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2. LITERATURE SURVEY
2.1 DELTA BLOWPACK INDUSTRIES
Delta Blowpack Industries & group of companies are in the Business of
manufacturing and marketing of HDPE Containers & Articles. The mission of the
company is profitability through Total customer Satisfaction. M/S. Delta Blowpack
Industries & group of companies have tried to touch the customer’s heart by making
Products. As per standards set by Indian Institute of Packaging and manufactured from
Prime Virgin grade material and qualified to keep Edible Oil, Dairy Products,
pharmaceuticals liquids and Semi-Solids fresh.
Moreover the company manufactures their products on latest fully automatic and
sophisticated machines, the shapes are registered with Government of India under “The
Patent and Design Act.” The virgin grade material is used that meets specification of
international stranded. Thus the company has taken most of the measures towards
Quality and Customer Satisfaction.
For ensuring above, the company insists on continuous R&D and Staff Training.
In future (also with any new project) they would not like to compromise with Customer
Satisfaction level.
2.2. CAR A/C DUCT
Car A/C Ducts are manufactured using high grade raw material and posses a
capacity to maintain seal under temperature and pressure changes. The company’s range
of product is widely appreciated for its various distinctive features such as accurate
dimension, high tolerance, durable, excellent finish and high functionality.
2.2.1. Parts of a Car A/C Duct
2.2.1.1 Air Inlet Duct
Air Inlet Duct is generally considered an essential part for improving the
efficiency of the engine. This duct also has a diffusion section above the compressor to
change the ram air velocity into high static pressure at the face of the engine. The thrust
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of the engine can be high only when the duct supplies the required airflow at the highest
possible pressure.
2.2.1.2 Centre Duct
Components like Center Duct Assembly that is widely used in the automobile
industry. These are made from fiber reinforced plastic that is of high quality. Further,
these are offered in various specifications to suit the needs of the clients and are highly
appreciated by clients for the superior quality, durability and effective functioning.
2.2.1.3 Left Hand Duct
Left hand air duct is an extension to the left hand side of the car air duct
assembly. This satisfies the function of the heating, cooling, ventilation to the driver’s
side of the car (India), and to the co-driver’s side in the foreign countries, based on the
steering wheel arrangement in the cars.
2.2.1.4 Right Hand Duct
Right hand air duct is an extension to the right hand side of the car air duct
assembly. This satisfies the function of the heating, cooling, & ventilation, to the co-
driver’s side of the car (India), and to the driver’s side in the foreign countries, based on
the steering wheel arrangement in the cars.
2.3 MANUFACTURING PROCESS FOR THE PRODUCTION OF AIR DUCTS IN COMPANY (BLOW MOULDING PROCESS)
Delta Blowpack Industries are mainly concentrating on the production of Air Ducts,
as their main product, which are used in the automobile air conditioning system and
automobile air-circulating system.
Now, the air ducts that are produced are not single piece manufacturing. Air Duct,
as an assembly consists of the center air duct part, left end air duct part, right end air duct
part and assembly of all these.
The process which is followed in manufacturing of each part of the air duct will be
explained in detail through the flow table.
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Blow molding (also known as blow moulding or blow forming) is a manufacturing
process by which hollow plastic parts are formed. In general, there are three main types
of blow molding: extrusion blow molding, injection blow molding, and stretch blow
molding. The blow molding process begins with melting down the plastic and forming it
into a parison or preform. The parison is a tube-like piece of plastic with a hole in one
end in which compressed air can pass through.
The parison is then clamped into a mold and air is pumped into it. The air pressure
then pushes the plastic out to match the mold. Once the plastic has cooled and hardened
the mold opens up and the part is ejected.
2.3.1 Types of Blow Moulding Processes
2.3.1.1 Extrusion blow molding
In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube
(a parison). This parison is then captured by closing it into a cooled metal mold. Air is
then blown into the parison, inflating it into the shape of the hollow bottle, containeror
part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected.
Continuous and Intermittent are two variations of Extrusion Blow Molding. In
Continuous Extrusion Blow Molding the parison is extruded continuously and the
individual parts are cut off by a suitable knife. In Intermittent blow molding there are
two processes: straight intermittent is similar to injection molding whereby the screw
turns, then stops and pushes the melt out. With the accumulator method, an accumulator
gathers melted plastic and when the previous mold has cooled and enough plastic has
accumulated, a rod pushes the melted plastic and forms the parison. In this case the
screw may turn continuously or intermittently.
2.3.1.2 Injection blow molding
The process of injection blow molding (IBM) is used for the production of hollow
glass and plastic objects in large quantities. In the IBM process, the polymer is injection
molded onto a core pin; then the core pin is rotated to a blow molding station to be
inflated and cooled. This is the least-used of the three blow molding processes, and is
typically used to make small medical and single serve bottles. The process is divided into
three steps: injection, blowing and ejection.
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The injection blow molding machine is based on an extruder barrel and screw
assembly which melts the polymer. The molten polymer is fed into a manifold where it is
injected through nozzles into a hollow, heated preform mold. The preform mold forms
the external shape and is clamped around a mandrel (the core rod) which forms the
internal shape of the preform. The preform consists of a fully formed bottle/jar neck with
a thick tube of polymer attached, which will form the body.
The preform mold opens and the core rod is rotated and clamped into the hollow,
chilled blow mold. The core rod opens and allows compressed air into the preform,
which inflates it to the finished article shape.
After a cooling period the blow mold opens and the core rod is rotated to the
ejection position. The finished article is stripped off the core rod and leak-tested prior to
packing. The preform and blow mold can have many cavities, typically three to sixteen
depending on the article size and the required output. There are three sets of core rods,
which allow concurrent preform injection, blow molding and ejection.
2.3.1.3 Stretch blow molding
In the stretch blow molding (SBM) process, the plastic is first molded into a
"preform" using the injection molding process. These preforms are produced with the
necks of the bottles, including threads (the "finish") on one end. These preforms are
packaged, and fed later (after cooling) into a reheat stretch blow molding machine. In the
SBM process, the preforms are heated (typically using infrared heaters) above their glass
transition temperature, then blown using high pressure air into bottles using metal blow
molds. Usually the preform is stretched with a core rod as part of the process. In the
single-stage process both preform manufacture and bottle blowing are performed in the
same machine. The stretching of some polymers, such as PET (polyethylene
terephthalate) results in strain hardening of the resin, allowing the bottles to resist
deforming under the pressures, formed by carbonated beverages, which typically
approach 60 psi. The main applications are bottles, jars and other containers.
Advantages of blow molding include: low tool and die cost; fast production rates; ability
to mold complex part; produces recyclable parts
Disadvantages of blow molding include: limited to hollow parts, wall thickness is hard to
control.
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2.3.2 Process Flow for Air Duct Manufacturing
Here, we will see the process that is involved in the manufacturing the air duct,
from the raw material. The air duct is basically divided into three main sub-parts, i.e. the
center part, the left hand side duct and the right hand side duct. Also, the process that is
involved in the assemblies of these part to form the main air duct, i.e. our final product,
which is ready to dispatch. We will see, one by one the flow of the process of each
product.
2.3.2.1 Process Flow for Center Duct Manufacturing
The above gives a clear operation description and process flow, that are followed in
sequence for the manufacturing of the center duct.
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2.3.2.1 Process Flow for Side Duct (Left Hand) Manufacturing
The above gives a clear operation description and process flow, that are followed in
sequence for the manufacturing of the side duct, left hand.
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2.3.2.1 Process Flow for Side Duct (Right Hand) Manufacturing
The above gives a clear operation description and process flow, that are followed in
sequence for the manufacturing of the side duct, left hand.
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2.3.2.1 Process Flow for Assembly of the Center Duct with Left Hand and
Right hand Air Duct.
The above gives a clear operation description and process flow that are followed in
sequence for the assembly of the center duct with left hand duct and right hand duct.
Dionisis Kandris, Nikos Papadimitriou, Nikolaos Pantazis, Romanos Fais, Giannis
Psaros,Giorgos Pantouvakis, Spyros Spyropoulos, has approached towards one of the
most common industrial quality control problems, which are involved in manufacturing
of plastic molded receptacles, that is of leakage detection. They begin with an
introduction to the characteristics and the quality problems of the blow molding method
for the production of plastic receptacles. Next, the existing methodologies and
technologies for quality control of such products are presented along with their
corresponding advantages and disadvantages. After their comparative collocation, the
‘pressure control’ method is adopted. [1]
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Serge Monteix, Yannick Le Maoult, Fabrice Schmidt, Jean Paul Arcens deals with
an application of blow moulding process applied to PET bottles forming. The most
important stage of this process is the radiative heating step which is realised with
infrared ovens using powerful halogen lamps. To validate a 3D thermal control volume
software, called Plastirad, developed in our laboratory, temperatures maps were needed
on the plastic performs as well as convective heat transfer coefficient inside the oven.
This measurement has been performed with two different methods : IR thermography
and hot wire anemometry. These two methods have been investigated and results are
compared to focus on the interest of IR thermography. [2]
P. Naughton, P. Shembekar, A. Lokhande K. Kauffman, S. Rathod, G. Malunjkar
The performance and design criteria for seat systems require that the seat be lighter for
reduced fuel consumption while still meeting the safety requirements as required by
legislation. The safety requirements for seats include headrests and seat back static and
dynamic structural performance, seat belt anchorage and luggage retention capability,
child seat anchorage and top tether requirements as defined by pertinent regulation. The
interior space constraints require that the seat be thinner. The seat design is expected to
address the growing concern for environmental friendliness. In addition to these main
criteria, various additional features such as adjustable and stow-able design are required
for customer delight. All these design objectives should be met within a given cost
target. [3]
K. Szczepański*, D. Kwiatkowski, J. Koszkul The main purpose of the performed
investigations was a multi-aspect analyzes of the blow moulding process in a mould
which takes two-stage nature of the process and the occurrence of uncontrolled
phenomena which influence the shape, size and quality of the products into
consideration. [4]
Sherry L. Baranek Blow mold design and build requirements—as well as challenges
and how to overcome them—through the use of a new rotary blow molding wheel
system. With a majority of the population constantly on the go, the market for single-
serving containers (plastic bottles) of both beverages and foods is exploding. While
designing and building blow molds is challenging, it is a niche worth exploring. [5]
2.4. QUALITY IMPROVEMENT TECHNIQUES
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There are various techniques that improve upon quality for betterment of higher
productivity with less rejects as compared to the process of the one without quality
improvement technique.
Quality improvement is a characteristic of quality management and it is the
continuous improvement of the output of products and services using management
systems. There are various quality management systems available. Many Quality
improvement tools today are used due to a high demand for large volumes of high value
products and services using cheaper materials in production during the second world
war. Present systems such as Kaizen, Total quality management (TQM), Quality circles
and Six Sigma have shown the power and effects a team-base improvement system can
have on production. Process capability design is at the forefront when using Six Sigma.
Some improvement tools includes Control charts, Lot sampling, Process
capability, Value Analysis (VA). A sustainable and continuous improvement program
in a company has to be part of the companies’ cooperate culture, and staff should be
trained on the system adopted for this type of management and improvement.
2.4.1 Six Sigma:- Six Sigma is a business management tool developed by the
Motorola Company in the mid 80’s. It seeks to improve the quality output and efficiency
of companies by identifying the probable defects in a given process and minimizing the
variability in output. This process uses a set of methods including statistical methods
creating an infrastructure of people within the organization. Each Six Sigma project
process in an organization follows a laid down sequence with the aim of reducing cost
and maximizing profit.
2.4.2 Total Quality Management (TQM):- TQM uses teams made up of
workers from all sectors in the company to solve issues. The teams undergo training in
the use of basic statistical tools that are used in the collection and analysis of data.
2.4.3 ISO 9000:- ISO 9000 is a standard of quality systems. The ISO 9000 family
of standards ensure that organizations meet the needs of customers and other
stakeholders. This process deals with the basics of quality management, emphasizing on
eight principles on which the family of standards is based.
2.4.4 Quality Control Circle (QCC):- Quality control circle is a small group of
workers who come together to discuss ways of identifying, analyzing, solving and
selecting work related issues.
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2.4.5 Failure Mode and Effect Analysis (FMEA):- Failure Mode and Effect
Analysis is a very important tool to improve upon the quality. In this tool, the failure
modes are earlier checked upon and necessary actions are taken to prevent that to avoid
the re-occurrence of the failure.
M.Y. Lam, Gary K.K. Poon and K.S. Chin has tried to establish a relationship between
organizational learning capability (OLC) and TQM culture (TC) based on a case study of
a leading vocational education institution of Hong Kong, and to develop an
organizational learning transformation model for vocational education in the context of
TQM culture. [6]
Jose´ Carlos Pinho analyzed the importance of developing a quality
management approach as a way to enhance the bottom line results of small and medium
sized enterprises (SMEs). The main goal is to examine the synergistic relationships
between TQM, performance, consumer orientation and innovation. [7]
Silvia Helena Boarin Pinto, Marly Monteiro de Carvalho and Linda Lee Ho has
identified the relationships as to complementarities and redundancies of the main quality
programs in large Brazilian companies by a comparative and critical analysis of their
implementation in those companies. [8]
Djoko Setijono and Jens J. Dahlgaard has presented a proactive quality costs
measurement methodology, which describes the value of quality improvements and the
implication of this value on customers’ perception regarding the value of the product. [9]
Alessandro Brun, Donatella Corti and Alessandro Pozzetti has provided a
methodology aimed at improving the setting up of air-jet looms by clarifying the
function which links different important variables involved in the setting procedure and
by proposing a method to measure the quality of fabrics depending on the factor values.
[10]
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2.5 FAILURE MODE AND EFFECT ANALYSIS
The first stage of an FMEA exercise is to decide on the type(s) of analysis
required, depending on the maturity of the design and decisions to be made, but this may
include: - System FMEA, Design FMEA, Process FMEA
The FMEA process uses rating scales to assess, the severity of the possible
consequences of specific types of failure (Severity). The Probability, that the causes of
failure will occur (Occurrence). The possibility, of detecting a problem, using the
current procedures, and intervening to avoid the consequences of failure (Detection).
Appropriate rating scales should be chosen for each project, and consistently applied.
Published standards1 include recommended rating scales for automotive
applications, and these may be adapted for general use as shown in The effects of
potential failures are assessed using a ‘Risk Priority Number’ or RPN that is calculated
by multiplying the individual scores together, so that,
RPN= Severity x Occurrence x Detection
Particular care must also be taken to address concerns that could cause serious
or fatal injury, even if the risk of occurrence is small. Especially in high volume
manufacture the statistical probability of “at least one failure” should always be
considered, and appropriate action taken to prevent that failure mode or mitigate
the consequences of failure. It is important that the rating scales established for a
particular project are applied consistently throughout the analysis and answers are not
fudged to become politically acceptable.
Dr. Ravikant and Bhavik Pathak has represents the results of the analysis of causes
and modes of failure of the automotive radiator as a part of the cooling system of vehicle.
Based on detailed review of the structure and operation modes of the observed object and
other relevant data, FMEA discovered the weak processes in the manufacturing of
radiator, and then after necessaries improvements we repeat investigation which gave
positive results. They concluded that the paper presents possible applications of FMEA
to identify the possible product enhancement points for automotive radiator. [11]
Dobrivoje Ćatić, Slavko Arsovski, Branislav Jeremić and Jasna Glišović has stated
that FMEA can be applied at all stages of the life cycle of one technical system.
However, its effectiveness is the largest, if applied at product development phase by a
13
team of experts from various companies’ functions. Therefore, conceptual, design and
process FMEA is discussed in this paper. A detailed description of the relations between
these methods and the order of application is considered. Based on FMEA working plan
it was formed the algorithm procedure of application of design FMEA method. The
specific steps of FMEA procedure starting from the formation of FMEA team until
documenting of the analysis is explained. [12]
Namdari M., Rafiee Sh., Jafari A., has aimed to reduce fuel consumption in moldboard
plowing using the failure mode and effects (FMEA) method. FMEA is a new
methodology to analyze potential reliability problems in the development cycle of the
project, making it easier to take actions to overcome such issues, thus enhancing the
reliability through design or process. FMEA is used to identify actions to mitigate the
analyzed potential failure modes and their effect on the operations. Application of FMEA
in this study revealed that plowing speed, soil moisture content and plowing depth are
the most important factors in tillage fuel consumption, with 640, 480 and 420 RPN
respectively. [13]
Joseph Barkai, has describes a project to convert the results of Failure Mode and Effects
Analysis information into a diagnostic knowledge base. Combined with a diagnostic
expert system, this knowledge base produced an effective diagnostic system for an off-
highway vehicle. [14]
Thomas A. Carbone and Donald D. Tippett proposes the extension of the
Failure Mode and Effects Analysis (FMEA) format to quantify and analyze project risks.
The new technique is labeled the project risk FMEA (RFMEA). The RFMEA is a
modification of the well-known process, product, and service FMEA technique. In order
to use the FMEA format for projects, the detection value of the standard FMEA is
modified slightly for use in the project environment. [15]
Yiannis Papadopoulos, Christian Grante & David Parker has analysis the compile
lists of component failure modes and try to infer the effects of those failure modes on the
system. System models, typically simple engineering diagrams, assist analysts in
understanding how the local effects of component failures propagate through complex
architectures and ultimately cause hazardous effects at system level. [16]
Riccardo Mariani, Gabriele Boschi, Federico Colucci proposes an innovative
methodology to perform and validate a Failure Mode and Effects Analysis (FMEA) at
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System-on-Chip (SoC) level. This is done in compliance with the IEC 61508, an
international norm for the functional safety of electronic safety-related systems. [17]
Lars Dittmann, Tim Rademacher, Stephan Zelewski, aims to introduce an approach
that integrates a technique of knowledge engineering (Ontologies) and a technique of
quality engineering (Failure Mode and Effects Analysis). An approach will be set up that
shows the potentials of combining IT-based systems of knowledge and quality
engineering. Particularly with regard to the quality engineering technique, the paper aims
to demonstrate the advantages of this approach. [18]
3. SUMMARY
The other relative works of my dissertation to be done are shown on the next page in the
form of GANTT CHART.
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