Optimizing Process and Systemof Auxiliary Machine to Zero Defect Effect

Optimizing Process and Systemof Auxiliary Machine to Zero Defect Effect

• ZERO DEFECT

• LOST TIME

• DOWN TIME

• COST EFFICIENCY

Optimizing Process and Systemof Auxiliary Machine to Zero Defect Effect

• MECHANICAL

• ELECTRICAL

• HUMAN

• MATERIAL

• ENVIRONMENT

Material and Process Identification

1. Properties of Plastic Materiala. Hygroscopic or Nonb. Bulk Densityc. Moisture Contentd. Drying Timee. Drying Temperature

2. Output/Production CapacityTotal production capacity to calculate of drying and system design.

3. Production Process Kind of production process working;

a. Injection / Extrusionb. Blow/Stretch Processc. Coating Treatment

4. Close Loop Design Systemd. Material Handlinge. Close Loop Design

5. System Designf. Injection / Extrusiong. Blow / Coating Process

Root Cause Analysis

Cause AnalyzingCause

High Moisture Content of plastic material

Dust Contamination

Metal Contamination

Problem Found

Fish Eye

Porosity

Lenses in Films

Gassing

Silver Streaks

Black Dot

Metal Spot

a. Incorrectly of drying calculation capacity.

b. Drying not working properlyc. Incorrectly of system design

a. Virgin raw material suppliedb. Granulating/recycle process

produce of high dust contain.c. contains of dust

Some of metal substance contamination

Problem Solving

Material Identification

1. Properties of Plastic Material2. Output/Production Capacity3. Production Process4. Close Loop Design System5. System Design

Recycling Handling1. Adding for dust cyclone features2. Dust separating system3. Regular maintenance for

granulator

Material Handling1. Adding for electromagnetic metal

detector/separator2. Controlling of material handling

Sampling

Porosity Fish Eye (Bubble/Blank Spot) or Black/Dust Spot

Sampling

Gassing/Fogging Metal Spot

Sampling

No Result Moisture Content Remark

1

Moisture :

1.A : 0,040%1.B : 0,012%

Unqualified

2

Moisture :

2.A : 0,052%2.B : 0,024%

Unqualified

A B

A B

Sampling

3

Moisture :

3.A : 0,130%3.B : 0,136%

Unqualified

4

Moisture :

4.A : 0,186%4.B : 0,243%4.C : 0,199%

Unqualified

A B

A B C

Material and Process Identification Flow

Material Identification

Properties of Plastic Material

Output/Production Capacity

Production Process

Close Loop Design System

System Design

Hygroscopic

Bulk Density

Recycle

Ratio of Mixing

Moisture Content

Drying Time

Moisture content allowed

Material Handling

Close Loop Process

Blow Stretch

Coating Treatment

Drying model

Drying/Hopper Capacity

System Design

Dehumidifying Model

Coloring Process / Additive

Coating Treatment

Additive Melting Point

Accuracy of Ratio

Lead Time

Material Processing Flow

Raw MaterialVirgin/Recycle

Process

Drying & Dehumidifying

InjectionExtrusion

Blow Molding

Coating Treatment

Output Quality(Quality Control)

OK

Not Good “NG”Reject

Granulating / Recycling

De dusting / Mixing

Not Good “NG”Reject

Waste

Output Quality(Quality Control)

OK

Factors That Affect to Zero Defect Target

1. Environments– Temperature– Relative Humidity (RH)

 2. Kind of Material

– Hydroscopic Material“Hydroscopic materials have an affinity for water and are sensitive to high relative humidity”

– Hygroscopic Material“Plastic materials that absorb moisture from the air”

 3. Material Properties

– Moisture Content;• Before Drying• After Drying• Target Moisture

− Drying Time, Drying Temperature, Bulk Density

4. Ratio– Recycle / Virgin / Master batch / Additive

 

Factors That Affect to Zero Defect Target

 5. Hopper Capacity

The related of material properties with hopper capacity– Output Capacity (Kg/hr)– Bulk Density (Kg/L)– Drying Time (hr)– Empty Space (±15 ~ 20%)

 6. Flow

When used for Per form or injection molding, the unit drying air reference value needed for PET is 1.7~2.5Nm/hr-kg; when used for extrusion molding, the corresponding value is 1.2Nm/hr-kg. In fact, since values from the raw material suppliers are often various, the specific values is necessary for reference.The related parameter for air flow calculation;

– Bulk Density– Distance– System Design (piping, conveying, etc)– Hopper Capacity

 

Formula:

HC = ((C x DT)/BD)/ES

Factors That Affect to Zero Defect Target

 7. Kind of Dehumidifier Type

– Molecular Sieve– Silica Gel– Honeycomb– UV

 8. System Handling and Maintenance

– Close Loop System Design– Standard Operational Procedure– Standby Procedure– Maintenance

 

Potential Lost Efficiency Calculation

Calculation for Potential Lost Efficiency:

Study Case:-Material : PET-Capacity : 1000 Kg/day-Bulk Density : 0.85 Kg/L-Drying Time : 6 Hours

Comparable product:a. SHINI Econo Hopper Dryer, type SHD-25T and SHD-50Tb. SHINI Euro Hopper Dryer, type SHD-40U and SHD-80Uc. SHINI All In One Compact Dryer, type SCD-40U/30H and SCD-80U/50Hd. SHINI Separate Vacuum Loader, type SAL-800G

Target of calculation:a. Electricity Efficiencyb. Waste of Productc. Potential of Lost Cost Efficiency

Potential Lost Efficiency CalculationSpecification of Comparable Product:

Hopper Dryer Auto Loader

Loading Capacity (kg/hour)

Heater Power (kW)

Blower Power (kW)

Conveying Capacity (kg/hour)

Motor Power (kW)

SHD-25T 3 0,12 300 0,75

SHD-50T 3,9 0,12 300 0,75

SHD-40U 3 0,12 300 0,75

SHD-80U 3,9 0,12 300 0,75

Drying systemConveying

System Dehumidifying System

Loading Capacity (kg/hour)

Process Heater Power (kw)

Process Blower Power (kw)

Conveying Blower Power

(kw)

Regenerating Heater Power

(kw)

Regenerating Blower Power

(kw)

SCD-40U/30H 3 0,18 0,75 3 0,18

SCD-80U/30H 3,9 0,4 0,75 3 0,18

Potential Lost Efficiency Calculation

NG = 20% NG = 10% NG = 0%

Econo Hopper Dryer Euro Hopper Dryer All In One Compact Dryer

ProductPre-Heating SHD-25T SHD-50T

SHD-40U (Pre-Heating) SHD-80U

SCD-40U/30H (Pre-Heating) SCD-80U/50H

Electricity Cost (Yearly)

IDR 300.931.200

IDR 185.457.600

IDR 210.651.840

IDR 129.820.320

IDR 660.527.784

IDR 381.466.260

Electricity Lost If Use

Pre-Heating

IDR 115.473.600

IDR 80.831.520

IDR 279.061.524

Reject/ NG IDR 540.000.000

IDR 270.000.000

IDR -

Total LostIDR

655.473.600 IDR

350.831.520 IDR

279.061.524

Note:

Waste material will be produce when using of Econo Hopper Dryer and Euro Hopper Dryer, we must add for additional process for recycling, mixing, etc. So we need to spare of cost for recycling process.For dehumidifying using, will be produce non-waste material, so will be optimized the production and reduce the Electrical power.

Potential Lost Efficiency Calculation

Production Material 1Ton/day

Reject / NG Potential Lost/ day Potential Lost/ month Potential Lost/ year

10% IDR 750.000 IDR 22.500.000 IDR 270.000.000

15% IDR 1.125.000 IDR 33.750.000 IDR 405.000.000

20% IDR 1.500.000 IDR 45.000.000 IDR 540.000.000

25% IDR 1.875.000 IDR 56.250.000 IDR 675.000.000

30% IDR 2.250.000 IDR 67.500.000 IDR 810.000.000

35% IDR 2.625.000 IDR 78.750.000 IDR 945.000.000

40% IDR 3.000.000 IDR 90.000.000 IDR 1.080.000.000

45% IDR 3.375.000 IDR 101.250.000 IDR 1.215.000.000

50% IDR 3.750.000 IDR 112.500.000 IDR 1.350.000.000

Potential Lost (Material Waste Only)