Академический Документы
Профессиональный Документы
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DECEMBER 2016
I hereby declare that all parts of this report are the result of my own work except for
the quotations and references, the sources of which have been acknowledged in the
bibliography and in my opinion this report is sufficient in terms of scope and quality
for the award of the degree of Diploma of Chemical Engineering Technology
(Process)
Signature :
Trainees Name : MUHAMMAD AFIQ BIN AHMAD SAFUAN
Date : 7 DECEMBER 2016
MANUFACTURING PROCESS OF RUBBER
AND RUBBER TO METAL BONDING PARTS
AT GUMMI METALL TECHNIK (GMT) (M)
SDN. BHD.
DECEMBER 2016
This report was read and verified by:
Signature :
Supervisor : DR. S. PUSPALATHA (COMPANY SUPERVISOR)
Date : 7 DECEMBER 2016
Signature :
Supervisor : MR. TENGKU FAZLI BIN TENGKU YAHYA (UNIKL
SUPERVISOR)
Date : 7 DECEMBER 2016
ii
A special dedication to all of my family members, my friends, my company
supervisor, my UNIKL supervisor and all operators in GMT Sdn. Bhd. for all your
love, support and believe in me. Thank you so much.
iii
ACKNOWLEDGEMENT
First of all, I would like to highlight my grateful and thanks to my God, Allah
S.W.T because gave me this gold opportunity and healthy to run and complete my
industrial training report successfully. Also, I owe my cordial gratitude to my
respected company supervisor, Dr. S. Puspalatha for his valuable guidance,
constructive suggestions, advices, encouragement, tolerances and concern during
the planning and development of this training. Other than that, in order to finish my
report, I met many peoples, friends and operators at each department as they assist
me regarding this training.
Plus, I also want say thanks to all of my friends for the friendship and sharing
the knowledge throughout this report until I have completed my report efficiently and
moreover, on time. Last but not least, I am also proud and want to say thanks to
myself for the attitude, patience and spirit until the end of the training.
iv
ABSTRACT
The report is divided into two sections; the economic section and the technical
section. Firstly, for the economic section contains the company profile of GMT (M)
Sdn. Bhd. Gummi Metall Technik (M) Sdn. Bhd., is fully owned company by Germany
associated with GMT group. The operation headquarters of GMT is at Buhl, Baden
Germany and branches in Switzerland, Republic of Ireland, United States of
American (USA), India and have offices in Austria, England, France, Belgium and
China. There are many products produced from this company. GMT Malaysia
produces all range of rubber to metal bonded products specializing in anti-vibration
mountings and also plant facilities for compounding and custom-tailored rubber
compounds. GMT is also specialized in anti-vibration solution for other industries like
Railway, Construction Machinery, General Engineering & Machinery, Defence
Technology and others. Besides, for the technical section, there was one project
given by company supervisor to the trainee which is to know the manufacturing
process of rubber and rubber to metal bonding parts. The objectives of this project is
to know all the process to make a product from beginning until the end. The trainee
was sent to 4 departments in order to know the whole process of making the product
which are Mixing Department, Research & Development (R & D) Department, Metal
Treatment Section (MTS) and Moulding Department. Each department has its own
purpose and functions.
v
ABSTRAK
Laporan ini dibahagikan kepada dua bahagian; bahagian ekonomi dan bahagian
teknikal. Pertama, untuk bahagian ekonomi mengandungi profil syarikat GMT (M)
Sdn. Bhd. Gummi Metall Technik (M) Sdn. syarikat Bhd., dimiliki sepenuhnya oleh
Jerman berkaitan dengan kumpulan GMT. Ibu pejabat operasi GMT adalah di Buhl,
Baden Jerman dan cawangan di Switzerland, Republik Ireland, United States of
Amerika (USA), India dan mempunyai pejabat di Austria, England, Perancis, Belgium
dan China. Terdapat banyak produk yang dihasilkan daripada syarikat ini. GMT
Malaysia menghasilkan semua pelbagai getah untuk logam terikat produk yang
pakar dalam cagak anti-getaran dan juga kemudahan loji bagi mengkompaun dan
sebatian getah adat-disesuaikan. GMT juga khusus dalam penyelesaian anti-getaran
untuk industri lain seperti Railway, Jentera Pembinaan, Kejuruteraan Am & Jentera,
Teknologi Pertahanan dan lain-lain. Selain itu, untuk bahagian teknikal, terdapat satu
projek yang diberikan oleh penyelia syarikat kepada pelatih iaitu untuk mengetahui
proses pembuatan getah dan getah ke bahagian ikatan logam. Objektif projek ini
adalah untuk mengetahui semua proses untuk membuat produk dariapada awal
sehingga akhir. Pelatih telah dihantar ke 4 jabatan untuk mengetahui keseluruhan
proses membuat produk iaitu Jabatan Mixing, Jabatan Penyelidikan &
Pembangunan (R & D), Bahagian Rawatan Metal (MTS) dan Jabatan Moulding.
Setiap jabatan mempunyai tujuan dan fungsinya yang tersendiri.
vi
TABLE OF CONTENTS
SIGNATURE PAGE ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF DIAGRAMS xiii
LIST OF ABBREVIATIONS xiv
LIST OF APPENDICES xv
vii
3.2.3 Process of making master batch (M / B) and
9
compound
3.2.3.1 Batching process 9
3.2.3.2 Mixing process 10
3.2.3.3 Compounding process 13
3.2.3.4 Extrusion process 14
3.3 Research and Development (R & D) Section 14
3.3.1 Organizational chart of R & D department 16
3.3.2 Procedures in R & D department 16
3.3.3 Flow chart of R & D department 19
3.3.4 Basic analysis of compound in R & D
20
department
3.3.4.1 Scorch time analysis 20
3.3.4.2 Hardness analysis 21
3.3.4.3 Elasticity analysis 21
3.3.4.4 Specific gravity analysis 22
3.4 Metal Treatment Section (MTS) 23
3.4.1 Organizational chart of building Plant 3 (MTS) 24
3.4.2 Machines used in MTS 24
3.4.2.1 Washer machine 25
3.4.2.2 Sandblasting machine 25
3.4.2.3 Heimer machine 27
3.5 Moulding Section 27
3.5.1 Organizational chart of moulding department 28
3.5.2 Process at moulding department 29
3.5.3 Type of press (machine) 30
viii
4.3.2 Research and development (R & D) section 34
4.3.3 Metal treatment section (MTS) 34
4.3.4 Moulding section 35
REFERENCES 36
Appendices A - C 37 - 40
ix
LIST OF TABLES
x
LIST OF FIGURES
xi
Continued
xii
LIST OF DIAGRAMS
xiii
LIST OF ABBREVIATIONS
xiv
LIST OF APPENDICES
A Compound Card 37
xv
CHAPTER 1
1.1 Introduction
1
1.2 Objectives of Industrial Training (INTRA)
1. To fulfill the award of the Diploma of University Kuala Lumpur (UniKL). This
is because INTRA is one of the subject for semester 6 in Diploma.
2. To apply theories learnt in the classroom to the actual working
environments. So, it can produce the knowledgeable, experienced and
skilled graduates, demanded by employers who are able to apply the
knowledge of acquired at university to the working world.
3. To expose students to the working environment, common practices,
employment opportunities and work ethics in the relevant field.
4. To provides opportunity for the students on practical engineering fields.
From this, the students will have better understanding of engineering
practice in general.
5. To inculcate soft skills of a trainee to the needs of employers. In addition,
INTRA also improve the communication and documentation skills of the
student.
6. To provide opportunities for students to be offered job in the same
organizations where they undergo Industrial Training.
2
CHAPTER 2
Gummi Metall Technik (M) Sdn. Bhd., is fully owned company by Germany
associated with GMT group. The operation headquarters of GMT is at Buhl, Baden
Germany and branches in Switzerland, Republic of Ireland, United States of
American (USA), India and have offices in Austria, England, France, Belgium and
China. Before the name of Gummi Metall Technik (M) Sdn. Bhd., it was known as
Rubber Metall Technik (M) Sdn. Bhd. It was incorporated in 1979 and started its
operations of production in May 1980. So, GMT Sdn. Bhd. has more than 35 years
of experience in manufacturing rubber to metal bonded elements and moulded
rubber parts, in the field of anti-vibration solutions for all kind of engines and
electronic equipment on-board ships. In Germany of Research & Development (R &
D) and also Technology Resources, the products are internationally renowned for
railway parts and engineering applications due to the support of GMT GmBh. This
company is accredited with ISO Certification 9001:2000 and export its products to
Europe, United States and South East Asian Countries including Australia and
China.
3
2.3 Product of company
There are many products produced from this company. GMT Malaysia produces
all range of rubber to metal bonded products specializing in anti-vibration mountings
and also plant facilities for compounding and custom-tailored rubber compounds.
The large product range of GMT mountings includes:
General application
Buffer type A
Railway application
Gummikorper
4
Continued
Engineering application
Machine feet
Defence application
Tank pad
Largerschale
Gummi Metall Technik (M) Sdn. Bhd., through the involvement of management
and employees are committed to achieve continuous improvement in quality
management systems, production and delivery of quality services. To achieve these
objectives, this company will:
5
CHAPTER 3
3.1 Preface
This part will explain about the process of making products from the beginning
until the end. Overall, there are 4 departments or sections of this company in order
to make the products which are mixing section, research and development section
(R&D), metal treatment section (MTS) and moulding section. These sections play
the most important role in this company.
Mixing section is the most important section for this company and located at
Plant 2 building. It is the place to make the compound in order to produce the
product. The purpose of this section is to mix the raw materials which are rubber
and chemicals that already been weighed. Basically, there are 5 machines are used
in this department to make M/B and compound which are Banbury, Roll Mill 1, Roll
Mill 2, Roll Mill 3 and Extruder. All of these machines are very important and have
their own functions. In simple, there are two types of elements produced from this
department which are master batch (M/B) and compound. Table 3.1 below shows
the differences between M/B and compound.
6
Continued
MIXING MANAGER
DR. S. PUSPALATHA
PRODUCTION
MIXING SUPERVISOR SUPERVISOR
MR. AZIZ BIN ISHAK MRS. HAWARIAH BINTI
AHMAD ZAKARIA
ASSISTANT SUPERVISOR
MR. ABD WAHID BIN
ABDUL AZIZ
OPERATORS
7
3.2.2 Flow chart of production
1. Batching
2. Mixing
Delivery
Roll Mill 2 Roll Mill 3
8
3.2.3 Processes of making master batch (M/B) and compound
Based on figure 3.2, it shows the process to make M/B and compound. For
making M/B, there are only have 2 processes which are batching process and
mixing process while for compound, it undergoes 3 processes which are batching
process, mixing process and compounding process.
Batching is the process of weighing the raw materials which are rubber,
carbon, oil, accelerator, chemicals and curatives according to its specific weight.
The value of the weight of each raw material are written on batching card to
produce master batch (M/B) and it was shown in Table A.1 at Appendix A. Different
types of compound have different type of raw materials and also its amount. The
function of batching card is as a reference for the operators. For the personal
protective equipment (PPE), the equipment needed are goggle, filter mask, gloves
and boot.
The raw materials for batching process are rubber, carbon or filler and
accelerator or chemical. Each raw material has its own function. First is rubber.
Rubber is the prime raw material in order to make a master batch (M/B) and
compound. Besides, it is also a tough elastic polymeric substance made from latex
of a tropical plant or synthetically. The main purpose of this raw material is to
change from large deformation to small quickly and effectively. The type of carbons
used in this company are shown in Table A.1 located at Appendix A.
9
Based on figure 3.3 below, it shows the step or procedures to carry out the
batching process.
The batching
card need to be The weighed carbon then
displayed when arranged on the pallet and The rubbers were
doing batching write down the total weighed at the top of
process. number of plastic bag and Banbury to facilitate
also its function. the work.
Mixing is the process to mix all the weighed raw materials (after batching
process) at Banbury GK-70 machine. There are two machines were used for this
process which are Banbury GK-70 and Roll Mill 1. This kind of process required full
set of PPE which are safety boot, filter mask and goggle due to dangerous work.
Before the mixing process started, it must have check list as a guide for the
operators. At the check list, it contains the time interval for each raw material to be
mixed up and was prepared by the supervisor at this department.
For example, is KSS 57. Firstly, put and mix the rubber and Renacit 11 for
1.5 minutes. After that, chemicals and HAF N330 (filler) are take 2.5 minutes. Then,
SRF N774 (filler) and aromatic oils (oil) are take 3 minutes. Last but not least, the
10
sweep time takes only 2 minutes and the total time are about 9 minutes. From the
observations, the average time that operators operate the machine for KSS 57 are
between 9 to 10 minutes. Figure 3.4 below shows the procedures of conducting the
mixing process.
Then, it will
First, make sure transfered into Besides, the master
the Banbury and promol solution to batches were dried
Roll Mill 1 improve the quality at the place
machines are in of masterbatch and provided for a few
good condition. prevent stick among minutes.
each other.
11
The diagram 3.1 below shows the schematic diagram for mixing process.
RUBBER +
CARBON OIL
CHEMICAL
BANBURY GK-70
WEIGHING
ROLL MILL 1
PROMOL SOLUTION
DRYING
12
3.2.3.3 Compounding process
13
3.2.3.4 Extrusion process
14
equipment has their own function. Table 3.2 below shows the function and purpose
of each machine.
Based on the project given, the trainee need to focus more only certain
machines and equipment which are Compression Press Machine, Die Rheometer
Machine, Hardness Tester, Rebound Resilience and also Specific Gravity Balance.
15
3.3.1 Organizational chart of R & D department
R & D MANAGER
DR. S. PUSPALATHA
R & D SUPERVISOR:
1. MR. NASARUDIN
2. MRS. ZARINA
OPERATORS:
1. MR. LIRU
2. MR. SHAHARUDIN
1A (Shift)
Diagram 3.2 Example of sample (compound) from mixing section to R & D section
16
Then, the operators from R & D department will take the sample and cut it
until get 5 grams and 10 grams of sample. The 5 grams will undergo one basic
analysis which is the determination of flow characteristic of compound using Moving
Die Rheometer machine by taking the value of TS2 and TS90. The steps to use the
Die Rheometer machine will explain in the next topic. While for 10 grams of sample,
it will send to Compression Press machine to mould the compound to be made as a
test specimen about 10 minutes and it will also explain in the next topic. After 10
minutes, it will take out from the compression press and immersed in the water for a
few minutes. Diagram 3.3 below shows the example of test specimen.
KBA 80
1A
10/9
Next, cut off the flakes of test specimen and it will undergo 3 basic analysis
of compound which are hardness analysis, elasticity analysis and specific gravity
analysis. All the procedures of these analysis will explain in the next topic. Diagram
3.4 until Diagram 3.6 below shows the equipment for the 3 basic analysis.
17
Diagram 3.5 Example of rebound resilience tester
After all of 3 analyses were carried out, the data was recorded at the
compound card and also in the computer. Each type of compound has its own
specification value of hardness, specific gravity and scorch time (TS2 and T90). The
result of the analysis must be in the range of the specification value. If the reading of
these analysis is out of range, the operators from R & D section will sent back the
compound card to the supervisor at mixing section and he or she will find the
solution to overcome this problem. But, if the reading of these analysis is in the
range required, the operators will write down in the book provided at the mixing
section.
18
3.3.3 Flow chart of R & D department
Operators
from R & D cut
the sample
5 10
grams grams
Immersed in
water
19
3.3.4 Basic analysis of compound in R & D department
There are only have 4 basic analysis of compound which are scorch time
analysis, hardness analysis, elasticity analysis and specific gravity analysis.
There are two results that need to be record for this analysis which are TS2
and T90. TS2 represent the time required for the beginning of the process of cross
linking. While T90 represents time corresponding to 90 % curing. This result is
considered the optimum vulcanization process. Besides, there are many safety
aspect during conducting this machine which are put on the gloves when loading or
unloading test piece, do not trap fingers between clamping platens and do not let
testing remnants or foreign particles get into disc hole. Furthermore, the procedures
of this analysis will be figured in Figure 3.9 below.
Set the
temperature
required at the
control panel Place the test specimen
(5 grams) on the centre Click "Yes" to save
and wait until it the result of tbe test
reached the of oscillating disk at the
machine. from the computer.
desired
temperature.
Then, turn on After that, open the file, Lastly, the reading of
the machine select the required TS2 and T90 were
motor power by compoun code and key appeared at the
pressing the in the data at the computer and the
button. computer provided. data was recorded.
20
3.3.4.2 Hardness analysis
21
A
There are a lot of steps to carry out this analysis. Firstly, place the sample
(button) at point B. Make sure it is place correctly. Next, pull the button A and
simultaneously C will move. Finally, take the reading at the equipment and record in
the compound card.
Specific gravity of rubber is the ratio of the density of a rubber to the density
of a standard, usually water for a liquid or solid, and air for a gas. Diagram 3.8 below
shows the specific gravity balance with the label.
F
A
E D
C
G
22
There are a lot of steps to conduct this equipment. Firstly, the beaker (E) was
filled up until reach optimum level of water approximately 75 % by volume. Then,
took the hardness button and the needle (A) was pierced at the centre of the button.
The needle-fixed button then suspended and the pointer moves up. After that, the
adjustment nut was adjusted to make the pointer sustain at level (F). Next, the
needle-fixed button was raised and gently pushed up the beaker holder (G) until it
become like Diagram 3.8. Besides, the button was dipped into the water and let it
float and remain calm in the water. At this moment, the pointer was moved and
marked of against the scale board (D). Lastly, the reading was taken and recorded.
Metal Treatment Section (MTS) is the third department in this company and it
is located at the building of Plant 3. It is very important section in order to produce a
product. Metal treatment is one of the process to produce metal at which the metal
was sprayed with Steel Grit in the Sandblast Machine and also sprayed with
bonding agents. At this section, clean gloves are very important in order to make the
metal. This is because dirty gloves will make the metal become rejected.
23
3.4.1 Organizational chart of building Plant 3 (MTS)
The figure 3.11 below shows the organizational chart of Plant 3 including
Metal Treatment Section.
PRODUCTION MANAGER
MR. K. SIVANJOTHI
SUPERVISOR
MR. AZRI
ASSISTANT
SUPERVISOR CLERK PLANT 3
There are 3 type of machines are used in MTS which are washer machine,
sandblasting machine and Heimer machine. There are 3 types of sandblasting
machines including Sandblast Tochu Machine, Sandblast Roto Jet Machine and
Sandblast Metalisator Machine. All of this machines have the same function but
used different type of metal.
24
3.4.2.1 Washer machine
The part name of this machine is Binitron Degreasing Machine. The main
function of this machine is to remove the oil from metals. For PPE, the operators
that conduct this machine need to wear goggle, respirator, rubber gloves, fabric
gloves, apron and safety boots. The steps to use this machine are figured in Figure
3.12 below.
25
After that, press Press button
Switch on the number 6 and 7
main switch. button number 5.
(Belt in) for spraying of
"Steel Grit".
Lastly, check
Press button the metal
Press button number
number 2, 3 and 4. visually and
1. (Dust collector)
(Bucket elevator) rework if the
metal is reject.
Figure 3.14 Flow chart of Sandblast Roto Jet and Metalisator Machine
26
3.4.2.3 Heimer machine
The purposes of this machine is to carry out spraying process. After the
metals are already sand blast, it will undergo spraying process. Firstly, switch ON
the machine and set up the machine correctly. There are two layers that need to be
sprayed on the metal which are primer and bonding agent. Then, the metal that was
placed on the trolley will be sprayed for the first layer which is primer paint. After
that, the metal was dried for 15 minutes. After 15 minutes, it will spray for second
layer which is bonding agent paint and also been dried for another 15 minutes.
Lastly, record the data in the report.
Moulding section is the last department to produce the product in this company
and it is located at the building of Plant 1. This department is important because it is
the main cord of company to get benefit or profit from the sales. Moulding is the
process which the compounds are placed in the mould and lastly put it in the Press
Machine with the high temperature and pressure. For safety, need to wear full set of
PPE because the works that carried out at this section are very terrible and
dangerous, so, the operators need to wear safety boots in order to prevent legs from
contact with sharp objects, hardware or crushed by the heavy objects. Besides,
cotton gloves and gloves arm are also required for the operators to prevent hands
from exposed to hot machine.
Moreover, moulding section have its own vision which are: First is to complete
the job order during required time or duration. Second, no comment from the
customer about the quality of the products or to satisfy customers. Third is to
produce the maximum quantity of products that can be achieved. After that, the
target of moulding section is to produce 100% quality of the product, 0% comment
from customer, 90% products do not reject each day and lastly less than 2%
products reject each day.
27
3.5.1 Organizational chart of moulding department
PRODUCTION
MANAGER
MR. K.
SIVANJOTHI
PRODUCTION
CLERK
MR. ZAINUDEEN
PRODUCTION
BIN KAMAR
SUPERVISOR
PRODUCTION ASSISTANST
SUPERVISOR
28
3.5.2 Process at moulding department
After that, for the time work of the operators, there are 3 period of time
working which are from 6.30 am until 2.30 pm, 2.30 pm until 10.30 pm and lastly
10.30 pm until 6.30 am. From these time work, this department or section is 24
hours running. Then, the operators will run the products which have been listed on
the production plan. The raw materials at moulding section are the compounds
produced from mixing section and metal produced from MTS.
After the products have been ready made, it will send to Plant 3 for final
inspection before issued and delivered to the customer. Before send to Plant 3, the
operators from moulding section also need to inspect the products produced with
naked eyes. If there is a reject of product at moulding section, the data will be
recorded in the monthly scrap report. This report consists the total amount of reject
of product for each day. Furthermore, the production clerk need to update the
moulding report every day. This report contain the total pieces of products produced
and the total pieces of reject from both sections which are moulding section and final
inspection section.
29
Blister
Short
Tearing
moulding
CLASSIFICATION
OF REJECT
Overcure Cracking
Rubber
Flush
dust
30
Table 3.3 Differences between compression, transfer and injection machine
Mould code KK 01 KK 02 KK 03
From the project, the trainee sees and helps the operators conducting the
machine. For example, Press 003. This machine is a compression type and it is a
manual machine. The purpose of this machine is to fit the size of the product. The
trainee was able to conduct this machine. Besides, the trainee also helps the
operators to lift or remove the products after the cure time have finished, for
example is the product of Gummilager.
31
CHAPTER 4
4.1 Preface
This chapter concluded about the result of the project of industrial training
and the future or recommendation of this training in section 5.2 and 5.3 respectively
in order to improve the quality of products produces and achieve the sales target
successfully.
4.2 Summary
Gummi Metall Technik (M) Sdn. Bhd. is one of the popular company in
producing the products of anti-vibration mountings. During the training, the trainee
knows the whole process to produce the products from the beginning until the end.
Next, the trainee also able to conduct a work that given by the supervisor or
operators successfully.
Firstly, at mixing section, the daily work that trainee do at this section is to
record the mixing report and also record rejected master batch in the logbook
provided. This report is to make as an evidence that the productions are running
every day. Besides, the trainee also helps other operators to do the batching
process. Make sure that there is a batching card to guide as a reference for the
trainee which contains the amount of chemicals that need to be weighed. Then, the
trainee also doing the packaging process with the help of other operators by
wrapping the pallets using wrapping plastics. Furthermore, the trainee helps the
operators to carry out Roll Mill 3 due to the lack of workers. As the conclusion, all of
these works are repeated throughout the trainee is in the mixing section.
32
4.2.2 Research and Development (R & D) section
At this section, the trainee is able to conduct the basic analysis of the
compound which are scorch time analysis, hardness analysis, specific gravity
analysis and elasticity analysis. Besides, the trainee was able to use 2 machines
which are moving die rheometer and compression press correctly. Sometimes, the
trainee also helps the operators to write down the pallets card and paste at the pallet
for the purpose of discharge the products. All of these works are also repeated
throughout the trainee was in this section.
For this section, the trainee work for 2 weeks. During this period of time, the
trainee knows the process of making the metal correctly. The trainee helps the
operators to conduct 2 machines which are sandblasting Tochu machine and
sandblasting Metalisator machine. Then, the trainee also helps the operators to lift
the rejected metal and sent to the place provided for the purpose of rework the
metals.
Lastly is moulding section. The first works that trainee do at this section is to
make a production plan and sent to other sections which are R & D section, mixing
section, store and MTS. Next, the trainee also conducts P003 with the help of other
workers. This press is a manual machine, so, it is easy to be used. Besides that, the
trainee also sees and helps the operators to remove and lift the product of certain
machines after the cure time was finished. In the nutshell, all of these works are also
repeated throughout the trainee was in this section.
33
4.3 Recommendations
For this section, a new set of Testometric Tensometer is bought recently. The
trainee hope with this new set of machine will shorten the time required to do the
analysis compared to the old set of machine. If the company have a lot of budget, it
can buy one more set of Zwick Machine due to the quantity of products increases. It
will shorten the time and faster to discharge the products.
34
4.3.4 Moulding section
For this section, the amount of product being rejected also need to be reduced.
This is due to the performance of the machines. During the training, there are a lot of
machines are under services and it will reduce the quantity of products produced. So,
the company needs to take the experienced maintenances workers. It will shorten
the time to do the maintenance works.
35
REFERENCES
1. Safety Operating Procedures (SOP) from each department which are Mixing
section, R & D section, Metal Treatment section and Moulding section.
7. Lightsey, J. W., Kneiling, D. J., & Long, J. M. (1998). U.S. Patent No.
5,763,388. Washington, DC: U.S. Patent and Trademark Office.
36
APPENDIX A
Compound Card
M/BATCH WEIGHT
NO DESCRIPTION DATE
NO KGS
REMARKS
TK
SMR 10
1 Check the batch number
(RUBBER)
in the logbook before
RENACIT 11 production starts
2
(CHEMICAL)
3 CHEMICALS
HAF N330
4
(FILLER)
SRF N774
5
(FILLER)
AROMATIC
6
OIL (OIL)
TOTAL WEIGHT 1
TEMPERATURE - 160C
RANGE
37
APPENDIX B
COMPOUND TIME /
PRESS ORDER CUSTOMER PART NAME BLANK SIZE KGS BATCH NO
CODE REMARKS
KKS 55 / OP
7 390 GMT Puff C 380 110 1.15 kg 1 50 Extrusion
720
KKS 55 / 39 + KS 40 / 11 + PVI 25 gm
38
Identification Tag
IDENTIFICATION
TAG
ITEM :____________________________
BATCH NO :____________________________
SERIAL NO :____________________________
PREPARED BY :____________________________
DATE :____________________________
39
Compound card
40