ORIENTATION REPORT SYED MOHSAN RAZA (1)

Preparedby MOHSAN RAZA (PRODUCTION EXECUTIVE)
engrmohsan@gmail.com Service industries Gujarat Pakistan
1
ORIENTATION / ASSESSMENT REPORT – MC-TUBE
1. Introduction. Service is the pioneer in tyre & tube manufacturing in
Pakistan since 1970. Specialized in manufacturing and marketing products for the
masses, our main business activity is producing tyres & tubes for Motorcycle /
Bicycle and footwear of different kinds. Our sister concern, Service Shoes,
operates a network of over 400 retail shoe stores and we also have a
successful export business catering to German and French markets. Service Industries
Limited has been dealing in bicycle tyre & tube business since 1970. Manufacturing
of motorcycle tyres & tubes was started in 1990. Our high quality products are swiftly
and efficiently distributed through a vast distribution network are a testament to their
own success. This makes us undisputed market leader in bicycle market and a
holder of majority share in motorcycle tyre & tube market. We are a major supplier
of tyres & tubes to Japanese motorcycles manufacturers like HONDA, YAMAHA
and other local motorcycle assemblers in Pakistan. Service Industries Limited is
listed as registered Company on all major stock exchanges of the country. With a
work force of above 6,000 employees and approximately $90 million dollars per
annum turnover, we are a low cost producer selling and growing profitably, doubling
our sales every three years, and earning a fair profit for the shareholders.
2. Aim of Report. To brief about the assessment / experience.
3. Execution

2
a. Organization of Tube Section
b. Manufacturing Process Flow Chart

3
c. Material
(1) There are two types/ properties of rubber being used
in tube production:-
(a) Natural (NR)
i. Natural Compound. Natural identification line is
yellow and has low elasticity as compared to Butyl
compound. Yellow Tags are attached for
identification. Natural rubber has a high tensile
strength and is resistant to fatigue from wear such as
chipping, cutting or tearing. On the other hand, natural
rubber has only moderate resistance to damage from
exposure to heat, light and the ozone in the air.
Natural rubber also has tack, which means it can
adhere to itself as well as other materials. It adheres
particularly well to steel cord, which makes it an
excellent material for use in tires.
(b) Butyl (BR)
i. Butyl Compound. Identification line is blue and has
high elasticity as compared to Natural Compound
Blue Tags are attached with raw compound for
identification. • In general, synthetic rubber offers
better resistance to abrasion than natural rubber, as
well as superior resistance to heat and the effects of
aging. Many types of synthetic rubber are flame-
resistant, so it can be used as insulation for electrical
devices. It also remains flexible at low temperatures
and is resistant to grease and oil.
(c) Comparison Natural Vs Butyl. Overall the
combined properties of natural rubber outweigh

4
synthetic rubbers or combinations of synthetic rubbers
available. However, synthetic rubber is advantageous
because it is easier to produce. Natural rubber is a
crop able to grow only in tropical climates and it
doesn't age well, so for many countries it is easier to
use synthetic rubber.. Synthetics may also be more
useful in certain applications because of their
resistance to extreme temperatures and corrosive
environments.

5
GREEN TUBESPACIFICATIONS EXTRUSION
S# Size
Width
STD
±1
mm
Length
± 10 mm
(Spliced)
Nozzle Point(mm)
Nozzle
Uesd
Nozzle
Weight
(gm)
Compound
Weight
(gm)
Total
Weight
±
10(gm)
Curing
Time
RemarksFrom
Side
(mm)
From
Head
(Inches)
1 2.25-17 NR 65 1435 Center 7 TR 4 NR 18 350 368 120
2 2.25/2.50-17NR 71 1435 Center 7 TR 4 NR 18 375 393 120
3 2.50-18 NR 71 1500 Center 7 TR 4 NR 18 414 432 120
4 2.75-18 NR 84 1500 Center 7 TR 4 NR 18 480 498 120
5 300-17 NR 94 1435 Center 7 TR 4 NR 18 500 518 120
6 3.00-18 NR( AFG) 94 1500 Center 7 TR 4 NR 18 475 493 120
7
3.00-18 NR(
Other) 94 1500 Center 7 TR 4 NR 18 527 545 120
8 2.25-17 65 135 Center 7 TR 4 18 295 313 165
9 2.50-17 69 1435 Center 7 TR 4 18 318 336 165
10 2.50-18 71 1500 Center 7 TR 4 18 330 348 165
11 2.75-18 84 1500 Center 7 TR 4 18 407 425 165
12 3.00-16 94 1405 Center 7 TR 4 18 407 425 165
13 3.00-17 94 1435 Center 7 TR 4 18 421 439 165
14 3.00-18 94 1500 Center 7 TR 4 18 441 459 165
15 3.00/3.25-8 NR 77 715 30~35 4.5 DINN7777 19 245 264 105
16 3.50-8 NR 101 705 30~36 4.5 DINN7777 19 273 292 105
With out
Infilation
17 4.00-8 NR 121 705 30~37 4.5 JS87 NR 19 370 389 165
With out
Infilation
18 3.50-8 BR 101 705 30~38 4.5 JS87 C 19 273 292 165
With out
Infilation
19 3.50-10 101 910 30~39 4.5 JS87 C 19 332 351 180
With out
Infilation
20 4.00-8 BR 124 705 30~40 4.5 JS87 C 19 313 332 180
With out
Infilation
21 1.35-10 124 900 45~50 6 TR 13 15 440 455 180
With out
Infilation
22 4.50-12 136 985 45~51 8 TR 13 15 506 521 240
23 5.00-12 145 1040 40~45 8 TR 14 15 579 594 240
24 6.15-13 150 1080 45~50 7 TR 13 15 671 686 240
25 6.00-16 152 1365 55~60 8 TR 15 15 804 819 240
26 6.50-14 179 1205 55~61 8 TR 13 15 865 880 240
27 6.50-16 177 1325 55~62 6 TR 15 15 895 910 240
With out
Infilation

6
(e) Types of nozzle Brand
i. DNN 7777 NR
ii. JS 87C BR
iii. Tr 15
iv. JS 87c NR
v. Tr13
vi. Tr4BR
vii. Tr4NR
(f) Nozzle pasting: - Nozzle is pasted on the pasting cement line. There are
two types of solvents. Natural and Butyl. Natural solvent thicker then
Butyl solvent.
(g) Capacity in nozzle pasting area. Only Tr4BR Brand Nozzle is
pasted on tube value cement line

7
4 persons
1 person
1 person
nozzles are double past in nozzles pasting line.
1 tray= 60nozzles MAN power = (6)
4 Tray cycle time = 1.5 min
Nozzle pasted 1 Min = 160
Nozzles pasted in 8 HR = 76800
If we add PBD 20 Min / 8 HR then actual production capacity is
73600nozzles
3. Sequence of Process Manufacturing
Loading in
trays
loading In
cement line (i)
Unloading from
trays
Loading on cement
line (ii)
unloading

8
a. Rolling or Warming
(1) Roller Sizes
(a) WR # 1 = (22x60) (only NR compound used at this time)
(b) WR # 2 = (22x60)
(c) WR # 3 =(22x60)
(2) Temperatures of Warming Rolls
(a) WR # 1 90c° to 110c° NR
(b) WR # 2 = 70 to 110 BR
(c) WR # 3 = 70c° - 90c° BR
(3) %age of Rework Used in Compound
(a) Mc Tubes 40kg to 50 kg Reworks added (Butyl)
(b) ULT tubes 15 kg to 25 kg
(c) Total load 140 kg 150 kg Ratio is 100/40
(4) Temperatures of compound
(a) WR # 1 100c° -120c° NR
(b) WR # 2 90c° - 110c° BR
(c) WR # 3 90c° - 110c° BR

9
b. Refining or Straining
(1) Butyl rubber inner tube compounds can be strained for foreign
material, un-dispersed carbon black particles, or other
contaminants. The master batch is best strained immediately
after mixing to eliminate an extra warm-up operation if suitable
capacity straining equipment is available. This can be done by
strip feeding the strainer from the batch-off mill or feeding
directly into a batch-off extruder and strainer. Equipment is
available which will handle the dumped stock within the duration
of the mixing cycle. If the treatment is not possible the more
common operation of a separate mill warm-up of the stock is
usually adopted. Strainer packs are usually 30 mesh or 20 mesh
backed up by 40 mesh. Efficient cooling and minimal heat history
are prerequisites for straining finalized compounds. Strained
finalized compound may go directly to the extruder. Often,
straining of finalized stock by a screen pack in the extruder is
practiced. The compound must be particularly well mixed and high
quality curatives used to minimize screen changing. However,
this process may not be suited to good tube dimensional
control due to output rate changes as the screen
becomes plugged. A double head extruder is advantageous to
minimize time lost during screen changes.
 Rpm 400 to 800 Rpm head pressure 80psi to 110psi

10
 Strainers sieves (i) 0.5 (ii) 2.6 (iii) 2.6 for butyl
 Sieves changed After 10 to 15 Min. if we don’t change sieves
then compound not refine properly and temperature build up in
refining machine which can change properties of compound.
 Strainers sieves are cleaned with petrol
 For natural compound Refining only 2 Strainer sieves are used
2.6mm
 Refining machine QTY= 03.Capacity of one refining machine is
sets for one feeding roll.
c. Feeding
(1) Roller Sizes
(a) FR#1 16x40
(b) FR#2 16x40
(c) FR#3 16x40
(2) Temperature of Feeding Rolls
(a) FR#1 BR = 70c° to 90c°
(b) FR#2 BR = 70c° to 90c°
(c) FR#3 BR = 70c° to 90c°
(d) FR#4 BR = 70c° to 90c°
(3) Temperature of Compound
(a) FR#1 BR 90c° to 110c° (however, NR 110c° to 90c°)
(b) FR#2 BR 90c° to 110c°
(c) FR#3 BR 90c° to 110c°
(4) Capacity of Feeing Rolls Sets
(a) FR# 1 feeds conveyor#1
(b) FR# 2 feeds conveyor#2,3,4,5
(c) FR# 3 feeds conveyor#6
(5) Faction Ratio of warming Rolls and Feeding Rolls
(a) WR #1 1:1.25
(b) WR #2 1:1.25
(c) WR #3 1:1.25
Note:-Nip adjustment changed according to size of products it
adjust from screw from rolling mill head.we should only

11
adjust nip after unload compound which is better for
warming and feeding rolls.
(6) Rework Ratio Adjustment Impact On Compound Behavior. If
rework Ratio is Maximize then following problem we face.
(a) Shrinkage Maximize
(b) Pulling factor Maximize
(c) Length shortening
(d) Width Max
(e) Thickness Max
d. Extrusion. In series industries we use Hot feed extrusion in inner
production.
(1) Guidelines for Extrusion. Hot feed extrusion can be
summarized as follows :
(a) Care should be taken to assure are adgute supply of
compound to the mills, prevent porosity and maintain the
uniform compound temperature a small bar should be
maintained on the feed mills.
(b) The feeding mills should not to be overloaded.
(c) Slight excess of stock is suggested in the extruder feed box
to ensure that the screen flights are full, I here by preventing
an excursive in that of air with the compound feed ships.
(d) A force feed roller which will insure the effective filling of the
screw flight at the feed end is useful but the occasional
addition of some extra strips of compound be the hopper
may also be advantageous .
(2) Temperature Controls
(a) Extruder barrel temperature 45-75c°
(b) Extruder head temperature 90-110c°
(c) Temperature of extruder cues them 120c°
(3) Take of Conveyor Instructions. Speed of the take- off
conveyor should match the extraction speed. Pull – Dean should be

12
avoided as it may resets in increased inner tube wall porosity and
uneven shrinkage on cooling:-
(a) Warming roll temperature should be 70-90c°
(b) Parentage of rework should not be more than 20%.
(c) Conditions of strained strings should be smooth.
(d) Time b/w straining a d extrusion should be more than 2min.
(e) Condition of wiping swap should be risible.
(f) In side dusting should be control not excessive.
(g) Size of green tube should be according to ills specification.
(h) Showering of water work properly.
(i) Air blower and deader are working properly.
(j) Punching pressure should be maintained according the size
specification. Blower position and vacuum pressure also
maintain.
(k) Brand identification line should be risible smooth.
(l) Nozzle fixing should be proper pressure and fix in center of
punch.
(m) Outside dusting should be control.
(n) Maintenance preventive maintenance not break down
maintenance.
(o) Air pressure is 6kg/cm2.
(p) Tube booking temperature less than 40c°.
(q) Puling factor less than 2%.
(4) Common Extrusion Issues
(a) Bubbles or Off Gassing. Check the moisture level
of compound.
(b) Scorching. Check the feed throat cooling and focus on
extruder zone.Remove any additional compound
contamination on screw and straining sieves should change
on time (10-15 min)

13
(c) Blocking or tacky surface:-
i. Compound temperature too high.
ii. Die temperature too high.
iii. Output excessive.
(d) Flow Lines
i. Compound temperature too low.
ii. Extruder output speed excessive.
iii. Poor mixing.
iv. Dirty extruder or die.
v. Die temperature too low
(e) Rough Surface
i. Contamination
ii. Die not streamlined
iii. Die land too high
iv. Excessive output
v. Extrusion temperature too low
vi. Straining or refining poor
(5) Parts of Extrusion Conveyor

14
(a) Extruder
A = Drive (motor)
B = Feed
C = Screen (6’’)
D = Barrel
E= Barrel liner
F = screen pack x
G = Breaker place
H = Die body (spider, nozzle, inside dusting rod + die)
I = Die head
J=Identification liner
(b) Take of conveyor
(c) Sops toner ( inside dusting) + Air pressure line
(d) Showering tub
(f) Air blowers + Dry heaters
(g) Cutter + heater
(h) Sensor of tub cuter
(i) Swiping petrol brush
(j) Sensor of punching and nozzle fixing
(k) Control Panel
i. Power light on/of
ii. Conveyor on/of

15
iii. Vacuum on/of
iv. Soaps tone on/of
v. Bower on/of
vi. Punching heater on/of
vii. Cutter heater on/of
viii. Dry heater on/of
ix Auto heater on/of
x. Auto cutter on/of
(6) Brand / Size wise production capacity tubes/min
Ser Brand name Tubes/ Min Remarks
1 2.25-17NR
2 2.25/2.50-17NR
3 2.50-18NR
4 2.75-18NR
5 3.00-17NR
6 3.00-18NR 15
7 3.00-18NR
8 2.25-17 18
9 2.50-17 18
10 2.50-18 18
11 2.75-18 17
12 3.00-16 16.5
13 3.00-17 16
14 3.00-18 15
15 3.00/3.25-8NR
16 3.50-8NR 22
17 4.00-8NR 18
18 3.50-10 19
19 3.50-8BR
20 4.00-8BR 18
21 1.35-10 16

16
22 4.50-12 15
23 5.00-12
24 6.15-13BR 12
25 6.00-16
26 6.50-14 9
27 6.50-16 8
(7) Production capacity of 6 conveyor individually (Data written
trolley booking / HR)
Size Tubes
/Min
Tubes
/HR
Trolley
Booking
Rework Rework%
CONV #1
3.50-10BR 19 1140 990 150 13%
6.50-14BR 9 540 380 160 29%
6.50-16BR 8 480 340 140 29%
4.50-12BR 15 900 480 420 46%
6.15-13BR 12 720 550 170 36%
1.35-10BR 16 960 640 320 33%
Tubes /HR AVG. = 790
Tubes /8HR AVG= 790x8=6320
Trolley Booking /HR =563
Trolley Booking/8HR= 563x8=4506
REWOK/8HR =226x8= 1813
Rework % = 28.9%

17
If add change over BR to NR then 37 mints Required. Then actual capacity
is tubes /Min x Time CO = 13x37 = 481
Production capacity conv#1 = 4506-481 = 4025 Tubs/8HR
Size Tubes
/min
Tubes
/ HR
Trolley
Booking
Rework Rework%
CONV #2
2.50-17BR 18 1080 820 260 24%
“ 18 1080 870 210 19%
Capacity 8HR = 1080x8 = 8640
Trolley booking 8HR = 845x8=6760
Rework 8HR = 230x8=1880
Rework %= 21%
Average PBD/8HR = 33 Mints 33x18=594
Actual production capacity = 6166 Tubes
CONV#3
Size Tubes
/min
Tubes
/ HR
Trolley
Booting
Rework Rework%
2.50-17BR 18 1080 820 260 24%
Capacity 8HR = 1080x8=8640
Trolley Booking 8HR = 820x8 =6560
Rework 8HR = 260x8 = 2080
Rework% = 24%
AVR PBD/8HR = 33MIN = 33x18 = 594
Actual prod capacity = 5966 Tubes
CONV#4
Size Tubes
/min
Tubes
/ HR
Trolley
Booking
Rework Rework%
2.50-18BR 18 1080 806 274 25%
Trolley Booking = 806x8=6448

18
Rework 8HR = 274x8=2192
Rework% = 25%
AVR PBD/8HR = 33MIN = 33x18=594
Actual prod capacity = 5854 tubes
CONV#5
Size Tubes
/min
Tubes
/ HR
Trolley
Booking
Rework Rework%
2.50-17BR 18 1080 716 364 23%
Trolley Booking = 716x8 = 5728
Rework 8HR = 364x8= 2912
Rework% = 33%
AVR PBD/8HR = 33MIN = 33x18=594
Actual prod capacity = 5134tubes
CONV#6
Size Tubes
/min
Tubes
/ HR
Trolley
Booting
Rework Rework%
300-17BR 16 960 770 190 19%
Capacity 8HR = 960x8
Trolley Booking 8HR = 770x8=6160
Rework 8HR =190x8=1520
Rework% = 19%
AVR PBD/8HR = 33MIN = 33x18=594
Actual prod capacity = 5566tubes

19
(8) Summary of Production Capacity 6 Conveyor
SR NO Production Rework %
Conveyor #1 4025 Tubes 28.9%
Conveyor #5 5134 Tubes 33%
Conveyor #6 5566 Tubes 19%
Total 32711 25.15%
(9) Time and motion study to improve productivity and counter
measures of reworks
(a) Conveyor #1
i. Running item:- 4.50-12BR
ii. Tubes/Min :- 900Tubes
iii. Data calculated: - 7:30 To 8:30 1 HR Dated: -
9/4/15
iv. Colour line missing:- 3.5 Min
v. Trolley Shortage: - 5.75 Min
vi. PBO : - 33/8 =4.1/HR
vii. Putti shortage: - 0.87
viii. Inside Dusting: - 1Min
ix. Size checking: - 2Min
x. Die change over: - 8 Min/HR
xi. Total time loses: - 25.15
xii. Tubes Rework: - 377 Tubes
xiii. Production: - 523x8 = 4184
xiv. Rework%:- 35%
(b) ONVEYOR #2

20
i. Running item:-2.50 -17 BR
ii. Tubes / HR :- 1080
iii. Data calculated :- 8:30 to 9:30 Dated :- 9/4/15
iv. Colour line missing :- 1.5Min/HR
v. Trolley shortage :- 9 Min/HRv
vi. PBD :- 4.1/HR
vii. Putti shortage :- 0.625
viii. Inside Dusting :- 0.625
ix. Outside Dusting:- 0.375
x. Pulling factor :-0.375
xi. Die change over :- 1.87
xii. Petrol brush changing:- 0.1875
xiii. Total time lose /HR = 18.27
xiv. Reworks = 18.27x18=328
xv. Actual progress= 752x8=6016
xvi. Rework% = 30%
(c) Conveyor#3
i. Running item:-2.5-17BR
ii. Tubes/min -18
iv. Colour line missing :- 2 Min/HR
vi. PBD :- 4.1/HR
vii. Putti shortage :- 0.870
viii. Inside Dusting :- 0.625
ix. Outside Dusting:- 0.50
x. Pulling factor :-0.375
xi. Die change over :- 1.87
xii. Petrol brush changing:- 0.1875
xiii. Total time lose /HR = 20.64

21
xvi. Rework% = 33%
(d) Conveyor#4
i. Running item:-2.50-18 BR
ii. Tubes/min -18
iv. Colour line missing :- 3.1 Min/HR
v. Trolley shortage :- 9 Min/HR
vi. PBD :- 4.1/HR
vii. Inside Dusting :- 1
viii. Outside Dusting:- 1
ix. Pulling factor :- 0.375
x. Die change over :- 1.87
xi. Petrol brush changing:- 0.1875
xii. Total time lose /HR = 20.97
xiii. Mechanical Fault – 0.50
xvi. Rework% = 34.90%
(e) Conveyor#5
ii. Tubes/min -18
v. Trolley shortage :- 7.5 Min/HR
vi. PBD :- 4.1/HR
vii. Inside Dusting :- 1
viii. Outside Dusting:- 1
ix. Die change over :- 1.87
xi. Petrol brush changing:- 1,5

22
xiii. Reworks = 21.15x18=380
xvi. Rework% = 35%
(f) Conveyor#6
ii. Tubes/min -18
vi. PBD :- 4.1/HR
vii. Inside Dusting :- 0.3
viii. Outside Dusting:- 0,3
ix. Die change over :- 1.87
xi. Petrol brush changing:- 0.18
xiii. Reworks = 15.18x18=273
xvi. Rework% = 25%
(g) Summary – Time and Motion (Conveyor # 1-6)
Conveyor Reworks Production Remarks
#1 35% 4184
#2 30% 6016
#3 33% 5736
#4 34.9% 5616
#5 35% 5594
#6 25% 6454
Total 32.15% 33600

23
(h) Electrical Capacity of Extrusion Section
Ser Make & Type Made Size Motor RPM
i. Warming Roll #1 Dailan 22’’x60’’ 95 KW
(128 HP)
980
ii. Warming Roll #2 Dailan 22’’x60’’ 110 KW
(147.5 HP)
730
iii. Warming Roll#3
iv. Feeding Roll #1 Taiwan 16’’x44’’ 40.2 KW
(50 HP)
725
v. Feeding Roll #2 Taiwan 16’’x44’’ 40.2 KW
(50 HP)
725
vi. Feeding Roll #3 Taiwan 16’’x44’’ 40.2 KW
(50 HP)
725
vii. Refining #1 Taiwan 6’’ 75 KW
(101 HP)
1480
viii. Refining #2 China 8’’ 75 KW
(101 HP)
1428
ix. Refining #3 Alpha One 8’’ 90-108 KW
(144.7 HP)
1480
X Extruder#1 Seyen
Taiwan
6” 100KW
(134HP)
1428
Xi Extruder#2 Yuan king
Taiwan
6” 45KW
(60HP)
1470
Xii Extruder#3 Kayton
Taiwan
6” 45-50KW
(67HP)
1475-
1775
Xiii Extruder#4 Kayton
Taiwan
6” 55KW
(78HP)
980
Xiv Extruder#5 Kayton
Taiwan
6” 45-52KW
70HP
1475-
1775
Xv Extruder#6 Kayton
Taiwan
6” 45KW
60HP
1470
Xvi Soapstoner#1 to
6(inside dusting)
1/2HP*6=3HP
Xvii Soapstoner#1 to
6(outside dusting)
1/2HP*6=3HP
Xviii Nozzle pasting 3HP
Xix Colour mixer 1HP
Xx Refining
conveyors
3HP
Xxi Refining hydraulic
motors
6.6HP
Xxii Dust collectors 6HP
Xxiii Conveyor drive 30HP

24
e. SPLICING:-
(1) TUBE SPLICING UNIT. Splicing units are there for jointing the
tubes.
(2) Specifications
(a) Temperature of splicing knifes( 220-240C NR)(240-260 BR)
(b) Butting time 4-7sec.
(c) Butting pressure 7-8 kg/cm²
(d) Low air pressure 4kg/ cm²
(e) High air pressure 6kg/ cm²
(f) Splicing cycle 10-16 sec.
(g) Hardness of splicing dies 70-75
motors 1 to 6
xxiv Conveyor
hydraulic pumps
3HP
Xxv Conveyor air
blower motors
6HP
Xxvi Feeding
conveyors motors
9HP
Xxvii Vacuum pump
motors
13.2HP

25
(3) Instructions
(a) Quality of green joint should be visible.
(b) Hardness of splicing dies 74-76 A Type.
(c) Width of green tube should be accurate to standard set
parameters.
(d) Dies cleaning should be visible and cleaned on hourly basis.
(4) Working Production Capacity in Splicing
(a) 2.50 - 17 BR, 2.50 - 18 BR
i. Working Capacity per 8 Hr = 2240 tubes, one splicer
ii. Running machines = 8 = 2240 x 8 = 17940 tubes
(b) 2.25 – 17 BR, 2.50 – 17 BR
i. Working Capacity per 8 Hr = 2240 tubes, one splicer
(c) 3.00 – 16, 3.00 – 17
(d) 3.00 – 18, 4.00 – 8
(e) 3.50 – 8 , 2.75 – 18
(f) 1.35 – 10, 4.00 – 8 NR
i. Working Capacity per 8 hr = 1600 tubes
(g) 4.50 – 12 , 6.50 – 16
(h) 6.5 – 14, 6.00 – 16
(i) 6.15 – 13, 5.00 - 12
i. Working Capacity per 8 hr = 716 tubes
(j) Grand Total = 35784 tubes (With 20 x machines &
operators)
(k) Rework Tubes = 870 tubes
(l) Remaining Tubes (j-k) = 34914 tubes (8 hours)

26
(m) Half time = 30 minutes = 30 x 72 = 2179 tubes
(n) Production 8 hrs excluding half time (l-m) = 32735 tubes
f. Guidelines for Curing of Inner Tubes
(1) Inner tubes are vulcanized in simple presses, often with a hot block
to increase the temperature in the thicker valve region. Air pressure is
applied internally to the inner tube. The pressure can be up to 7 to 8 Bar.
Low air pressure can result in the inner tube wall flowing over the
valve, whilst an excessively high air pressure can force the inner
tube into the mold parting line, produce excessive flash, and
cause a localized deformation or gauge thinning around the inner tube.
Inner tubes are sometimes inflated inter nally with steam to gain a
cure time reduction. Butyl rubber inner tube curing temperatures of
175C to185 C are suggested and curing time will vary with size and
thickness. Typical passenger inner tubes are cured for 3.5 to 5
minutes and truck inner tubes 6 to 8 minutes including blow down
time.
(2) Mold surfaces should be smooth and clean, both from the
standpoint of the appearance of the finished inner tube and from
the ease with which the stock flows in the mold. Dirty molds can
lead to poor stock flow and buckles. Sandpaper or steel wool should
be avoided in cleaning the molds, as these cause scratches in the
mold which may be quickly filled with foreign deposits.
(3) A combination wax-abrasive material applied with a cloth
buffing wheel is suggested. Molds should be well vented and the
vents kept clear to prevent dimpling. An example of an inner tube
vulcanization press is shown in Figure below.

27

28
g. Tube Curing
(1) Mould temp upper limits 160-180ºc.
(2) Mould temp lower limits 160-180ºc.
(3) Inside air pressure 8-9 kg/cm².
(4) Steam pressure 10-11 kg/cm².
(5) Loading time is 10 sec.
(6) Exhaust time is 10 sec.
(7) Unloading time 10 sec.
(8) Mould should be clean.
h. Common Faults in Manufacturing Process
(1) Extrusion Faults (Brust NBD NP B.Thin FM)
(2) Splicer Faults (Gape J.Cut J.Thin J.open)
(3) Curing Faults (Crease O.Lap PF F.C Ballon S.Fault)
(4) Tube Faults and Their Possible Countermeasures
Ser Tube Faults Reasons Possible Counter
measures
I. There two types
of crease,
a. Inner crease
b. Outer crease
When there will be excess inflation
inS green tube during performing,
then this fault will occurs.
Pressman should be
trained &inflation must be
proper according to tube
size.
II. Ballon Due to shortage of curing time Due
to shortage of steam pressure/less
mould temperature Over curing
NR / BR tubes also cause this
fault.Trap valve out of order
Standard time should be
given to tube. Steam
pressure should be
accurate & also mould
temp.(13~14. Kg/Cm² &
above 200 ºC), mould
temperature should be
160 ºC ~ 180 ºC Trap
valve should be properly
worked

29
III. Burst After curing of tube, if press open
before completing exhaust of
inside steam Nozzle blockage,
press / tube
Exhaust should be with in
standard (10~30 Secs) &
must be working properly
Nozzle should be OK
IV. Over lap Exhaust should be with in standard
(10~30 Secs) & must be working
properly Nozzle should be OK
Nozzle should be properly
adjusted in the mould.
Length should be proper
Mould nozzle should be
proper set
V. Nozzle damage If the lock of press &outer nozzle is
not properly adjusted then nozzle
will damage .Manufacturing fault.
Lock of press &outer
nozzle should be properly
adjusted. Nozzle should
be proper manufactured
VI Nozzel base
damage
Usage of wet pasted nozzle Over
pasted nozzle .
Unbalanced nozzle fixer pressure .
Excess use of wiping swap
solution Nozzle out problem
Rework /re pasted nozzle
Excessive powder inside the
nozzle base
Nozzle should be proper
dry
Nozzle should be properly
pasted(1~2 coated).
Nozzle fixer pressure
should be balanced.
Proper use of wiping
swap.
Nozzle out problem
controlled by proper
maintenance work.
Avoid to use poor edges
nozzle
Nozzle fixing area should
be proper clean
VII Foreign Matrial If foreign particles like dust ,stone,
hard compound, iron piece are in
green tube then this fault occur.
irregularity of changing in refining
mesh
More care full during
green tube extrusion.
Refining mesh should be
change after 10 ~ 15
minutes
VIII. Joint Gap Width variation in green tube both
edges.
Width should be same
both end

30
Splicer dies up down/improper
dies setting
If operator not set green tube into
splicer dies then this fault occur
Less die hardness & low butting
pressure
Unequal buffing of dies
Dies damaged at corner area
Improper anvil adjustment with
respect to dies
Splicer dies should be set
properly
Operator should fully
trained.
Die hardness should be
within standard range (72
~ 74)
Butting should be normal
Die should be OK at
corner area
Proper anvil adjustment
with respect to dies
IX Joint Thin Thickness variation. in green tubes
folders
Unequal dies weight
High butting pressure
Improper splice die setting.
Untrained operator
Thickness should be
same both end
Dies weight should be
equal
Butting pressure should
be within limit.
Splicer dies should be set
properly
Operator should fully
trained.
X. Joint leak Under size green tube
Due to thickness variation in
folders. Splicer dies are not proper
clean. any rubber particle between
dies then this fault occur.
Green tube width should
in specification.
Thickness should be same
both end Splicer dies
should be properly
cleaned.
Operator should be fully
trained.
XI Body Thin Green tube width should in
specification. Thickness should
be same both ends.
Green tube thickness
should be standard range.

31
Splicer dies should be properly
cleaned. Operator should be fully
trained.
.Inside steam pressure
should with in standard
range(90~110psi) .No any
hard particle in green tube
.Pressman should be fully
trained. Green tube width
should be match with flat
width.
XII Nozzle Thin Excess nozzle holder pressure
(unbalanced holder pressure)
If nozzle punched not in centre.
Due to shortage of inside steam
Nozzle fixer pressure
should be properly
balanced.
Nozzle should be punched
in center.
Standard steam pressure
inside
Pressman should be fully
trained
XIII Mould
Mark/Dirty
Mould
If any rubber particle found in the
mould & not clean properly, then
other tubes put for curing, these faults
will occur.
Mould should be clean
regularly.
Chrome hardening layer
should be maintained
properly
XIV Under cure Steam condensate not drain properly Drain valve must be
functioned properly
XV Press Fault Due to air / steam / hydraulic oil
leakage
Hydraulic pump not work properly
Trap valve not work properly
Any electrical problem
Electrical / mechanical /
boiler works should be
done in time
XVI Power Break
Down
Suddenly power break down
Steam / air pressure drop age due to
power break down
These parameters should
be monitor regularly
Compound (TS,MH, ML
Pulling Factor Max 15 %
Shrinkage ratio Max 2
Die hardness 72- 74
Nozzle pasting solution
Wiping swap solution
Cured tube TS
Joint Strength Min

32
50Kg/cm
Silicon solution
4. Demand Vs Production
a. Reasons of Less Production
(1) Power Break Down
(2) Mechanical Faults
(3) Reworks
(4) Rejection
(5) Shortage of Manpower
(6) Absenteeism
(7) Un-Skilled Labour

33
5.` Profit / Loss Statement
a. If the daily production less than 75000 tubes. Outcome of the slippage will
be in negativity.
b. If the daily production increased from 75000 tubes. Outcome of the
slippage will be in positivity.
6. Problem Areas / Observations
a. Owing to congested space available for trolleys / aging storage,
production is adversely being hampered.
b. Turn over of skilled manpower.
c. Improper record of manufacturing traceability.
d. Mould washing in curing is not maintained properly.
e. Precaution measures are not being adopted as per Standing Operating
Procedures.
f. Preventive maintenance schedule is not standardized.
g. Owing to non availability of correct ventilation system extrusion and curing
process being affected which causing loss of production. Moreover, such
environment is also un-satisfactory for newly recruits.
h. Temperature Control System is required more attention.
i. Aging Storage area (trolley area)is required up-gradation as per
international specifications.
7. Suggestions
 nozzle fixer should be trained for conveyor operator
 salary system should be improve by calculating the budget of small family
otherwise turn over not control and rejection also matters because skilled
labour are moving. So over time should not adjust by rest of worker.
 MTC (manufacturing traceability cards) should be use for traceability
extrusion to curing.
 Trolley area should be treated as a department.
 Fatigue of workers should be minimized.
 Strength of workers and organization chart should be revised.

34
 MOULD WASHING procedure should be improve by arranging mould
washing machines scrubbing of mould damage the layer of chrome
hardening.
ORIENTATION REPORT MC-TUBE PRODUCTION
Submitted To:
 Mr. Raja Imran
(Factory Manager)
 Mr. Baseer Ahmed
( Manager Production)
 Mr. Wasif taimoor
(production engineer)
 Ahtizaz ahmad khan
(Deputy HR Manager)
Submitted By:
 MOHSAN RAZA(Production Executive)
engrmohsan@gmail.com
mob#03144700209

35
ACKNOWLEDGEMENT
The whole praise is to almighty ALLAH, creator of this universe. Who
made us the super creature with great knowledge and who able me to
accomplish this work. I feel great pleasure in expressing my deepest appreciation and
heartiest gratitude to my Teachers of University of Gujrat and to the staff of Service
Industries Limited for their guidance and great help during the Training period.
I would like to express my deepest affection for my parents and Friends
who prayed for my success and encouraged me during this Training period.
I appreciate and acknowledge the patience, understanding And love provided by
employees of Service Industries Limited.
A special thanks to the following people who had been very friendly ,
cooperated with me throughout my Training period in Service Industries Limited and
made it possible for me to learn and gather all the information needed for my
Orientation report with as much detail as I could. These are the people
who in spite of their busy scheduling took time out to explain to me the
procedures and mechanics of work in the organization. My Training would not have
been possible without friendly and helpful attitude of following people.
Mr. Raja Imran (Factory Manager)
Mr. Baseer Ahmed (Production
Manager)

36
Mr. Wasif taimoor (production
engineer)
Mr. Asif (senior production executive)
Mr.afzaal shabbiri (production
executive)

ORIENTATION REPORT SYED MOHSAN RAZA (1)

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (18)

En vedette

En vedette (13)

Similaire à ORIENTATION REPORT SYED MOHSAN RAZA (1)

Similaire à ORIENTATION REPORT SYED MOHSAN RAZA (1) (20)

ORIENTATION REPORT SYED MOHSAN RAZA (1)