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on by the JD power Asiapacific st udy. FUNCTIONAL DEPARTMENTS OF JK INDUSTRIES There are the functional departments at JK Industries (Vikrant type plant) [JK]( VIP) and they are follows. 1. Materials 2. Production 3.Engineering 4. Technical 5. Quality Assurance 6. Human Resource Management 7. Production Planning 8. Personal & Administration Secretarial 9. Internal audit 10. Electronic Data Processing (EDP) 11. Industrial Engineering 12. Finance 13. Marketing 14. Technical services. Due to time constraint, only the basic departments such as production,marketing, Human Resources and Finance, quality assurance have beenstudies. 1. MATERIALS STORES DEPARTMENT :There are the three stores in JK industries (Vikrant tyre plant); Raw materials stores Engineering stores Finished goods stores The function of raw materials stores and finished goods stores arecentralized in

the Head Office itself. For all 4 plants of JK industries theHead Office itself controls purchase decisions and supply of raw 9 JK TYRE INDUSTRIES LTD materials. RAW MATERIALS STORES In JK industries (Vikrant Tyre plant) follows First in First Out method for inve ntories. Everything is controlled by the head of the department. Someof the raw materials accumulated in stores are Natural rubber, Syntheticrubber, Chemicals ( Sulphur, Zinc oxide), Carbon and so on FINISHED GOODS STORES The finished goods are stored & preserved in finished goods stores inorder to pr otect it from rain, dust & water. The duty of FGS head to distribute the finished goods directed by thesupply chai n management. Supply chain management decides the day today distribution. All the finished goods after the final inspection are kept at thetransferring ar ea. A finished goods transfer note is prepared in triplicatecopies. The note con tains details about material description & quantity.The original copy is sent to central excise wing & duplicate to productiondepartment & another copy to produ ction & planning control (PPC)department. The current status of the stock can be checked by using transfer notes.If the fi nished goods require packaging then it transfers to packing area. If not it is s end to storage area. STAGES IN TYRE MANUFACTURING PROCESS 1. COMPUND AT BANBURY Compounding is the process of mixing the necessary raw materials withselected El astomer in the banbury. Banbury is an internal mixer, which consistsof a complet ely enclosed mixing chamber with two spiral shaped rotors. There isa hoper to fe ed the ingredients & door to discharge the mix. The rubber ingredients like chem icals are weighted as mentioned in specification file & fedinto the hoper. Then the mixing process takes place. Required mixing time isfixed to get better quali ty mixing. 2. EXTRUDER 10 JK TYRE INDUSTRIES LTD The main function of an Extruder is to produce tread & side wall, bead, apex.Ext rusion is a process of forcing the mixed compound by means of screw, whichrotate s inside the barrel. There are two types of extruder a. Screw extruder b. Ram extruder Screw extruder In screw extruder the screw is rotated by means of a motor through reductiongear s. The extruder consists of hoper, dye-hard, barrel & dyes.There are twotypes of screw extruder

 Cold feed extruder Hot feed extruder 3. ZELL PLANT The dipping process takes place in a Zell plant. Here rayon, nylon,polyesters ar e dipped in a solution containing normally a latex basedresorcinol formaldehyde to improve adhesive properties. Then the fabric isdried at a temperature of abou t 280 to 300 Celsius & it stretches to about0-15%. 4. CALENDARING Calendar is machine, consists of number of rolls held in a frame workused to pro duce the rubber sheets of required strength & lengths. To get abetter quality ca lendared fabric with uniform gauges, viscosity plays animportant role & required temperature is about 110 to 137 degree Celsius. 5. BIAS CUTTER It is a machine used to make the plys or the rubber coated fabrics at arequired width & angle. Which are used in the production of tyres. Biasangle is the angle of cords in tyres w r t the central line. Based on the idealcurved angle which is required type, size & pattern. Bias angle iscalculated for a particular drum. If the angle is not as per the specification,it will affect the performance of the tyre. In general the angle 45 degree &the width of the sheet is 100 to 137 m m. 6. POCKET MAKING 11 JK TYRE INDUSTRIES LTD It is process of making the pocket from the angle cutter fabrics. In pocketmakin g section, three types of pockets are constructed. They are first,second, third pocket. The ply s used for the first & second pocket areknown as inner ply & those u sed for third pocket are known as outer ply,pockets are made for easy building o f heavy vehicle tyres. 7. BLADDER Butyl rubber compound is used for making the bladder. As first butylrubber is mi xed with specified chemicals properly & then it enters theextruder section by th e use of the extruder, a specific length & width of slug is extruded. Then the e dges of the slug are cut into specified anglefor joining purpose. 8. BEAD MAKING Bronze plated steel wire is coated with layer of rubber compoundsto form a bead. 9. BEAD FLIPPING A Filtering compound called apex is provided over the bead. A stripfabric is use d to bind the apex with the bead and the bed with the tyre. It iscalled flipper bead, which is another component of tyre. 10. GREEN TYRE BUILDING All the above components (Pocket, Bead, Flipper, Tread & Chaffer)are assembled, during the tyre building to form Green Tyre. 11.AWLING Green tyres are then sent for awling where air traps are removed byrandomly pier cing the green tyres using awling gun. 12. TYRE CURING It is a process of cross linking the rubber compounds through heat &pressure. Fo r the process of curing tyres presses are used. These presses arepre warmed befo re loading of green tyre is done in top ring raise condition withvacuum. Shaping is done by centering the green tyre correctly. Bladders areused for tyre curing

. 13.POST CURE INFLATION 12 JK TYRE INDUSTRIES LTD Cured tyre are loaded onto post cure inflation units to coolpressure, this is do ne to avoid shrinking of the nylon fabric. 14. TYRE MOULDING Before moulding operations, the green tyre has to be made ready for painting wit h inner lubricants inside the tyre for easy release from thebladder & the side w alls are to be coated with blemish paints. Blemishpaints contains carbon black, naphtha, styrene butadiene rubber components & this enables easy flow of compoun ds while curing in themould pattern. The blemish paint helps in minimizing the s urface flowmarks. As a whole to obtain better results, green tyre should not tou ch thefloor & there should no any contamination on the tyre surfaces.Tyre mouldi ng is a complex type of compression moulding normallycured in presses. The raw t yre has to be placed over a bladder. Then thebladder & tyre expands together due to steam pressure & simultaneouslythe tyre gets compressed between two moulds i n closed position. In this,the operation cycle time, pressure, temperature has t o be maintainedproperly to get optimum vulcanization during moulding process of the tyre. 15. TYRE FINISHING & INSPECTION After curing, the tyres obtained are further finished by trimming of the project ion on the tyres surfaces & are checked for defects. Thus theprocess of removing excess materials on the tyre after curing is calledfinishing.The finishing proc ess is done either by buffing or trimming method.Buffing is done using emery pap er wrapped on a cylindrical rubber press.Thus all tyres are inspected in systema tized process. If anydefects are found it has to be separated & remaining can be stored inwarehouse. 16. TYRE TESTING There are two types of tests o Non destructive tests o Destructive tests Non destructive tests 13 of 23 Leave a Comment Submit Characters: 400 J.K.Tyres Download or Print 2,277 Reads Info and Rating Uploaded by Sunil Gowli Follow Search TIP Press Ctrl-F to quickly search anywhere in the document. More from This User Related Documents 23 p.

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