Applicability of Process Control Techniques in PET Strapping Production Process

Banu al Banu Tuba Turgut !le" #en$ar Prof% &r% S%'"it ()tay *rat
+ar"ara ,ni$ersity*aculty of Engineering&epart"ent of .ndustrial Engineering

Content
Overview Literature Summary Process Control Techniques Applied Studies and Findings
PET Strapping Production Process ata Collection and Preparation Findings

Conclusions and !ecommendations

($er$ie/
The concept o# applica$ility o# Process Control Techniques %PCTs& to PET %Polyethylene terephthalate& strapping production process is presented $y using 'istograms Control charts Process capa$ility #or #our main CT(s %$rea)ing strength* width* thic)ness* and total weight&

SPC 0Statistical Process Control1

SPC is a well,esta$lished procedure in which data is collected* organi-ed* analy-ed and interpreted so that a process can $e maintained at its present level o# quality or improved to a higher level o# quality. SPC involves using statistical techniques to identi#y source o# variation to improve per#ormance and quality simultaneously.

Process Control
Process control #ocuses on reducing the process varia$ility to achieve the potential $ene#its coming along with process improvements The aim o# process control is to )eep )ey process operating parameters within narrow intervals and to streamline the system $y minimi-ing the occurrence o# quality related pro$lems. There are many ways to implement process control. PCTs give the advantages o# monitoring the production processes and maintaining proper #eed$ac) control ad0ustment.

Typical Process Control Techniques

2ey monitoring and investigating tools are given $elow3 'istograms Control Charts Chec) Sheets Pareto Charts Cause and E##ect iagrams e#ect Concentration iagrams Scatter iagrams

4n this study* mainly histograms and control charts are used.

2istogra"

'istograms are very use#ul in estimating process capa$ility and #or visuali-ing process per#ormance. 6ormality Assumption %quality characteristics are assumed to have 6. & can $e investigated $y loo)ing at the shape o# the histogram. 4# the histogram is #airly s)ewed* then the 6ormality Assumption might $e a concern. Thus* the estimate o# the capa$ility is unli)ely to $e correct.

2istogra" 0continued1
Trans#orming data is the remedy o# dealing with this pro$lem. 8y this way* data are converted into trans#ormed metric so that they have 6ormal istri$ution appearance. There are use#ul graphical and analytical approaches #or trans#orming the data. 4n this study log9* 9" and 1:9 tran#ormations were used.

Control Charts
Control charts are tools used to determine whether a manu#acturing or $usiness process is in a state o# statistical control or not. These charts consist o# a centre line %CL& which is the sample grand mean %average o# averages& and upper and lower control limits %<CL and LCL&. The control limits are de#ined $ased on the variation o# the process.

Control Charts
4# a control chart indicates that the process is currently under control* then it can $e used with con#idence to predict the #uture per#ormance o# the process. 4# the chart indicates that the process $eing monitored is not in control* the pattern it reveals can help to determine the source o# variation to $e eliminated in order to $ring the process $ac) into control.

Control Charts 0continued1

3hy ,se Control Charts4 ?onitor process variation over time i##erentiate $etween assigna$le and common cause variation Assess e##ectiveness o# changes Communicate process per#ormance ?onitor process mean and varia$ility o# the process together @

Control Charts 0continued1

Control Chart Basic Procedure 1. Choose the appropriate control chart #or data. ". etermine the appropriate time period #or collecting and plotting data. +. Collect data* construct the chart and analy-e the data. /. Loo) #or Aout,o#,control signalsB on the control chart. Chen one is identi#ied* mar) it on the chart and investigate the cause.

Control Charts 0continued1

Process Capability 0PC1

PC deals with the uni#ormity o# the process. Daria$ility o# CT(s in the process is a measure o# the uni#ormity o# the output. PC study #requently "easures #unctional parameters or CT(s on the product. PC does not "easure the process itsel#.

5iterature Su""ary 6
Author- 7ear 8igel P% 9rigg- :eannette &aly and +ar;orie Ste/art 9e"ai Chen and S"iley 3% Cheng 5auro +% +% @ibeiro and :%A% Sarsfield Cabral T% C% Chan! and *% *% 9an Ahongsa) Sri)aeo- :ohn E% *urst- :ohn Ashton +% &ude) Burli)o/s)a Shan)ar Cha)raborty and &iganta Tah 7ear Sector *ish Product +anufacture Type of Control Chart >?Bar- @ , chart ferrous castings foundry .C asse"bly process Biscuit Production Pipe Production .ndi$idual- +@C,S,+ >?Bar >?Bar- @- Cp- Cp) >?Bar- @ >?Bar- @

6<<= 6<<= 6<<< 6<<< BCCD BCCD BCCE

Ali @!a +otorcu and Abdul)adir 9FllF

BCCE

+achining

>?Bar- @-

5iterature Su""ary B
Author- 7ear 7ear Sector Type of Control Chart C,S,+- +5? C,S,+ E3+A- C,S,+ CJ 0Coefficient of Jariation1 >?Bar- s- *u!!y P >?Bar 0design of chart1 >?Bar- @ E3+A >?Bar- s 8ylon *iber Production 3ater toGicity Clinical Che"istry Auto"oti$e .ndustry *ertili!er Plant Production Blood Co"ponent Production Asset +anage"ent dish/asher production

:ianGin @oger :iao H Petri T% 2elo Eleni +% S"etia- &e"etrios E% Aorona)isb- Spyridon A% 9olfinopoulosa Aang- 5ee- Seong- 2a/)ins Jahid A"ir!adeh- +ashaallah +ashinchiAbbas Parcha"i 8eelufur nil H Srini$asa @ao Araleti HJen)ata Subbaiah Aa"bago/ni 8% Bec)"an- +% :% 8ightingale H &% Pa"philon Jasyl 9olosnoy and 3olfgang Sch"id BurKin +% &,@+A8- 7rd%&oK%&r% *at"a PAA&L5

BCCE

BCCI BCCI BCC< BCC< BCC<

Applied Studies and *indings

PET Strapping Processes PET Strapping $ecomes more an more popular day $y day $ecause o# the advantages versus steel hoop. As compared to steel hoops* PET strapping tapes meanwhile o##er a range o# considera$le $ene#its3
The sta$ility o# PET tapes is compara$le to that steel hoops ue to its higher elasticity* the PET tape does not damage the edges o# the goods pac)ed. The ris) o# in0ury in considera$ly lower than that steel hoops Less e9pensive than steel hoops.
17

Applied Studies and *indings

*ir"Ms Profile 4mplementation is done in Polipa) Plastic Pac)aging San. Ltd Eti which has $een esta$lished in 1=;5* and started to produce PP strapping* since ">>+ Company started to produce PET strapping.

Applied Studies and *indings Cont%

Selected product to analy-e is 1"mm >.7>mm Pet Strapping that is produce $y using twin,screw technology that is a computer $ased control and data acquisition system. 8y using this technology all process parameters are controlled and monitored via '?4 %'uman:?achine 4nter#ace& so#tware

Applied Studies and *indings Cont%

Process *lo/ of PET Production process o# the 1"mm Pet strapping can $e de#ine asF The material #la)es are melted in e9truder* then #iltered and shape in die into several straps emerging side $y side. A#ter $rie# cooling in the water $ath* the straps undergo secondary processing in the production line namely several annealing and streching stages to provide them the required tensile strength. Produced straps winding $y using wrappings.
">

Applied Studies and *indings Cont%

For PET Strapping production process* / main CT(s as the product varia$les3 $rea)ing strength* width* thic)ness* total weight %gram:mt&

are analysed separately in order to identi#y the status o# the o$tained data whether they are in statistical control or not.

So"e of The Standards related to PET 0Polyethylene terephthalate1

%TSE& E6 11+/;
Plastics ,!ecycled plastics,Characteri-ation o# PET recyclates

%TSE& E6 5>5;/,+,/"> to /""

Fle9i$le insulating sleeving
Part +3 Speci#ication #or individual types o# sleeving Sheets /"> to /""3 PET te9tile sleeving with acrylic $ased coating

TSE 5==+ TSE 5>/1/,+,11 %TSE& E6 5>5;/,+,+/>* +/1*+/"

&ata Collection and Preparation

">= o$servations >1.>1.">>= G 1".";.">>= ata
Strength ma9,min daily Cidth ma9,min daily Thic)ness ma9,min daily Total weight %Hram:mt& daily

&ata EGa"ination
'istograms Assesing 6ormality, Trans#ormations Control Charts Process Capa$ility

&escripti$e Statistics
Mean
$rea)ingIstrengthImin $rea)ingIstrengthIma9 widthImin widthIma9 thic)nessImin thic)nessIma9 totalIweight %gram:mt& "5/*>7 "75*51 11,469 11,729 0,72680 1,118 9,6733

Variance
/;7*;7 1>/*+; 0,0157 0,177 0,000190 27,486 0,0225

Median
"5;*>> "7=*>> 11,500 11,700 0,73000 0,750 9,7100

S)e/ness
,;*77 ,=*1; 0,10 0,19 -0,59 14,35 -4,10

Aurtosis
100,09 113,45 0,14 -0,23 0,09 206,00 31,05

2istogra" of brea)ing strength?"in

6ormal 1"> 1>> ;> *requency 5> /> "> >
?ean St ev 6 "5/*1 ""*>= ">5

>

5>

1"> 1;> brea)ing st rengt h? "in

"/>

+>>

2istogra" of thic)ness?"in
6ormal 7> 5> 1> *requency /> +> "> 1> >
?ean St ev 6 >*7"5; >*>1+77 ">5

>*5=

>*7>

>*71 >*7" >*7+ t hic)ness? "in

>*7/

>*71

>*75

2istogra" of thic)ness?"aG
6ormal ">>
?ean St ev 6 1*11; 1*"/+ ">5

11> *requency

1>>

1>

>

>

11

+> /1 t hic)ness? "aG

5>

71

Transfor"ations
1/x
$rea)ingIstrengthImin $rea)ingIstrengthIma9 widthImin widthIma9 thic)nessImin thic)nessIma9 totalIweight %gram:mt& Very Narrow Very Narrow Continuity Continuity Continuity Veri Narrow Right Skewe Continuity Continuity Continuity Narrow Narrow

x2

5og0G1
Very Narrow Very Narrow Continuity Continuity Continuity Very Narrow

Applied Studies and *indings Cont%

J At the begining of the study- the control charts are prepared by using +initab soft/are- /hich are gi$en belo/%

+1

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

J A#ter graphing control charts* outliers are determined and related data are eliminated and control charts are drawn with modi#ied data. J For the 8rea)ing Strength data* three times elimination is usedF #or Thic)ness and Cidth data* two times elimination is doneF and #inally #or Total Ceight %Hram:?t& data only one elimination is implemented J 6ew control charts are as #ollow3

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

J Last control charts are analy-ed $y using Kone !ules which areF
G One or more points outside o# the control limits G Two o# three consecutive points outside the two sigma warning limits $ut still inside the control limits G Four o# #ive consecutive points $eyond the one sigma limits G A run o# eight consecutive points on one side o# the centerline G Si9 points in a row steadily increasing or decreasing G Fi#teen points in a row in -one C%$oth a$ove and $elow the centerline& G Fourteen points in a row alternating up and down G Eight points in a row on $oth sides o# the centerline with non in -one C G An unusual or non random pattern in the data G One or more points near a warning or control limit

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Applied Studies and *indings Cont%

Process Capability 0PC1

PC deals with the uni#ormity o# the process. Daria$ility o# CT(s in the process is a measure o# the uni#ormity o# the output. PC study #requently "easures #unctional parameters or CT(s on the product. PC does not "easure the process itsel#.

*indings for Process Capability

Process capability indeG for Total 3eight 09ra"N"t1 using &ouble?sided specifications

The upper speci#ication limit %<SL& L =.=1 The lower speci#ication limit %LSL& L ;.+/ The standard deviation L >.11 The mean L =.57++ The actual process capa$ility is Cp)O C%E6D The potential process capa$ility is CpO 6%I=<

The PP+ calculations for potential process capability

The process fallout is approGi"ately C%C= PP+ 0defecti$e parts?per?"illion1

@eference Jalues
9eneral @eco""endations for Processes
For an e9isting process* the Cp is a$ove the recommended minimum %1.++& For a new process* the Cp is a$ove the recommended minimum %1.1>& For an e9isting critical process %sa#ety* strength&* the Cp is a$ove the recommended minimum %1.1>& For a new critical process %sa#ety* strength&* the Cp is a$ove the recommended minimum %1.57&

Conclusions and @eco""endations

Apart #rom histograms and control charts* other PCTs can $e applied to control the process and improve product uni#ormity. 4n this study log9* 9" and 1:9 tran#ormations were used. 4t is reali-ed that assumption o# normal distri$ution is valid. So original data is used without trans#ormation. A#ter monitoring the process* causes o# out,o#,control signals can $e determined and eliminated so that improvement can $e attained #or overall process per#ormance.

Conclusions and @eco""endations

4mportant signals #or each parameters are o$served asF For Total weight %Hram,?t& "* +* = and 1>* For 8rea)ing Strength 1* + and 1>* For Thic)ness 1* + and 1>* For Cidth data + and 1>. ?ost o# the out,o#,control signals are detected #or the third and tenth rules.

Conclusions and @eco""endations

For the #irm* a pac)age program can $e permanently used to monitor the process and -one rule + and rule 1> may $e investigated in detail. 4n #act* monitoring only the #our CT(s o# a product is not seen su##icient to de#ine and improve a process.

Conclusions and @eco""endations

Controlling manu#acturing processes during operation is also suggested in order to satis#y customer requirements.

The $ene#its derived #rom SPC in the areas o# reduced internal and e9ternal #ailures should o##set any additional costs incurred #rom sample collection* testing and data analysis.

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