movement will have no effect. With both GRP and FRP materials, there is a 100% guarantee that it cannot rust or corrode
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and f
The document discusses additive manufacturing (AM) at the Manufacturing Technology Centre (MTC). It outlines the MTC's goals of accelerating AM standardization, developing robust AM supply chains, and building confidence in AM. It describes various AM processes like binder jetting, powder bed fusion, and vat photopolymerization. The document also discusses benefits of AM like design freedom, mass customization, and reduced lead times. Finally, it provides examples of using AM for ceramic foundry filters and turbine blade casting cores.
Keywords: six sigma; foundry SMEs; small and medium-sized enterprises; design of experiments; DOE; measurement system analysis; MSA; failure mode and effects analysis; FMEA; non-conforming products; cost of poor quality; hypothesis testing; defects per million opportunities; DPMO; process capability; DMAICS; analysis of variance; ANOVA; India; make-to-order foundries; scrap reduction; productivity.
This talk by Clive Ayling, Managing Director, Meteor Inkjet Ltd, at the IMI InPrint USA conference, April 2017, highlights the key considerations in making the most important design decision for ink jet printing systems - printhead selection. Printheads are the highest cost system component and printer performance and output quality are dependent on printhead characteristics and specifications.
Learn the key parameters and methodology to make an informed printhead selection decision for your industrial ink jet system.
The document summarizes a final year project presentation on applying the SMED methodology to reduce changeover times at Yunus Textile Mills. The group analyzed changeover processes in four areas - singeing & desizing, bleaching, mercerizing, and printing. Through separating internal and external changeover elements and streamlining tasks, they were able to reduce average changeover times across the areas, in some cases by over 50%. For example, changeover time was reduced from 20.28 to 11.02 minutes in singeing & desizing and from 803 to 400 seconds in bleaching. The results indicate SMED is effective at reducing changeover waste at Yunus Textile Mills.
Improvement strategy by using ML and TM. A case study for solving cracking i...q-Maxim
1. The case study aimed to reduce cracking in steel castings produced via sand casting by optimizing process parameters.
2. In Phase 1, exploratory data analysis of over 6500 records identified furnace number, tap temperature, ladle temperature, and chemistry variables like C and Ni as most influential on cracking.
3. Linear regression and LASSO regression confirmed these findings and shortlisted key variables to focus on in subsequent experimentation and optimization.
1. Dicomol is a plastic molding company that has been operating for over 30 years, specializing in design, manufacturing, repair, and maintenance of plastic injection molds.
2. They have extensive experience and capabilities, including lasers welding, CNC machining, mold modifications, and production of parts.
3. Dicomol serves various industries such as automotive, appliances, IT, electrical, packaging, and more, with high-quality molds and services.
Indespa Industries is an aluminum casting foundry located in Coimbatore, India established in 1995. The foundry has a capacity of 3000 tons per year and facilities for gravity die casting and sand casting. It has ISO 9001:2008 certification and produces aluminum alloy components for automotive and industrial applications weighing from 0.08kg to 20kg. The document provides details on Indespa's facilities, processes, customers, quality systems and certifications.
This document provides a dissertation submitted by Kannan P for the degree of Master of Engineering in Mechanical Engineering with specialization in Lean Manufacturing. The dissertation focuses on improving productivity in the manufacturing division of a sheet metal industry located in Coimbatore, India. It involves analyzing the current production process through time studies, layout analysis, and identifying wastes. Based on the analysis, modifications are proposed to the layout and a scrap management system is developed to improve material utilization and reduce waste. The dissertation documents the methodology, analysis of the current state, proposed improvements and their implementation to enhance productivity in the sheet metal manufacturing process.
CAB Automotive is a privately owned company established in 2005 that develops and manufactures automotive interior solutions. It has 200 employees and a turnover of £18M in 2011. As a tier 1 supplier, CAB Automotive offers a wide range of interior products and processes to automotive manufacturers. It has the capabilities to cut, sew, trim, assemble, and integrate various materials like leather, carpet, and composites.
The 3D printing process builds a three-dimensional object from a computer-aided design model, usually by successively adding material layer by layer, which is why it is also called additive manufacturing,
Design and fabrication of working model of abrasive jet machineNirmaljit Singh
This document is a project report submitted by Jitesh Kumar for the partial fulfillment of a Master's degree in Mechanical Engineering. It discusses the design and fabrication of a working model of an Abrasive Jet Machine. The report includes sections on the components of an AJM, variables that influence the machining process, advantages and limitations, applications, and a literature review. It also provides details on the design of the major components of the machine being developed for this project.
Plast-Pro Solutions [Pune] are known to be among the most eminent organizations involved in offering a broad array of Mold flow CAE Capabilities, Mold Cooling Analysis and Optimization, Designing Services, Product Modeling Service and Plastic Filing Case.
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
IRJET- Controlling the Formation of Rust in the Rocker Panel using Cavity...IRJET Journal
This document discusses a study that aimed to prevent rust formation in the rocker panel of vehicles using cavity wax. The researchers used Deming's PDCA (plan-do-check-act) cycle to guide their methodology. In the plan stage, they selected a vehicle body and cut out the rocker panel. In the do stage, they applied cavity wax to the rocker panel using a pump. In the check stage, they evaluated if the wax was applied evenly. In the act stage, they identified areas for process improvement. The results showed that applying cavity wax to the rocker panel via this process helped prevent rust formation.
For the bioprocessing and biopharmaceutical professional, this presentation discusses the topic:
Is Standardization Possible in a Custom Single-use World.
Key learning objectives are:
1. Understand why single-use design processes can become protracted
2. Understand how standardization can help to shorten the design phase
3. Discuss the opportunities for standardization in single use
This presentation was first given as a live webinar by Guy Matthews to an audience of biopharmaceutical professionals from around the world in June 2016.
Guy Matthews has worked in the biopharm industry for the last 20 years during which he has been involved in many projects implementing single-use technology in bioprocessing. Guy now works as Market Development Manager for Parker domnick hunter where he is focused on bringing Parker's expertise in motion and control to bioprocessing.
This document provides an overview of 3D printing and tooling. It begins by stating the educational objectives and outcomes of the course, which are to understand the principles, methods, materials, possibilities, limitations and environmental effects of additive manufacturing technologies.
The document then covers the different units that will be taught, with the first unit providing an introduction to additive manufacturing. It discusses the history and need for additive manufacturing, provides a classification of the different technologies, and discusses how additive manufacturing is used in product development. It also introduces the different materials that can be used for additive manufacturing.
In closing, the document emphasizes that additive manufacturing enables both a design and industrial revolution across many industries such as aerospace, energy, automotive
PPT on GRP pipes and fittings - manufacturing and testinganoopmanoharan2
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and flexing/movement will have no effect. With both GRP and FRP materials, there is a 100% guarantee that it cannot rust or corrode
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and fl
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and flexing/movement will have no effect. With both GRP and FRP materials, there is a 100% guarantee that it cannot rust or corrode
WHAT IS GRP MATERIAL?
GRP stands for Glass Reinforced Plastic. It is also called fibreglass, composite plastic or FRP. It is strong, extremely light and highly versatile. GRP behaves differently to the conventional thermoplastics that are used in everyday items. This means that it has properties that are useful for a range of applications within many industries.
WHAT IS FRP?
FRP stands for Fibre-Reinforced Polymer. FRP is a composite material formed of polymer matrix reinforced with fibres. Although the fibres used are usually glass fibre, as in GRP, others such as carbon, aramid or basalt are also utilised.
FRP is a broader general term more often applied to engineering materials used in a wide range of industrial applications. The term FRP is, however, often used interchangeably when referring to GRP.
WHAT IS GRP MADE OF?
grp material
GRP is made from strands of glass called fibres. These are extremely fine fibres that are woven together to create a flexible fabric. GRP is a moulded product, meaning it must be placed in or around the shape of the item it is required to take. GRP composite incorporates aluminium oxide aggregate surface, which is diamond hard, and offers a high resistance to long-term wear.
With GripClad products, the anti-slip grit cannot be knocked out as happens with over-coating methods. No peel-back or chipping can occur around localised damage points, the colour cannot be worn off and f
1. Six Sigma Green Belt
Certification
Reduce rate of defects of powder coating
PROJECT LEADER : DINESH GOONARATHNE
8/28/2015
2. SIX SIGMA
Reduce rate of defects of powder coating process
Designed and implemented by
Mr. Dinesh Goonarathne
Project Leader
Project Members
Mr. Amal
Mr. Narada
Mr.Suranga
PROJECT CHAMPION : GROUP MANAGER, Mr. S.D.Kumarasekara
Consultant :DMA Kulasooriya-ISL-Certified six sigma black belt
Alumex PLC
Hayleys Group
Pattiwila road,sapugaskanda,Makola,Sri lanka
3. SIX SIGMA
Table of Contents
1.0 Background....................................................................................................................................... 4
1.1 Company Profile............................................................................................................................ 4
1.2 Project organization……………………………………………………………………………………………………………..5
1.3 Problem Opportunity................................................................................................................ 5
1.4 Goal …………………………………………………………………………………………………………………………………… 6
1.5 Target…………………………………………………………………………………………………………………………………..6
1.6 Project Scope ………………………………………………………………………………………………………………………6
2.0 Problem is Defined........................................................................................................................... 6
2.1 Rate of Scraps ............................................................................................................................... 6
2.2 SIPOC ……………………………………………………………………………………………………………………………………….9
2.3 QFD ………………………………………………………………………………………………………………………………………….9
2.4 In-Out Matrix………………………………………………………………………………………………………………………….10
2.5 Measurement Stage Planning Sheet……………………………………………………………………………………….10
3.0 Defects Measure………………………………………………………………………………………………………………………..12
4.0 Defects Analysis ……………………………………………………………………………………………………………………… 15
5.0 Process Control………………………………………………………………………………………………………………………….17
5.1Parato chart .............................................................................................................................17
Discussion………………………………………………………………………………………………………………………………………..20
4. SIX SIGMA
Outline of the project
Project title
Project champion, leader and team members
Business case & problem/opportunity statement
Goals
DMAIC Methodology
Action Plan
Resource Requirements-Budget
Project implementation
Project monitoring, Evaluation
Celebration of results & Dash board
Project Title
5. SIX SIGMA
Reduce rate of scraps of powder coated profiles
1.0 Background
1.1 Company profile
RELATION WITH ALUMINUM POWDER COATING INDUSTRY
Process of ALUMININUM MANUFACTURING
MELTING PROCESS
EXTRUSION PROCESS
POWDER COATING
ANODIZING
DIE DESIGN AND CORRECTION
My role in industry
Working on powder coating plant as in-charge of plant. In this section
approximately around 40 workers are working . The two polyester powder
coating plants have combined capacity of over 1,800 M/T per annum. Polyester
powder coating, also known as color coating on aluminum, is a solvent-free,
durable, factory-applied coating for aluminum substrates. It is a thermosetting
coating where the resin cross links after stove at around 220˙C (curing).
Powder coating offers protection against adverse outdoor weather
conditions. Its mechanical properties can be crafted to meet the varied
requirements of customers.
6. SIX SIGMA
1.2 Project organization
1.3 Problem/opportunity
Following reasons directly effected to the process which was increasing
rate of defects of powder coating.
LM
HM
P/C DAMAGE
OTHERDAMAGE
DUST/powder bowl
EXTUSION DAMAGE
ALUCHIP
Champion
Leader- Dinesh
Mr. Amal
Quality Manger
Mr.Suranga
Prod. Executive
Mr. Narada
Quality T.O
7. SIX SIGMA
1.4 Goal
Remaining minimum reject rate Ex.2.5% monthly
Higher production output within minimum time period.
1.5 Target
Highly customer satisfaction providing profiles and also reduced
cost of waste as scraps.
1.6 Project Scope
Get the observation of defects categories
Collection data production out and planning
Finding out root case of coating process
2.0 Problem is defined
Nature of Customer Order
No of Profiles
Length of profile
Section no
Powder color
Order No.
2.1 Burning Problem is high rates of scraps
Defect: Any damage or improperly (High /low micron thickness on profiles
ect.)
8. SIX SIGMA
Time Analysis
Problems born from manual racking
Reasons for this issues
Racking Time is very high
Racking mistakes are high
Some times Nothing available profiles to racking
High rate of powder coated scraps
Problem was why the varies time was taken to racking for same section code. That
problem is born from manual workers issue.
Solution : set the leader for racking and get the target value within 1 hour. The supervise the
target valve hour to hour.
Now time management is okay after take the above solution. So therefore no need to analysis
more and more because my major part is defect analysis.
9. SIX SIGMA
Six sigma quality Level of my plant
DPMO
Unit : Powder coated profiles given order
Defects : Scraps at completing order
Opportunities : CTQ ‘s of VOC
Area: Aluminium powder coating Manufacturing
Customer Quote: good condition profiles without low quality
CTQ Name: non damages
CTQ Measure: well surface finishing
CTQ Specification: profiles are properly (they will not properly if any individual
profiles are bad)
Unit: : A killo gram (Total cumulative out put production weight within time period)
Opportunity: may be defective issues in powder coating process
Units and Defects can be varied during time period.
Opportunities : 1.Gum Tape
2. Alu chips
3.low/High Microns
4.pin holes
5.powder dust/bull
6.water deposit
7. air bubbles
10. SIX SIGMA
2.2 Sipoc model
supplier Input Process Output Customer
Dispatch Mill finish item Surface finishing Readymade
items for
racking
Alu FAB
Stores Powder Powder coating Coated profiles N-Rich
Man power Manual Worker Racking and
Packing,
Loading/unloading,
Cutting
Help to process Aluroma
Stores Chemicals,
Acids,
Chromate
Pretreatment Treated profiles Sanken
Construction
Utility Diesel,
Electricity
Machinery
Operation
Finishing items MAGA
Engineering
Supplier Process Business Process Customer Process
CTS CTI CTP CTQ VOC
Store powder coating High quality Price
store chemicals Pre treatment Low rejects durability
Dispatch and
logistic Dep.
Mill finish
items
Surface cleaning &
racking
Regular
packing
Quality/Good
condition
utility Electricity
power
Automated process Delivery on
time
2.3 QFD Chart
4-Strong
o 2-Medium
∆ 1-Week
importance
Surface
cleaning
Racking&
packing
Pre
treatments
Powder
coating
Machinery
operation
VOC
1. Price 5 ∆ o o
2. Durability 4 ∆ ∆ ∆
3. Quality of
product
5 ∆ ∆ o
4. Delivery on
time
5 ∆ ∆
Total 49 39 61 46 44
11. SIX SIGMA
2.4 IN-Out Matrix
Scope In Out
Customers Dubai- Aluminium
Akzonobel
DGL
JOTUN
ALU FAB,Aluroma,
N-Rich,Salasi, MAGA Engineering, Sanken
construction
Product Al-Billet ,Powders,
chemicals
Powder coated Aluminum profiles
Process steps Order mill finish items
from dispatch
Surface cleaning , racking , pretreatment ,
powder coating , curing , packing
According to QFD chart
My critical process were Pretreatment ,surface cleaning and powder coating process.
2.5 Measurement stage planning sheet
CTP CTQ/CTI Operational
Definitions
Data
Type
Stratification Sampli
ng size
Freque
ncy
responsi
bilities
Pretreatme
nt
Nos. of
chemical cans.
How many liters
included to bath
Count Put the chemicals
every 6 hrs.
24 hrs. 3 Producti
on
Executiv
e (LAB)
Concentration
of bath
Measure the
conc. Of baths
time to time
contin
uous
Control the water
valve of bath
6 hrs. 3 P.E (
Plant)
Surface
cleaning
Supervis
or
Powder
coating
Auto booth
gun settings
Set the relevant
value of guns
Count Set values for
Every racks
15 min. 96 Gun
operator
Booth speed
(m/min)
Set the speed
according to
curing cycle of
item
Contin
uous
Depend upon
Changing the
powder category
Custom
er order
1 P.E
(plant)
Data Analysis for get the just only idea about process.
12. SIX SIGMA
Time Production output
12/07/2015 ; 24 hours 4051.15
13/07 5748.15
14/07 6140.7
15/07 4370.93
16/07 5562.8
17/07 5794.9
20/07 6539.8
0
1000
2000
3000
4000
5000
6000
7000
Production Output
Mean
15. SIX SIGMA
Reject Rate : 4.93 %
0
1000
2000
3000
4000
5000
6000
7000
8000
1-Jul
3-Jul
5-Jul
7-Jul
9-Jul
11-Jul
13-Jul
15-Jul
17-Jul
19-Jul
21-Jul
23-Jul
25-Jul
27-Jul
29-Jul
31-Jul
Productionoutput Production in July
production output
scraps
mean
Production
Scraps
reject rate 4.933003
Production 126043.5
Scraps 6217.73
16. SIX SIGMA
Units/Kg 126043.5
Opportunities 7
Defects 6217.73
DPMO 7047
Yield(%) 99.30
Process Sigma 2.45
4.0 Defects Analysis
Compare June and July months.
Evaluation June July Target Difference
with target in
June
Diff. with
target in
July
Production
/Kg
95270.5 126043.5 135000 39729.5 8956.5
Scraps/Kg 6500.3 6217.73 3500 3000.3 2717.73
Reject rate % 6.823 4.933 2.6
Sigma level 2.33 2.45 2.68
Target sigma level
Units/Kg 135000
Opportunities 7
Defects 3500
DPMO 3704
Yield(%) 99.63
Process Sigma 2.68
17. SIX SIGMA
1332.86
1045.76
0.00
114.25
295.77
120.33
424.75
334.73
705.36
535.18
114.69
2.25
32.1
30.95 457.43
0 0 0
602.38
Low Microns
High Microns
Test or Trail Operation
Oil Patch
Powder Coating damage
Curing /Dry oven
problem/Back Initation
Carbon dust
Trasport Damage/Despatch
Dmage
Dust
Water Patch
Different reasons to defect and their percentage.
Mainly consider following defects and immediately reduce those reasons
Low micron
High micron
Water deposit
Dust (powder or surrounding )
18. SIX SIGMA
sample analysis of June month production
5.0 Process Control
5.1 parato chart
Cause for
defects
Frequency Cumulative
fre.
Percentage
%
Cumulative
%
Low Micron 15 15 38.46 38.46
High micron 12 27 30.77 69.23
Water Deposit 9 36 23.08 92.31
Powder Dust 3 39 7.69 100
Total 39
0
500
1000
1500
2000
2500
3000
3500
0
1000
2000
3000
4000
5000
6000
6/1/2015 6/2/2015 6/3/2015 6/4/2015 6/5/2015
Production
Scraps
Target
19. SIX SIGMA
Scraps summery of August 1st
to 10 th. 9 opportunities have in this month.
Low Micron 302.43
High Microns 14.19
Dust Environment 480.79
Powder Coating
Damage
45.30
Water patch 66.89
gum tape 49.55
oil patch 43.28
curing problem 16
powder dust 90.25
reject 1163.59
production 28500
Units/Kg 28500
Opportunities 9
Defects 1163.59
DPMO 4536
Yield(%) 99.55
0
20
40
60
80
100
120
low high water dust
frequency
cumu. Frq.
percentage %
cumu. Perc %
20. SIX SIGMA
Process Sigma 2.61
Net savings calculate
June month production :95.27MT
Defects :6.5MT
After improvement
Production :126.05MT
Defects :6.2MT
Production cost for 1kg :1200LKR
Productivity cost :(126.05-95.27)*1000*1200
: 36936000 LKR
Defect saving cost :(6500-6200)*1200
: 360000LKR
Net savings :37296000 LKR
Expected control chat after achieved the sigma level.
21. SIX SIGMA
Final result
Achievement factors June Month ( Start) July (After Improving
)
August ( Process
Control)
Process Yield 99.03% 99.63% 99.55%
DPMO 9747 3704 4536
Sigma Level 2.33 2.68 2.61
In here specially calculated data of august month only within 10 days. therefore
require target can not be reached.
Discussion
In this project I focused powder coating sections only our produced profiles not be defect when
consider hole process why that on of the product unit if defect for my section that mean it cant
select for particular order but it can be select for another type of order. Then in hole process defects
may be minimum ,but difficult to zero because environmental conditionals ex dust condition.
However I have done my project only for my section . So there is many defects .I tried to minimize
one defect per selected order because it may influence some improvement of the process on spec .
In this case I could analyze what are the reasons for product should be defect then I do some
suggestions to minimize defects and done some work study to reduce defects .the result of that I
could increase sigma value from previous level .