INTERNSHIP PROJECT REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF GRADUATE PROGRAM

(BACHELOR OF TECHNOLOGY)
(MECHANICAL ENGINEERING)

J.C.BOSE YMCA UNIVERSITY OF SCIENCE AND

TECHNOLOGY
FARIDABAD

Submitted by

Nikita Shishodia
M-4202-2K16
Training Completion Certificate

ii
 Candidate’s Declaration

I hereby declare that the work of project TO REDUCE WASTAGE ON

EXTRUDER is being presented in the partial fulfillment of the requirements for the
award of the degree of BACHELOR OF TECHNOLOGY (MECHANICAL), of the
J.C.BOSE University of Science and Technology, YMCA, Faridabad. This is an
authentic record of my work carried out as our internship in my VIIth semester under
the supervision of Mr. Neeraj Singh, Staff engineer, GOODYEAR INDIA LTD.

The matter embodied in this report has not been submitted by me for the
award of any degree or diploma.

Nikita Shishodia
M-4202-2K16

iii
 Examiner Certificate

The following examiners have access the project report and conducted the viva-voice
examination:

Internal examiners: External Examiners:

Name: _______________________ Name: _______________________

Affiliation: ___________________ Affiliation: ___________________

_____________________________ ____________________________

Contact No. ___________________ Contact No.__________________

Email Id. _____________________ Email Id. _____________________

Signature _____________________ Signature _____________________

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 Acknowledgement

“Learning is a continuous process of combining the familiar with unfamiliar”.

The role of instructor is to get the stage for learning and encouraging the students to
gather out of the terms, to perform his new skill and to solve problems in new way.

I express my sincere thanks to Mr. Neeraj Singh, for giving me the

opportunity to work on this project and his constant encouragement, valuable
guidance and constructive suggestions during all stage of this work. His deep
knowledge and such a long experience helped me a lot to complete this project.

I want to express my deep hearted gratitude to Mr. K.P Singh, Mr. Sheilendar,
Mr. Vikas, Mr. Narinder Singh, Mr. Suresh Sethi and Mr. A.R Pant who all really
helped me by giving their valuable time and guidance whenever needed.

Lastly, I give my all the credits to my parents for their encouragement and
inspiration to work at this project. Their loving care is so necessary to bring this task
to completion. Hope this dissertation would serve the appropriate purpose for which it
was written.

Nikita Shishodia
M-4202-2K16

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 Table of Contents

S.NO TOPIC PAGE NO.

a. Training Completion Certificate Ii
b. Candidate’s Declaration Iii
c. Examiner Certificate Iv
d. Acknowledgement V
e. Table of Contents Vi
OVERVIEW
1. Company Profile 1
2. Process Diagram 3
3. Banbury 4
4. Extruder 7
5. Calendering 10
6. Bead Building 13
7. Band building 15
8. Tire building 16
9. Tire curing 18
10. Post cure inflation 22
11. Quality control 23
12. Inspection 24
13. Maintenance 27
PROJECT
14. Project 30
15. Introduction of project 32

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16. Need of the project 34
17. Analysis 36
18. Suggestions 51
19. References 53
20. Student details 54

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1. COMPANY PROFILE

Goodyear is one of the world’s largest tire companies. It employs about 68,000 people
and manufactures its products in 50 facilities in 22 countries around the world. Its two
Innovation Centers in Akron, Ohio and Colmar-Berg, Luxembourg strive to develop
state-of-the-art products and services that set the technology and performance
standard for the industry.

Goodyear’s winged-foot trademark was inspired by a newel-post statuette of the

Roman god Mercury in the home of Goodyear founder Frank Seiberling. Seiberling
felt Mercury embodied many of the characteristics for which Goodyear products were
known.

Goodyear India Limited is engaged in the manufacturing and trading of tires, tubes
and flaps. The Company supplies tires to a range of original equipment manufacturers
(OEMs). The Company manufactures automotive bias tires, such as farm tires and
commercial truck tires at its Ballabgarh plant.

The Company also trades in Goodyear branded tires, including radial passenger tires
(consumer) and off the road (OTR) bias tires, manufactured by Goodyear South Asia
Tires Private Limited (GSATPL), Aurangabad.

The other products, which the Company markets and sells, include radial OTR
imported tires. The Company offers products under the brands, such as Assurance
TripleMax, Assurance Duraplus and Wrangler AT/SA. The Company also offers
tubeless radial tires. It offers Goodyear tires to the tractor companies. The Company
also offers Goodyear Eagle Efficient Grip, Goodyear Eagle F1 Directional 5 and
Goodyear Excellence, among others.

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i) Goodyear Vision:

Become a market–focused tire company providing superior products and services to

end-users and to our channel partners leading to superior returns for our shareholders.

Goodyear’s Values:

For the better part of the century, Goodyear’s corporate values have been centered on
the phrase, “Protect Our Good Name.”Today, this is brought to life through
developing culture in which a committed and competitive team of associates can
excel.

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2. PROCESS DIAGRAM

Process Map GOODYEAR

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 3. BANBURY

The Banbury mixer is a tangential type internal mixing machine, in which two slightly
spiraled rotors revolve side by side towards each other within a chamber shaped like
two short cylinders lying together with adjacent sides open.

The chamber has a top opening called hopper, which can be closed by pneumatic
means for inserting the material and a bottom gate, which can be hydraulically
opened, to drop out the contents after mixing.

The Banbury is charged by raising the ram completely out of hopper and dropping in
bales of rubber weighed up properly to fill the chamber. The ram is then lowered
under pressure and the rubber forced and held in the chamber while it is needed and
blended by the rotors.

Breakdown of rubber is accomplished by shearing action between rotor blade tips and
rotor walls and between rotor-rotor, with one rotor running slightly faster than the
other to prevent sticking to the blades.

Banbury Mixer

Mixing Process in the Banbury Mixer:

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 1. A place where the mixing of raw materials like rubbers, oil, carbon black and
pigments takes place.
2. Raw material is weighted and fed to mixer.
3. Hydraulic ram is used to force the rubber out of mixer.
4. Thin continuous sheets are made with the help of mills known as non
productive compound.
5. Non productive sheets of rubber are further processed into productive one by
adding pigments.
6. Sample is provided to testing department.

Basic Operation Cycle of Banbury Mixer:

1. Start operation
2. Discharge door closed
a) Ram up
b) Hopper door open
3. Compound inputted
4. Mixing started (Rubber + Chemical powders)
5. Close hopper door
6. Carbon is charged
7. Mixing for given period
8. Ram up
9. Oil injection
10. Ram down
11. Ram up/down
12. Ram float
13. Open discharge door
14. Start the next cycle
The temperature in each step changes simultaneously initially the temperature is 350c
and the mixer speed is set at 55 rpm and the ram pressure is at 135 bar then the
mixing starts and the temperature goes to 1050c and the ram pressure decreases to 110
bar after the mixing completes the temperature in the mixer is 1300c and discharge
time after the ram float is 10 to 12 sec.

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Controllable Factors at Banbury Mixers:

1. Batch size
2. Sequence of addition
3. Ram cylinder pressure
4. Rotor speed
5. Mixing time
6. Temperature of the finished mix, chamber, rotors, discharge door top
7. Energy for mixing.

Product obtained from banbury mixer

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 4. EXTRUDER

The extruder machine consists of a screw and barrel, screw drive, heaters, and a die.
The extruder applies two conditions pressure. The extruder screw also provides for
additional mixing of the compound through the shearing action of the screw.

The compound is pushed through a die, after which the extruded profile is vulcanized
in a continuous oven, cooled to terminate the vulcanization process, and either rolled
up on a spool or cut to length. Tire treads are often extruded with four components in
a quadraplex extruder, one with four screws processing four different compounds,
usually a base compound, core compound, tread compound, and wing compound.
Extrusion is also used for sidewall profiles and inner liners.

Extruder

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Production Process on Extruder:

1. Productive rubber from banbury mixer is fed to the breakdown mill and
the feed mill.
2. The breakdown mill and the feed mill are used for heating and proper
mixing of the productive rubber which is passed to the cap and base side of
the extruder.
3. In the cap and base side the rubber is passed through the die with the help
dead weight.
4. The hot tread formed is passed through the cooling unit.
5. A skiver is used to cut the tread in required length and at an angle of 22.5
degree.
6. It is weighted with the help of sensors and weighing scale and then moved
on to tire building area.
7. Tread, sidewall, apex are made by this method.

Types of Extruder:

1. Hot Feed: In the hot feed extruder the productive rubber is heated in the
mills at a temperature above ambient temperature. This system is less
complex than cold feed.
2. Cold Feed: In cold feed the productive rubber is fed at ambient
temperature and is heated inside the extruder screw with the help of steam.
This technology requires lesser manpower.

Components Manufactured On Extruder:

1. Tread: The tread is a thick extruded profile that surrounds the tire carcass.
Tread compounds include additives to impart wear resistance and traction
in addition to environmental resistance. Tread compound development is
an exercise in compromise, as hard compounds have long wear
characteristics but poor traction whereas soft compounds have good
traction but poor wear characteristics.

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 2. Sidewall: Sidewalls are non-reinforced extruded profiles with additives to
give the sides of the tire good abrasion resistance and environmental
resistance. Additives used in sidewall compounds
include antioxidants and antiozonants. Sidewall extrusions are
nonsymmetrical and provide a thick rubber area to enable molding of
raised letters. The sidewalls give the tire resistance against the
environment. Sidewall plays an important role in strengthening of tire.

3. Apex: The apex is a triangular extruded profile that mates against the
bead. The apex provides a cushion between the rigid bead and the flexible
inner liner and body ply assembly. Alternatively called "filler".

Tread

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 5. CALENDERING

The calender is a set of multiple large-diameter rolls that squeeze rubber compound
into a thin sheet, usually of the order of 2 meters wide. Fabric calenders produce an
upper and lower rubber sheet with a layer of fabric in between. Calenders are used to
produce body plies. A creel room is a facility that houses hundreds of fabric that are
fed into the calender. Calenders utilize downstream equipment for shearing and
splicing calendered components.

Rubber Calender Machine

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Production Process of calendering:

1. Calendering is a process in which productive rubber is pasted on nylon

fabric with the help of heated rollers forming ply.
2. The nylon fabric is first heated with the help of hot cans and stretched to
some limit.
3. The rubber is pasted either side by side or simultaneously on both sides.
4. The fabric allows your tire to be flexible but not elastic.
5. A beta gauge is used to check the thickness of ply formed.
6. The ply is then passed through a pricker roll, to remove any air bubbles
present.
7. The ply formed is passed through the cooling drums before storing.
8. It is wrapped in nylon cloth for storage and transportation.
9. Ply is cut either straight, known as Radial ply, or at a particular angle
known as bias ply.

Movement of Fabric Roll through Calender Drums

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Bias Ply and Radial Ply Crossection

Nylon Fabric

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 6.BEAD BUILDING

The bead component of the tire is a non-extensible composite loop that anchors the
body plies and locks the tire onto the wheel assembly so that it will not slip or rock
the rim. The tire bead component includes the steel wire loop, apex or bead filler; the
chafer, which protects the wire bead components; the chipper, which protects the
lower sidewall; and the flipper, which helps hold the bead in place. The bead wire
loop is made from a continuous steel wire covered by rubber and wound around with
several continuous loops. The bead filler is made from a very hard rubber compound,
which is extruded so as to form a wedge. The bead wire loop and bead filler are
assembled on a sophisticated machine.

The precision of the bead circumference is critical. If too small, tire mounting can be
a problem; but if too loose, the tire can come off the rim too easily under loading and
cornering conditions. After the circumference is checked, the bead component is
ready for the tire building operation.

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 Working of a Bead Building Machine:
1. Wires from 18 wire stands moves to the break pulley from where it moves
to the alignment and feed pulley.
2. Drive shaft responsible for stopping of wire roll is attached to the break.
3. From the feed rollers the wire moves into the baffle which is attached to
the inside of the die. There is continuous supply of rubber at the die which
is connected to the extruder.
4. As the bead wire moves forward, it gets covered with hot rubber and is
carried toward the cooling drums.
5. Pressure cylinder forces the bead towards festoner which stores the bead
when the machine stops during the cutting process.
6. Mechanical clutch and pressure rollers force the feed in forward direction
via cutter which divides the bead into two equal halves.
7. Bead moves forward on the bead chuck taking the required shape and
turns. Pneumatic cutter is used for cutting of the bead.
8. Bead is forced out of the bead chuck with the help of rollers.
9. The first bead of every batch is checked using bead measuring device. If
the size is incorrect changes are made in the chuck size accordingly.

Bead wrapping:

1. After the bead is formed, it is wrapped with help of bead wrapping

machine.
2. Apex is applied on the bead and the bead moves towards final wrapping.
3. The bead is stored and transported further.

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 7. BAND BUILDING

Band building is the process of formation of bands of various codes. The ply from the
calendering wrapped in the nylon cloth is transferred to the cutters mainly banner
wise cutter and scoop wise cutter. The cutter cuts the ply at an angle of 62 degree with
the help on sensors and motor cutter.

The pieces of the ply are pasted to one another and fed to the festoner. A festoner is a
machine that gives a continuous supply of ply to the band building machine. The ply
is supplied to the band building machine with the help of two conveyors and with a
specific amount of stretch. If the stretch is increased than the specific amount width of
the ply reduces. This results in scrap formation.

Green Tire Bands

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 8. TIRE BUILDING

Finally, the tire is ready to be built by a highly robotized machine which ensures
quality and efficiency. All components—bead assemblies, calendered plies, belts and
innerliner, tread and sidewall sections—are assembled and the building process
begins.

A typical radial tire is built on a flat drum in a two-stage process. In the first stage, the
innerliner is wrapped around a drum and the first body ply is wrapped on top,
followed by the second body ply. The bead assemblies are then positioned, and a
bladder on the drum is inflated and pushed in from both ends of the drum, forcing the
body plies to turn up to cover the bead assemblies. The sidewall sections then are
pressed onto both sides.

In the second stage of the tire building process, another machine is used to apply the
belts, nylon cap, and tread on top of the first stage. At this point, the tire still needs
curing because there is no tread pattern on it.

Tire Building Machine

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Processes Involved in Tire Building:

1. Building is the process of assembling all the components onto a tire

building drum.
2. Body plies, sidewalls and tread are wrapped around the drum, the beads
are placed, and the assembly turned up over the bead.
3. Product formed here is known as green tire.

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 9.TIRE CURING

A green tire is placed inside a large mold for the curing process. A tire mold is
shaped like a monstroclam which opens to reveal a large, flexible balloon called
a bladder. The green tire is placed over the bladder and, as the clamshell mold closes,
the bladder fills with steam and expands to shape the tire and force the blank tread
rubber against the raised interior of the mold. During this curing process, the steam
heats the green tire up to 280 degrees. Time in the mold depends on the characteristics
desired in the tire.

After curing is complete, the tire is removed from the mold for cooling and then
testing. Each tire is thoroughly inspected for flaws such as bubbles or voids in the
rubber of the tread, sidewall, and interior of the tire. Then, the tire is placed on a test
wheel, inflated, and spun. Sensors in the test wheel measure the balance of the tire and
determine if the tire runs in a straight line. Because of the design and assembly of a
modern tire, rarely is one rejected. Once the tire has been inspected and run on the test
wheel, it is moved to a warehouse for distribution.

Fig. 20

Cured Tire

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Tire Curing Process:

The green tire obtained is cured by following two presses-

1. Watch Casing Press

 For curing of green tire by Watch casing press, the green tire is
first passed through a bagger machine.
 The green tire is kept on the table and a bagger tube is inserted
in it at vacuum state.
 The bagger is then filled with air and taken out of the machine.
 Green tire takes the shape of the bagger.
 The tire is checked for any defects and sent to the press for its
curing.
 The curing of the green tire takes place for a specified time
which is fixed for every tire.
 During the curing process steam, nitrogen and cold water are
passed for different intervals of time.
 After the tire is cured, the bagger tube is still kept in the tire to
prevent its deformation.
 When the tire cools down the tube is extracted with the help of
extractor machine.

Bagger Machine

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 Bagger Tube

Green tire from bagger machine

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2. Bag o Matic Press
 In bag o matic type press the green tire is directly inserted in
the press after inspection.
 The green tire is inserted on the bladder, which is responsible
for its inflation.
 Before the green tire is inserted, air is blowed into the mould
for removal of any impurities.
 The tire is cured for specified time duration during which
nitrogen, steam and cold water enters the bladder.
 These presses are more advanced than watch casing and hence
reduce cure time.
 After the tire is cured a silicon based compound is sprayed on
moulds of both the presses.
 This is done to prevent sticking of next green tire to the mould.
 The cured tire is sent to post cure inflation (PCI) for cooling the
tire and preventing its deformation.

BAG O MATIC Press

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 10.POST CURE INFLATION

 The post curing inflation stage involves mounting the tire on the flanges,
inflating it and cooling it.
 The post curing inflation pressure has to be about 20-35 % higher than what
the normal inflation pressure of the tire would be.
 The inflation time has to be long enough (at least one curing cycle) depending
on the size of the tire (thickness of materials).
 Post curing helps stabilize the shape of the tire.
 Post curing inflation will help eliminate the influence of hot shrinkage on the
tire.

Post Cure Inflation

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 11.QUALITY CONTROL

Quality control begins with the suppliers of the raw materials. Today, a tire
manufacturer seeks suppliers who test the raw materials before they are delivered to
the tire plant. A manufacturer will often enter into special purchasing agreements with
a few suppliers who provide detailed certification of the properties and composition of
the raw materials. To insure the certification of suppliers, tire company chemists make
random tests of the raw materials as they are delivered.

Throughout the batch mixing process, samples of the rubber are drawn and tested to
confirm different properties such as tensile strength and density. Each tire assembler
is responsible for the tire components used. Code numbers and a comprehensive
computer record-keeping system allow plant managers to trace batches of rubber and
specific tire components.

When a new tire design is being manufactured for the first time, hundreds of tires are
taken from the end of the assembly line for destructive testing. Some of the tires, for
example, are sliced open to check for air pockets between body plies, while others are
pressed down on metal studs to determine puncture resistance. Still other tires are
spun rapidly and forced down onto metal drums to test mileage and other performance
characteristics.

A variety of nondestructive evaluation techniques are also used in tire quality control.
X-ray videography provides a quick and revealing view through a tire. In an X-ray
tire test, a tire is selected at random and taken to a radiation booth where it is
bombarded with X-rays. A test technician views the X-ray image on a video screen,
where tire defects are easily spotted. If a defect shows up, manufacturing engineers
review the specific steps of tire component assembly to determine how the flaw was
formed.

In addition to internal testing, feedback from consumers and tire dealers is also
correlated with the manufacturing process to identify process improvements.

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 12. INSPECTION

1. Visual Inspection
a. Tread Depth
b. X-RAY Inspection
2. Weight And Measurement Inspection
a. Tire Uniformity Analysis
b. Tire Balance
3. Final Inspection
a. Tire Rotation Analysis
b. High Speed Test
c. Damage Rate Inspection

Visual Inspection for outer defects

The above inspection processes comes under non destructive testing.

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Sometimes the testing of the final product is destructive. This is done to check the life
of a tire or to check the internal structure of a tire after curing process. This type of
testing results in damage of the product hence destructive testing. It is an important
part of inspection as it results in good product quality and reduces tire manufacturing
costs hence increasing profit. This type of testing is done randomly on different tire
codes.

Destructive Testing-

Various types of destructive testing are performed on farm tires at Goodyear:

1. Plunger Energy-
This test is used to determine the inch/pounds of penetration energy
required to effect tire bruise in tread area. The test is performed on
Plunger machine. The test duration is about one day.
2. Indoor Wheel Durability Test-
The test is used to evaluate rear tractor durability under free rolling
conditions. The test is performed on Resiliometer. The test duration is
five to six days.
3. Circle Durability-
The test is used to evaluate various modes of durability i.e. Carcass and
Wear. The test is performed on the farm track. The test duration is
forty to fifty days.
4. Stubble Resistance-
The test is the comparative study of puncture resistance. The test is
performed on farm track. The test duration is two days.
5. Load Deflection Test-
The test is the comparative deflection under different loads. The test is
performed on the farm track. The test duration is two days.
6. Hydro Burst-
The test is done to evaluate the strength of the tire. The test is
performed on hydro burst machine. The test duration is one day.

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Stubble Test

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13. MAINTENANCE

 Maintenance involves keeping the workplace, its structures, equipment,

machines, and facilities in good shape, operating efficiently and safely. It
includes many tasks including repairing, replacing, servicing, inspecting and
testing.

 It helps to eliminate workplace hazards.

 Lack of maintenance or inadequate maintenance can lead to dangerous

situations, accidents and health problems.

Press maintenance

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Types of Maintenance:

1. Breakdown maintenance
Breakdown maintenance is maintenance performed on equipment that has
broken down and is unusable. It is based on a breakdown maintenance trigger.
It may be either planned or it can be unplanned
2. Preventive maintenance
Preventive maintenance is maintenance that is regularly performed on a piece
of equipment to lessen the likelihood of it failing. Preventive maintenance is
performed while the equipment is still working, so that it does not break down
unexpectedly.
3. Autonomous maintenance
It is a daily basic maintenance done by the operator of the machine like
cleaning, removing foreign material or debris by using compressed air in
order to prevent any further complications.

Extruder Maintenance-

 General problems in extruder are-

1. Due to entry of a foreign material like metal object with the productive
compound leads to breakage of the mill drum in two parts.

2. Corrosion of mill drums due to continuous supply of water for cooling.

3. Breakage of mill drums due to sudden change in temperature at the

inner and outer side. This is caused due to stoppage of cooling water
for sometime and the again releasing of water which creates a
temperature difference.

4. The die used in the extruder wears out due to heat and friction.

5. Conveyor belt sometimes stuck in the bearing of the shaft which

results in breakage of the belt and breakdown of the machine.

6. Proper lubrication of moving parts at regular interval of time.

7. Proper maintenance of motors and gearbox.

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Bagger Maintenance-

 General problems in bagger are-

1. Proper lubrication of shafts, pistons, cylinders and all moving parts of

the bagger machine.

2. The hydraulic shafts used in bagger machines bends due to continuous

usage which results in breakdown.

3. Cup assembly of the main hydraulic cylinder wears out due to friction.

4. Lead cylinder (opening of head).

Curing Press Maintenance-

 General problems in curing presses are-

1. Worm shaft bearing requires replacement due to wear out caused by

continuous movement.

2. Seal gauge wears out due to continuous piston movement which results
in leakage.

3. Shaft diameter change.

4. Proper lubrication of moving parts.

5. Brass bush wear out.

6. C.P cylinder shaft bend.

7. Piston seal change.

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 14. PROJECT

Objective: To reduce the waste produced on extruder machine.

Executive Summary

Extruder is a machine which is used to produce the treads and sidewall of a tire. The
tread of a tire or track refers to the rubber on its circumference that makes contact
with the road. Tread is that part of the tire that comes in direct contact with the road,
for superior grip, performance, mileage tread plays a very important role. The design
of the tread depends on the type of application that the tire has to perform.

The sidewall is that part of the tire that bridges between the tread and the bead. The
sidewall transmits torque applied by the drive axel to the tread in order to create
traction. The sidewall, in conjunction with the air inflation, also supports the load of
the vehicle. Sidewall gives comfort due to its flexible nature.

In this project we have to deal with the rejection during the extrusion process and
suggest ways to minimize it, which can be beneficial for company because company
has to incur rework costs for the rejection produced from the extruder machine which
also hampers the productivity of the plant. So our main focus of the project was to
save the cost associated with the rework of treads and this will result into process
enhancement.

In this project first of all problem was defined with the data collected during the data
collection period and potential for reducing the waste was determined and then a
target was set and project was proceeded accordingly.

From the analysis done it was found that maximum percentage of rejection was due to
low weight inn treads followed by high weight, lumps, torn edges etc. after getting the
root cause of the problem it was found that maximum percentage of rejection which is
low weight is caused by feed break, line stoppage, viscosity variation and it was
ascertained that feed break was caused maximum due to unavailability of compound,
mechanical/electrical faults. Problems such as lumps and torn edges are completely
controllable under perfect conditions but some percentage of defects due to low and
high weight is bound to happen at start and end of running of die.
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So major plan was to minimize the rejections caused by low and high weight for
which there was lot of scope of improvement. There were some measures suggested
to control the low weight problem which include proper planning to ensure timely
availability of compound to feed mills so that there is no line stoppage, daily checks
of the line on a regular basis during lunch in each shift in order to deal with the
problem of stoppage. Temperature monitoring devices to be installed at breakdown
mill in order to keep track on temperature due to which overheating of compounds
can be avoided which causes lumps and creates viscosity variation. In the end
management should look for these key areas for improvement.

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 15. INTRODUCTION

Extrusion is the process used to create objects of a fixed cross-sectional profile. A

material is pushed or drawn through a die of desired cross-section. Extrusion may be
continuous (theoretically producing indefinitely long material) or semi-continuous
(producing many pieces). The extrusion process can be done with hot or cold
material.

Tire component such as tread, sidewall, apex are prepared by forcing uncured rubber
compound through an extruder to shape the tire tread or sidewall profiles. Extrusion is
one of the most important operations in the tire manufacturing process because it
produces most of the rubber compound produced from mixing operation and then
prepares various components for the ultimate tire building operation. The extruder in
a tire manufacturing process is a screw-type system, consisting primarily of an
extruder barrel and extruder head. First, the rubber compound is fed through extruder
barrel where it goes through the heating, blending and pressurizing process. Then, the
rubber compound flows through the extruder head where it is shaped under pressure.

Tire tread, or portion of the tire that comes in contact with the road, consists of tread
itself, tread shoulder and tread base. Since there are at least three different rubber
compounds used in forming this complex tread profile, the extruder consists of three
different extruder sharing an extruder head. Three rubber compounds are extruded
simultaneously from different extruders and then merged into a shared extruder head.
The next move is to a die plate where the shape and dimensions are formed, and then
through a long cooling line- from 100 to 200 ft long – to further control and stabilize
the dimensions. At the end of the line, the tread is cut according to a specific length
and weight for the tire being built.

Extruder is further divided into two parts:

Dual compound extruder-

When two different compounds of different properties are extruded through one and
same die. Such extruder is called dual compound extruder (10*10).

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Purpose-

It is used for the production of tread whose upper side is known as cap side and lower
side is known as base side. They two are joined with each other at a point of line
known as split line.

Single compound extruder-

When one compound of different properties is extruded through one and same die.
Such extruder is called single compound extruder (8*8).

Purpose-

It is used for production of sidewall of the tire.

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 16. Need/Justification of the project

The project deals with waste reduction of tire treads from an extruder machine. As
waste is a non value added activity for which customer is not willing to spend any
money, therefore it has become imperative for the company to deal in waste
reduction, moreover waste hampers the quality and efficiency of the plant.

In this project our objective is to focus on waste reduction from the extruder, it
produces tire treads which plays a very crucial role in making of tire because if tread
is not produced with right quality then defects will be there in the making of final tire
and tread id that portion of the tire which comes in direct contact of the road therefore
we have to make sure that the tire tread are made in accordance with the
specifications given for a particular tread for a particular tire, if we deviate from the
specifications then tire produced from the tread can lead to serious consequences.

Defects produced in the tire can lead to scrap or rework which has extra cost on
treatment and due to rework on treads, company has to incur lot of rework costs
which hampers its profit and moreover efficiency of the plant gets affected.

Therefore it is justified to work on this project which deals with the waste from
extruder due to which we can solve the above mentioned problems and improve the
efficiency of the plant and clearing the equipment.

34
 Project Defination

The main objective of doing the project is to reduce the waste from extruder machine
which produces tire treads so as to reduce scrap/rework cost and improve the
productivity of the plant.

During the data collection period it was observed that:

 Total number of tread produced-12207

 Total number of tread rejected-1674
 % of rejection-13.71
 Rejection due to low weight-851
 Rejection due to high weight-373
 Rejection due to lumps-266
 Rejection due to torn edges-130
 Rejection due to others(fabric, die cut)-54

The above mentioned figure is in numbers.

From the above data following conclusions can be delivered:

1. Treads rejected due to low weight constitute 50.83% of total rejection.

2. Treads rejected due to high weight constitute 22.28% of total rejection.
3. Treads rejected due to torn edge constitute 7.77% of total rejection.
4. Tread rejected due to lumps constitute 15.89% of total rejection.
5. Treads rejected due to other reasons constitute 3.22% of total rejection.

By observing the extruder line during this period it was concluded that defects
produced by lumps and torn edges are completely controllable under normal
conditions whereas defects due to low weight can be controlled by 40% and defects
due to high weight by 20%.

35
 17. Analysis and Findings

Analysis for the type of defects produced:

S.No Type of defect QTY(No’s)

1 Low weight 851
2 High weight 373
3 Lumps 266
4 Torn edge 130
5 Others 54
Table 1

Type of defects in treads

3%
8%

Low weight
16%
high weight
Lumps
51%
Torn Edge
Others
22%

Inference: From the above table and figure we can infer that low weight constitutes
the maximum amount of rejection in treads followed by high weight and lumps.

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Analysis for number of defects produced due to stoppage of line:

S.NO Type of defects QTY(No’s)

1 Low weight 114
2 High weight 7
3 Lumps 8
Table 2

Types of defects produced due to line

stoppage

6%
6%

Low weight
Torn edge
Lumps

88%

Inference: From the given figure it can be inferred that 88% of defects are caused due
to low weight whenever there is stoppage of line.

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Analysis of number of defects produced due to feed break:

S.NO Type of defect QTY(No’s)

1 Low weight 117
2 High weight 4
3 Lumps 15
4 Torn edge 13
5 Others 0
6 Total 149
Table 3

Types of defects produced due to feed brake

160

140

120

100
No of defects

80

60

40

20

0
Low weight High weight Lumps Toen edge Others Total
Types of defects

Inference: From the given figure we can infer that maximum defect occurs when
there if feed break is low weight.

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Fishbone analysis of major contributors of rejections:

MAN MATERIAL

Absenteeism Lumpy compound (M)

Negligence (M) Viscosity variation (M)

LUMPS

Temp/TCU Waiting for compound

Line stoppage (M) Operating Skills

MACHINE METHOD

Fishbone for lumps

Here M denotes the cause which has occurred maximum number of times.

From the given figure major contributors for lumps are as follows-

 Lumpy compound
 Viscosity variation
 Line stoppage

Now we will use Why-Why analysis of each major cause to determine the root cause
of the problem.

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Cause number 1: Line stoppage

Why #1 Why #2 Why #3 Why #4 Why #5 Why #6 Why #7

Feed Compoun Compoun Compoun Operator
break d not d not d not was not
available available milled by present at
to feed from B.D operator machine
mill mill
Feed Compoun Compoun Compoun Operator Operator’
break d was not d not d not failed to s
available available milled by sent negligenc
to feed from B.D operator material to e
mill mill feed mill on
time
Why Safety Safety Tread Operator Operator’s
was from was put slipped failed to negligence
there cooling up by from notice the
stoppag tank operator cooling movement
e of line tank of tread
dancer
roller
Safety Safety Inspector Booking Forklift Forklift
from was put unable to trolleys driver was driven by
booking up by book not unable to a
conveyo booking treads on available get trolley substitute
r inspector booking on time
trolleys
Safety at Feed Compoun Belt was Non
takeawa break in d slipped loose conformanc
y cap bite from cap which e in
conveyo rollers bite would maintenanc
r rollers in feed e of belt
extruder compound
head from feed

40
 mill to
extruder

From the given table we can derive following root cause for line stoppage-

 Operator was not present while line was running.

 Operator showed negligence during running of B.D mill.
 Forklift driven by substitute due to which he was not able to get trolleys on time to
inspection line.
 Non conformance in maintenance of belt.
 Safety put up at cooling tank due to operator’s negligence.

Cause number 2: Lumpy compound

Why #1 Why #2 Why #3 Why #4 Why #5

Chemicals not Weight not Operator’s
mixed in proper negligence
appropriate
proportion
Lump was Mill tailings Mill tailings Mill guides
formed on waste was was formed were not
batch off mill added to the from mill maintained
under fresh compound guides
Banbury coming from
mixer Banbury mixer
Lumpy tread Lumpy tread Inspectors Ignorance
Why was was mixed in was not didn’t regarding
compound Banbury segregated at segregate the segregation of
lumpy mixer which extruder lumpy treads lumpy treads
came from at extruder among
extruder inspectors
Compound Compound was Mill operator Mill operator’s

41
 got lumpy in preconditioned didn’t kept negligence
B.D mill for a time more track of time
than the
specified time
limit
Compound Inappropriate B.D mill was Regular
got lumpy in method was run by a operator not
B.D mill used on B.D substitute as present on
mill against machine
regular
operator
Compound Compound was Orbit Non
got lumpy in preconditioned conveyor was conformance in
feed mill for longer not used on use of orbit
duration cap side conveyor by
operator

From the given table we can derive following root cause for lumpy compound:

1. Negligence showed by operator in Banbury pigment room and B.D mill.

2. Ignorance regarding segregation of lumpy treads among inspectors of extruder
mill.
3. Lumps were created as a result of mill tailings waste in batch off mill under
Banbury mixer.
4. Non conformance showed by operator to use orbit conveyor at B.D mill.
5. Inappropriate method used when B.D mill was run by a substitute.

42
 Cause number 3: Viscosity variation

Why #1 Why #2 Why #3 Why #4

Mixing was not Ingredients not Non conformance in
properly done in mixed properly in mixing cycle by
Why was there Banbury mixer Banbury mixer operator
viscosity variation Viscosity was Compound milled Operator’s
varied in Banbury for a longer negligence
batch off mill duration than
required

From the given table we can derive following root cause for viscosity variation-

1. Non conformance in mixing cycle by operator of Banbury mixer.

2. Operator’s negligence shown at batch off mill under Banbury mixer.

MAN MATERIAL

Feed break (M) Low viscosity (M)

Die setting not proper Low specific gravity (M)

LOW WEIGHT

Line synchronization Waiting for compound

not proper

Mechanical stoppage (M) Operating Skills

MACHINE METHOD

43
 Fishbone for low weight

Here M denotes the cause which has occurred maximum number of times.

From the given figure major contributors for low weight are as follows-

 Low viscosity
 Low specific gravity
 Feed break
 Mechanical stoppage

Now we will use Why-Why analysis of each major cause to determine the root cause
of the problem.

Cause number 1: Low viscosity

Why #1 Why #2 Why #3 Why #4 Why #5

Viscosity of Compound was Mill operator Operator’s
compound preconditioned didn’t kept negligence
dropped for a long time track of time
Why was at B.D mill
viscosity low Viscosity of Temperature at Water Water valve
compound extruder head circulation was closed
dropped increased more stopped at head which would
than specified to keep circulate
limit temperature at cooling water
specifies limit

From the given table we can derive the following root cause for low viscosity:

 Negligence of operator at B.D mill due to which compound was milled for
longer time.

44
  Water valve was closed which would supply water for cooling from power
house.

Cause number 2: Low specific gravity

Why #1 Why #2 Why #3 Why #4

Wrong non Operator didn’t Operator’s
productive use check the negligence
identification of
the stage
Why was specific compound
gravity low Compounding not Chemicals not Scaling error in
okay from mixed in Banbury for auto
Banbury appropriate loading of carbon
quantity in mixing and oil
room
From the given table we can derive following root can derive following root cause for
low specific gravity:

 Operator’s negligence shown during mixing of non productive compound at

Banbury mixer.
 Scaling error in Banbury for auto loading of carbon and oil.

Cause number 3: Feed break

Why #1 Why #2 Why #3 Why #4 Why #5 Why #6
Compound Compound Compound Operator
not not available not milled by was not
available to from B.D operator present on
feed mill mill line
Compound Compound Compound Operator Operator’s
not not available not milled by failed to negligence
available to from B.D operator send

45
 feed mill mill material to
feed mill on
time
Compound Material got Mill operator Operator’s
stuck at mill accumulated failed to negligence
guard at cap at top of the notice the
feed mill mill guard accumulated
compound
Compound Compound Compound Material not Compound
not not available not milled by available to not ready
available to from B.D operator mill from
feed mill mill operator Banbury on
from time
Banbury
Compound Proper Maintenance
slipped distance of bite rollers
from bite between bite not done
rollers at rollers was
extruder not
maintained

From the above table we can derive following root cause for feed break:
1. Operator unavailable during running of line.
2. Negligence shown by operator at B.D mill.
3. Negligence shown by operator at cap feed mill due to which compound got
accumulated on mill guide.
4. Compound not available from Banbury for smooth running of line.
5. Maintenance of bite rollers was not done on time.

46
 MAN MATERIAL

Inefficient pushout Viscosity variation high (M)

TORN EDGE

TCU Failure Running of higher width

Machine stoppage for die after smaller width (M)

long time (M)

MACHINE METHOD

Fishbone for torn edge

Here M denotes the cause which has occurred maximum number of times.

From the above figure major contributors for torn edges are as follows:

 Machine stoppage for long time.

 High viscosity variation.
 Running of higher width die after smaller width.

Now we will use Why-Why analysis of each major cause to determine the root cause
of the problem.

Cause number 1: Machine stoppage

Machine is stopped when there is feed break or line gets stopped due to safety applied
at extruder line or due to mechanical/electrical stoppage, the root cause of these
problems have beendiscussed in the previous fish bone diagrams.

47
Cause number 2: Running of higher width die after smaller width

Why #1 Why #2 Why #3 Why #4 Why #5

Planning done There was
in that way by requirement in
PPC in that the BTB
Why higher order assembly to
width die was follow that
run after order
smaller width Compound of Compound was Compound Compound not
die smaller die was not milled by was not prepared in
not available to B.D line available to Banbury
continuously B.D line from
run the line Banbury

From the given table we can derive following root cause for using higher width die
after smaller width:

1. Planning was in that way from BTB curing that it requires die to be run in that
way.
2. Compound was not available from Banbury.

Cause number 3: High viscosity variation

Why #1 Why #2 Why #3 Why #4 Why #5

Why was Compound Compound Less time than Non
viscosity was hard was not the required conformance to
higher properly milled time was given specifications
in B.D mill during mill of by operator.
compound

From the given table we can derive following root cause for high viscosity:

48
  Compound milled for less than required time.

Cause number 1: improper breakdown of compound at B.D mill

Why #1 Why #2 Why #3 Why #4 Why #5

Compound Operator Compound was Feed mills
was milled for milled it for a urgently were running
Why was lesser time lesser time required at feed short of
improper than required mills compound to
breakdown of on B.D mill extruder head
compound at Compound Operator Non
B.D mill was milled for milled it for a conformance to
lesser time lesser time specified time
than required shown by
on B.D mill operator

From the given table we can derive the following root cause for improper breakdown
of compound at B.D mill:

 There was urgency of compound at feed mills due to which operator of B.D
mill milled the compound for lesser period.
 Non conformance to specified time shown by operator at B.D mill.

Cause number 2: high viscosity variation

Why #1 Why #2 Why #3 Why #4 Why #5

Compound was Compound was Less time than Non
hard not properly the required conformance to
milled in B.D was given specifications
mill during breaking by operator
of compound
Compound was Compound was Non

49
 hard not properly conformance in
mixed in mixing cycle by
Banbury mixer operator

From the given table we can derive the following root cause for high viscosity
variation:

 Non conformance to specified time shown by operator at B.D mill.

 Non conformance in mixing cycle shown by operator at Banbury mixer.

50
 18. Opportunities/Suggestions

 Mill operator should make sure that OK compound is loaded on B.D mill which
should be free from lumps.
 Daily checks should be incorporated for critical parts of extruder line such as
conveyor belt, mill conveyor, skiver cutter, extruder motor on daily basis during
lunch or when the machine is not in operation to prevent breakdown which
hampers the production.
 Lumpy treads should be segregated from inspection line before going into
Banbury mixer for rework by inspectors at booking line, they should be properly
trained to separate lumpy treads from non lumpy ones.
 100% implementation of orbit conveyor at the cap feed mill and blender at the
base feed mills should be incorporated in order to avoid excessive heating of
compound which can cause lumps in the compound.
 Temperature monitoring device should be installed at B.D mill and batch off mills
below Banbury mixer to keep track of temperature because deviation from them
can cause lumps and viscosity variation.
 Adequate planning should be incorporated in Banbury in order to make sure that
there is uninterrupted flow of material to extruder line to prevent untimely
stoppage of line.
 Mill operator should make sure that there is enough compound for a particular
tread code for smooth running of line, if enough material is not there then he
should inform the supervisor before starting the B.D mill.
 A predefined level should be set up at cap feed mill guard which should prevent
the accumulating the compound at top of mill guard which causes stoppage of
line, for this a sensor should be deployed at the maximum level of mill guard
which would stop the conveyor automatically connecting to the cap mill when the
material exceeds the specified limit.
 TCU leakage should be monitored frequently by shift supervisor.
 Feed mill operator should make sure that there is timely availability of compound
to the feed mills which are required to feed the extruders continuously, in order to
avoid feed break and if some deviations exists should immediately inform the shift
supervisor for corrective action.

51
 Proper distance between the bite rollers should be maintained and its axis
straightened so that rollers work properly.
 All mill to mill conveyors should be checked by maintenance department to avoid
the problem of extruder stoppage due to compound stuck at conveyor.
 Operator counseling should be done on regular basis for all operators doing
critical job to make them aware about the importance of their contribution.
 Die should be properly cleaned and operator should make sure die has reached the
specified temperature which is required before setting it, to avoid problems of torn
edges.
 Ensure calibration conformance all measuring scales.

Result: The waste product produced on the extruder line can be reduced using above
methods.

52
 19. REFERENCES

 www.goodyear.com
 A text book of tire making and merchandising by F.R Goodell.
 A text book of quality control and management by Evans and Lindsay.
 en.wikipedia.org/wiki/tier manufacturing process.
 Slideshare.n.d

53
STUDENT DETAILS

Student Name Nikita Shishodia

Roll No. M-4202-2K16

Email address Nikitashishodia29@gmail.com Phone No. 9205280255

PROJECT DETAILS

Project title To reduce the waste produced on extruder machine.

Project 6 months Date of 25th June

duration reporting 2019

ORGANISATION DETAILS

Name of GOODYEAR INDIA LTD.

organization
Address 21/4 Milestone, NH2 Mathura Road, Ballabgarh, Faridabad

Mentor Name Mr. Neeraj Singh

Designation Staff engineer

Email address Neeraj_singh@goodyear.com Phone no. 9910939333

54