CHAPTER 1 1.

ELASTOMERIC TECHNOLOGIES (PVT) LTD

1.1.1Introduction
Elastomeric, part of HEXPOL with manufacturing in North America, Europe and Asia pacific. HEXPOL is a multinational company. It is a globally leading supplier of polymeric wheels and other products for the transport and material handling industry. Elastomeric was founded in 1992. It was acquired by Hexagon in 1998. Mother company is situated in Sweden. Factory spread over 5 acres land in Sri Lanka. More than 500 workers are working in the factory at bokundara. Other factory was located in horana.

1.1.2Functions of the organization

Gasket for plate heat exchangers (PHE Gaskets) and black tyre compound mixing is done at the bokundara factory. Solid tyre and caster wheels are manufactured in horana. Following process are carried out in bokundara premises. . Mould designing (tool shop) Gaskets manufacturing (Compression molding) Extruding Compound mixing Post curing

Elastomeric has its own mould shop. So they can make compression mould and injection moulds. Their tooling facility facilitate them to response their customer inquiries very quickly. R&D department can achieve customer requirement as soon as possible. Production department also work together with R&D to provide better service to their customers. Production department work hard and use their full strength to supply good quality products on time to their customers. Elastomeric export their total output to various countries in Western Europe, USA, Japan and Australia. Sales and marketing of Elastomeric products in Europe and USA are handled through Stellana AB of Sweden which is subsidiary company of HEXPOL. Sales and marketing in Asia is handled by Office in Sri Lanka.

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President

Secretary

Director/Financial Controller Sales Manager IT/Finance

General Manager (Marketing)

General Manager (Gasket) Logistics& Planning/FGS

General Manager (Wheels)

FGS

R&D Manager

ISO Systems Management Representative

Commercial

Mixing Production Executive Production Production Assistants

Production Assistants Commercial Executives QA

PHE Gasket R&D Assistant Production Engineering Tool Shop

Assistants

Planning/Production Maintenance Assistants

Maintenance

Figure 1.1: Organization structure of Elastomeric Technologies (pvt) Ltd.

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Vision

It is our vision to be universally regarded as an efficient customer focused quality supplier, which globally brings value to customers through innovation.

Mission Our mission as a wheel specialist is to develop, manufacture and market high quality wheels and adjacent polymer products for transport and material handling.

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1.1.3Present performance of the organization. Most of works are automated in mixing process while more manual work is involved in gasket production process. The plant at the Bokundara is the only gasket manufacturing plant in Sri Lanka. More than 7000
quality approved gaskets are produced in plant per week. Nearly 60 compression mould presses, 3 rubber extruders and 15 curing ovens are operated in gasket production plant. Workers work according to shift basis in both gasket and mixing department. In gasket two shift systems available. One shift system operates according to 12 hours basis and the other 8 hours basis. In mixing department shifts operates according to 8 hours basis. Normally plant runs 6 days per week but workers in gasket department can work Sunday if they like. However plant was shut down during Sunday night shift. Mixing department was not operated during Sundays in beginning of the year. But after mid of the year mixing department also started to operate morning and evening shifts during Sundays. This was done because mixing department got more orders after mid of the year. In early days maintenance work carried out during Sundays but now it carried out during week days when it is possible. The company is running successfully and contributes to Mother Company as well employees. The success of the company lies on the hand of the employees and the practices involved within the company itself. Elastomeric has a strong management who steering the company towards success. All department heads work together to achieve the company goals and enhance the productivity of the company. They are very familiar with the process and workers under them. They work very closely with supervisors and workers to solve the problems involve in production. They learn from experience and practiced in present. Engineering manager work hard to resolve the problem entitled in machineries during production. Research and development department is the heart of the company. They work hard to develop the quality of products and satisfy the customer. They help to run smooth production. Mould designing department also help to maintain the quality of the products and achieve customer requirement.

1.1.4My suggestions for improvement During my training period I observed some task in production process which should improve. Person who work in mixer communicate with mill operator through pipe line. When mixer operator needed to talk to mill operator he has to ring the bell wait until bell rang in mill operator. Mill operator also used same method when he needed to speak to mixer operator. It was not efficient communication method in nowadays. My suggestion is to establish

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wireless internal communication system. Safety equipment which were given to workers not used in all time. So rule should be implemented to avoid that. Workers attitude should improve through workshops and lectures.

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Chapter 2 My Training Experience 1. Introduction to factory

2.1.1 Familiarize with factory premises
My first task was familiar with factory premises and workers. In first day Mr .Bandara take me to factory premises and explain the processes carried out in each area. After that I went through all processes and got thorough knowledge about each process. Finally I was able to draw factory layout. Figure 2.1.0: Factory layout

Nitrogen generator Raw material stores Rest room Post curing area Raw material stores

Gasket compound stores

RMS

FGS

Inspection & packing area

Gasket Lab

Office

Carbon bin Mixing area

Extruders Tool shop

Gasket press area Engineering work Boiler

oil tank

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2.1.2 Steam generation system.

Steam is used for gasket press for gasket curing. Steam lines running throughout the whole factory. This is powered by two fire tube boilers. Steam generation system was observed during my training.

Boiler

Steam

Steam header

Steam

Molding presses Condensate

Chemical are pumped for treatment

Collecting water tank

Water softening process Make up water input

Figure 2.1.2 Steam generation system

2.1.3 Boilers
Elastomeric has two wet back design. They are fire tube boilers each with capacity of 8000PPH. These boilers are nozzle type burners. 1500sec furnace oil is used. Once the oil is atomized, it catches fire by the spark produced by an ignition transformer. The boilers run by fully automatic system. Water level is controlled at same level. The first low water alarm should sound and cut-off the burner after the water level has fallen approximately 45.5mm below normal working level. The second low water alarm should sound and lock-out the burner when the water level has fallen approximately 63mm below normal working level. The burner too works automatically according to pressure generated in the boiler. Working pressure of the boiler set as 15bar. If pressure goes below than this value burner switched on. When burner exceeds 15bar it is shut down. This is done by photo electric cell with a synchronous sequence controller. The burner runs on two stages one is high flame and low flame. This is also controlled by automatically. Blow down is carried out once every shift. This was done by manually. 3000l of furnace oil were used every day for steam generation. Boiler inlet nozzles and knobs were cleaned once a week before starting the boiler. Boiler interior is cleaned every 4 months. Boiler inspection carried out annually. The water which is used to generate steam is treated before sending into boiler. In this company they use water softener and chemicals were used for that. This process happen automatically when water running to boiler.

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Oil pumped from tank

Motor which drives the impeller

A metal plate which can be adjusted to control the volume of air sucked in

Blower (impeller) Air is sucked in

Figure 2.2.3: Burner arrangement

Figure 2.2.4: 3-pass wet back design fire tube boiler

tubes

Combustion chamber

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2.1.4 Steam distribution system

Four globe valves are used to distribute the steam to molding presses from steam header. The amount and rate of steam distribute from each are different.

Steam from boiler no1 To molding presses

steam from boiler no 2

Steam Header

Condensate is sent into the softening process and then to the collecting tank

2.1.5 Nitrogen gas generator.

Gaskets are post cured in ovens. Some gaskets are post cured in ovens which use nitrogen gas rather than normal air. For that purpose nitrogen gas is generated. There are two nitrogen gas generators. That generation process is as follows.

Air compressor Air

PNEUDRI Pre treatment package Clean oil-free and dry air Nitrogen outlet Nitrogen generator removes oxygen from the air supply,producing nitrogen at purities from 3% to 10ppm oxygen content

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2. Mixing department
2.2.1 Raw materials and their function.
Raw rubber alone is not suitable for the production of useful articles. It is due to following reasons: 1. It is tough and cannot be shaped easily in the form of an article 2. Low temperature softening 3. Its strength is weak 4. Molecular degradation undergoes easily. 5. Due to high cost of rubber.

So to make useful products at reasonable cost, it is necessary to compound raw rubbers with other chemical ingredients. These ingredients are classified according to their function.

Compounding Ingredients Chemical plasticizer Filler Softeners Antidegradant Vulcanising system

Function in rubber To increase level of plasticity To increase strength, Hardness and reduce cost To aid filler incorporation into rubber To increase service life of rubber product To form crosslinks among rubber molecules.

During my training I was observed chemicals used in production and reason for addition these chemicals to rubber compound. Raw materials are stored in raw material stores. Main raw material stores are situated separately from production. Raw materials were sent to production as per requirement. It was handled by store keeper. Raw materials are stored according to standard. Store room is fully ventilated. Direct sunlight is avoided. Raw material store and handling conditions are published in charts. This chart is available in raw material stores and chemical weighing area. Raw material store is situated in lower land. Area is heavily affected by flood in rainy season. So raw materials are placed in higher place using pallet.

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Table 2.2.1 Raw materials and their function Name Common Abbreviation N-N-Disulfidemorpholine Tetra ethyl thiurane Disulphide N-Cyclohexyl-2-benzothiazole sulfenamide Diphenyl Guanidene N-tertiary-butyl-2-benzothiazyl sulphenamide Hexamethylene tetramine 2,2,4-trimethyl-1,2-dihydroquinoline Deoflows HMT TDQ Accelerator Antioxidant Lubricant and dispersing agent BKF 2 Mercaptobenzimidazole Octylated diphenylamine Wingstay100 Naugard SP PEG4000 Bis[3 (triethoxysilyl)propy] tetra sulfide ``````````````````````````````````````````````````````````` Antilux Antiozonant Protect rubber articles against cracking cause by ozone weathering influence. HP669 MB2 ODPA Antioxidant Antioxidant Antioxidant Antioxidant Antioxidant Deactivation agent Coupling agent It improves reinforcing properties of filler Provide long term heat and ageing resistance Heat resistance when used in sulphurless vulcanisation Good efficiency against thermo boxidative ageing Improve ageing resistance Improve heat and ageing resistance Use when silica use as filler Medium accelerator Provide long term heat and ageing resistance Improves flow properties of elastomers CBS DPG TBBS Accelerator Accelerator Accelerator DTDM TETD Accelerator Accelerator Slow curing speed Fast curing ,Peaky cure curve Delayed action accelerator Slow to medium accerator Delayed action accelerator Type Properties

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Structol AW1 Coumarone resin Cotton flocks Silicate SiO2

Plasticizer Tackifier Filler Non black filler

Antistatic plasticizer mineral filled rubber Improve impact strength and dimensional stability Improve tear strength and resistance to chipping

China clay Carbon black ZnO Stearic acid Napthanic oil Paraffin wax Titanium Oxide Calcium Carbonate Sulphur Pre Vulcanisation Inhibitors Eco Viridis Rubber TiO2 CaCO3 S PVI EVR

Filler N375,N550,N774 FIiller Activator Activator Processing Aid Antiozonant Pigment Whiting Vulcanising agent Vulcanising agent Filler

Reduce cost, filler for colour products Improve hardness of product Activate accelerator Activate accelerator Help to disperse ingredients Help to disperse ingredients Mainly pigment To obtained low cost light colour articles Croslinking between rubber molecules Inhibit pre vulcanisation Reduce cost used as white action of action of

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2.2.2 Rubber mixing formulation preparation

Rubber batch is compounded according to formulation. Formulation is prepared according to final product and process requirement. This formulation is developed by R&D team. First they were carried out trial on lab mill. If that compounded batch gives required properties then they compounded batch in factory as a trial. In that step they concern about processing of batch in factory. If it is ok then they issue it for production.

Not ok Customer requirement R&D team prepare formulation Mix in lab mill Properties were tested Ok Prepare formulation for mix in mixer Mix in mixer Check processing and properties Ok

Not ok

Issue formulation for production

Figure 2.2.1 R&D process for new formulation. Most of time R&D team takes base formulation which they have and develop it for requirement. It was not mixed in lab mill. It was mixed in mixer directly and properties were checked.

2.2.3Preparation of formulation for mixing in internal mixer

Internal mixer cannot fill totally by rubber and ingredients. Free space is needed for mix. So formulation should recalculate for mix in internal mixer. Batch cost also calculated at the same time. Total volume of internal mixer = 210l Fill factor = 0.554

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Ingredients RSS Whole tyre reclaim HAF black Clay Pine tar ZnO Stearic acid Paraffine wax Vulkacit F TMT Vulkacit A Sulphur IPPD Vulcanox EC Total

Phr 65

S.G(g/cm) 0.92

Volume(cm) 70.65217

Kg 44.76

Cost per Kg(Rs) 400

Cost(Rs) 17903.47

70 15 40 3 5 1.2 1.25 1.3 0.2 0.5 2.4 0.6 0.6

1.1 1.8 2.5 1.08 5.6 0.85 0.9 1.2 1.38 1.2 2.1 1.1 1.14

63.63636 8.333333 16.0 2.777778 0.892857 1.411765 1.388889 1.083333 0.144928 0.416667 1.142857 0.545455 0.526316 168.9527

48.20 10.33 27.54 2.07 3.44 0.83 0.86 0.90 0.14 0.34 1.65 0.41 0.41 141.89

75 150 10 60 50 40 35 25 35 25 40 15 20

3615.12 1549.34 275.44 123.95 172.15 33.05 30.13 22.38 4.82 8.61 66.11 6.20 8.26 23819.02

Mix weight scale up factor = 210*0.554/168.9527 = 0.6885951 Material wastage % during mixing = 1% Actual weight of batch = 141.89*99/100 = 140.4711Kg Cost of 1Kg of batch =23819.02/140.5= Rs169.50 N0TE: Above formulation and prices of ingredients are not actual they are only for explanation.

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2.2.4 Machineries used for mixing Internal mixer

Elastomeric bokundara branch uses intermeshing internal mixer. The mixer was made in India. The mixer is fully integrated. It is programmed using PLC. The mixing procedure changes from compound to compound. Mixing procedure was entered to program for each compound type. Carbon black, china clay, whitening and oil feed automatically. Rubber and other chemicals are feed manually through feed door. The rotors of mixer run by DC motor. The motor speed can change. However the maximum speed of motor is 95rpm. If motor exceed this value it is stopped. There are 2 pump oil lubricating system for the motors. It is help to cool motor components. Usually mixing procedure controlled by time or temperature. End of the mixing cycle discharge door opens automatically and batch discharge on two roll mill. But compound is not always mixed properly at the end of mixing. So mixer operator observes the behavior of ram and decides the mixed level. By the experience mixer operator knows whether batch is mixed or not.

Figure: 2.2.2 Internal mixer

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In university we learnt about banbury mixers. But in Elastomeric bokundara factory uses intermeshing internal mixer while banbury uses in horana factory. Differences between these two types were observed during my training period.

Banbury has tangential rotor type.

Intermeshing internal mixer has intermeshing rotors.

Mixing occurs between rotors and the jacket in Banbury.

Mixing occurs between rotors, rotors and the Jacket, rotors and the ram, rotors and the discharging door.

Banbury use in high volume application. Easy to mix formulation in banbury. Banbury use in multiple mixing applications.

Internal mixer use in specialty rubber goods. Internal mixer use extreme quality applications. Internal mixer use in single step mixing applications. Internal mixer use in reactive mixing applications

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Elastomeric use fully integrated mixing process. There are 5 carbon bins, one china clay bin and one whitening bin. Whitening input N220 N375 N550 N762 N774 China clay input

Input

Carbon scale

Feed hopper Oil

Discharge door

Figure 2.2.3 Integrated mixing process of internal mixer

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Two roll mill

Mixing department has one two roll mill. It is wide about 2.0m. This mill is used for sheeting out batch which comes out from mixer. Mill was placed under the mixer. So discharging batch from mixer directly put on mill nip. Mill also used for adding sulphur to gasket compounds. This mill is single geared mill. In this mill the back roll is driven from the gearbox or backshaft, and the front roll from the back roll through roll end gears. Front roll can move forward and back. Clearance between two rolls is called nip. It can adjust by moving front roll. Nip can adjust from 1-14mm. This adjustment is carried out by electric motor. Speed of the back roll is higher than front roll. Front roll to back roll speed ratio is 1.0:1.2. Two roll mill is cooled by circulating chilled water. Guides are fitted the roll ends to prevent rubber being contaminated with grease etc. Cutting knives are provided under to rolls in front roll side to cut rubber. Width between knives is same to width of conveyer belt of batch off. Metal tray is provided under the two rolls. So ingredients which dropped on tray can collect easily and remix.

Figure2.2.4: Two roll mill

Batch off
Batch off was used to cool the sheeted compound. Batch off consist with tank consisting antitack solution and cooling fans. Sheeted batch from two roll mill is placed on conveyer belt of the batch off and it was started. Rubber sheet was went trough antitack solution and entered to fan area. In this area rubber sheet cooled and dried out. Rubber batch was taken out from end of batch off. Rubber batch was packed on pallet.

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Figure 2.2.5 Batch off

second floor

Chemical and material stores

Control room

ram feeder First stage compound stores

First floor

Rotor arrangement

DC Motor

Ground floor

Batch off Finished goods stores Two roll mill

Figure 2.2.6 Machinery layout Page 19

2.2.5Quality Control Tests for Rubber Compound

Quality control tests were carried out for fulfill following purpose. 1. Determine suitability of rubber compound for production. 2. Quality control purpose. 3. Research and development purpose.

The tests are essential in all phase of rubber industry and can be classified into two groups as bellows 1. Tests on raw rubber and raw materials. 2. Test on vulcanisate.

During my training following quality control tests were carried out for vulcanisates. 1. Moving Die Rheometer (MDR) test. 2. Hardness test. 3. Resilience test. 4. Specific gravity test 5. Tensile test 6. Dispersion analysation test.

Moving Die Rheometer test

Moving Die Rheometer was used to obtain rheographs for rubber compound. This is a testing equipment which analysis the cure characteristics of rubber compound. It helps to monitor processing characteristic as well as physical properties of material. In university ODR was used to obtain rgeographs for rubber compound

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Table 2.2.2 Comparisons between MDR & ODR Moving Die Rheometer Rotor less instrument. Thermal recovery is fast. The instrument has very high repeatability and reproducibility. Oscillation Disc Rheometer In here rotor placed in the middle of the dies oscillates. Rotor is connected to torque sensor to measure the torque. Test time required for complete curing of the sample is slightly greater than MDR When different kind of rubber are used blank test to clean the rotor is required. Limited to obtain repeatable results.

Die configuration of MDR Figure2.2.7 Die configurations Testing Procedure

Die configuration of ODR

Test piece was taken from compounded batch. It was warm up in lab two roll mill. Small square shape test piece was cut by using scissors. Batch data was entered to MDR software. Test piece was placed on lower die and test was started. Rheograph was drawn automatically and print was taken. Results Results were printed on sheet with graph. It gives ML- Minimum torque value

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MH- Maximum torque value ts2 - Scorch time tc90 Cure time TanD@tc90, Rh and tRh From above results can get idea of curing time and temperature of rubber item going to prepare from compounded batch. I had to consider above results for each batch before passing them for product

Figure 2.2.8: MDR 2000

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Hardness Test Hardness means the resistance to penetration to the hard surface of the rubber. Therefore it is determined by measuring the penetration of a rigid ball into rubber test piece under standard conditions. Various types of hardness testers are available. They are Dead Load Hardness tester, Shore Durometeres etc. But in my training place Shore A durometer was mainly used for test. Shore A Durometer These are more convenient for general use. It is a portable instrument and can be used for even odd shaped objects but frequent adjustments are necessary and personal errors are involved The indentor in shore A is frustoconical. Scale varies from 0 (Soft) to 100 (rigid). Readings with shore A nearly equal to International Rubber Hardness Degree (IRHD). The instrument consists of calibrated spring to provide the indenting force and the load indented by the spring varies with indentation. Values are subject to variation as the springs are liable to incorrect settings and indentors prone to wear or damages. Load application time also not carefully controlled and this can lead to error.

Figure 2.2.9 Shore A hardness meter Preparation of Hardness test piece Test piece was taken from compounded batch. It was warm up in lab mill. It was cut in long thin piece. It was rolled and placed in mould in lab press mill. Motor was started and up switch was pressed until mould plate compressed. Bumping was carried out. After curing buttons were taken and allowed to cool.

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Standard Procedure The rubber sample is placed on a hard horizontal surface and the durometer is held in vertical position with pointer at least 12mm away from any edge. The pressure foot of the indentor is then applied on the sample surface rapidly as possible without shock. Sufficient pressure is applied to obtain firm contact between press foot and sample. Final reading is taken after 15sec. There are difference between standard test procedure and practical procedure. Table 2.2.3Difference between standard procedure and practical procedure Standard Method Cured hardness buttons should keep at standard laboratory temperature for more than 16 hours before test carried out. Rubber sample should place in hard horizontal surface and durometer held in vertical position. Final reading is taken after 15sec. Rubber sample was taken to one hand and durometer was taken to other hand it was hold horizontal position. Reading is taken 5sec. Practical method Test carried out within 1 hour from curing

Specific gravity test Specific gravity of rubber compound was measured by using Archimedes principles. It is very important to find out weight need to fill mould. Densimeter was used to obtain specific gravity of rubber compound. S.G = M/V M = V*S.G Mould cavity volume is constant. So if S.G is greater than specification value blank weight should increase. If S.G value is less than specification value blank weight should decrease. Preparation of test piece It was prepared same as hardness test button but size is small than hardness buttons. Test Procedure - S.G button was first balance in air and then balance in distilled water. S.G value was taken from scale attached to densimeter

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. Figure 2.2.10: Densimeter Resilience Test This property of rubber is important to most of its uses. It shows the ability of rubber vulcanisate to retain energy used to deform it. There are various methods and instrument which are used for find out resilience. They are Bashore Rebound Resilience meter and Lupke pendulum. During my training I was used Lupke pendulum method. The property mathematically expressed as the percentage. Resilience = Energy return/Energy input*100% Resilience value can read as % directly from special scale attached to the instrument. Test procedure Hardness button was used for resilience test after hardness test. Hardness button was placed position shown as figure. Pendulum was released from higher position 3 times consequently. Finally pointer was set to 0 position and pendulum was released. After impact pointer stop at point on scale. Value regard to that point was taken as resilience value for button. There is difference between standard test procedure and practical procedure. This difference was observed during my training.

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Figure 2.2.11: Resilience meter Table 2.2.4 Difference between theoretical method and practical method Theoretical method Button should have smooth surface. Three rebound readings are noted and their median value is taken as the rebound resilience. To report rebound resilience the average rebound resilience values of two test piece should be considered Cured button should keep at standard laboratory temperature for more than 16 hours before test. Resilience test was carried out within 1 hour for cured button. Practical method Button is not 100% smooth. One rebound reading was taken as rebound resilience. Only one test piece was used for test from each batch.

Tensile test Rubber products are tested under tension to assess the product quality. Tensile strength and elongation at breaking point are determined. Different types of test pieces are used to determine tensile properties. In my training place dumb-bell test pieces were used for test. Also electronic transducer type tensile testing machine is employed for the determination.

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Preparation of test piece Rubber piece was taken from compounded batch. It was warmed up on lab roll mill. It was placed on table. Line was drawn on rubber sheet using compound pen shown as below.

Two test pieces were cut from this sheet. Dimensions of test pieces were suited to mould dimension. Test pieces were cut as follows.

Test pieces were cut as above to avoid grain effect. In one test piece rubber molecules stretch in line direction and other test piece molecules stretch in perpendicular to line. In master test piece rubber molecules line up-in line direction. Test pieces were put into press mould and cured. Procedure Cured test piece were kept at laboratory temperature for more than 16 hours. 4 dumb-bell test pieces were cut by using test piece cutter and cutting machine. Thickness of dumb bell test piece was measured using vernier caliper and it was entered to software. Test piece was inserted between grips of tensile test machine and test was started. 4 test pieces were tested as mentioned. Results and graph was printed on paper.

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Figure 2.2.12: Tensile testing machine Dispersion analysation test Dispersion analyzer was used to identify the perfect mix of material and doze to suit the end product. Since dispersion of carbon black in rubber is directly related to quality. It is important that the best possible dispersion be obtained. A visual photograph can easily pick up this poor dispersion of black in compound. Results depend on eye sight of person who carried out the test. Test piece should cut smoothly to get clear photograph and cut surface should not touch before testing. We can compare results with standard photograph. Mixing standardize according to dispersion rate. Visual Dispersion rating classification 9-10 Excellent 7-8 Good 5-6 Acceptable 3-4 Poor 1-2 Very poor This analyzer is connected to computer and operates via software.

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Figure2.2.13: Dispersion analyzer

2.2.6 Batch passing process for production

Batches which are compounded in mixing department have to send for tyre production. Mixing process can describe as follows.

Rubber and major materials Mixing formulation Chemicals

Mixing in mixer

Sheet out in mill

Ok Pass

Test for physical properties Not ok

Cooling in batch off

Hold

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3. Gasket production department

2.3.1 Gasket products
Many types of gaskets are manufacturing in elastomeric. Types of gaskets are M15B, CLIPPON, M10B, M20M, MX25B, J185, AK20 etc. They are named according to design. Gaskets are available in various lengths. They varied from 0.5m to 3.0m. They manufacture gaskets for Alfa Lavel, APV, GEA, Hisaka, API schmidt, Sondex, Swep, Trante etc. Acrylonitrile Butadiene Rubber (NBR), Ethylene propylene Diene Monomer (EPDM), Butyl rubber (IIR), Hydrogenated Nitrile (HNBR) and Fluorocarbon (FKM) are use for gasket manufacturing. Most of compounds are NBR and EPDM based. Every compound has number. EPDM 70804, 70806, 70807, 70812, 70814, 70816, 70817, 70824, 70826, 70829, 70840, 70903, 70910 NBR 63614, 63746 , 63811 , 63812, 63829 , 63830 , 63805 , 63815 Not only the material, but also the gasket types are varied according to the design & size of gaskets.

The designs of gaskets * Glued

* Clips

* Para clip

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* Diagonal

* Parallel

The sizes of gaskets Jumbo ( 3.5m) 3m 2m 1.5m 800*800mm Splicing (Length is varied according to requirement)

2 3

10 7

5 4 Length 6 Thickness

A rough drawing of a gasket

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2.3.2 Usage of gaskets

The gaskets are use in plate heat exchangers. A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids spread out over the plates. This facilitates the transfer of heat, and greatly increases the speed of the temperature change. Plate heat exchangers are now common and very small brazed versions are used in the hot-water sections of millions of combination boilers. The high heat transfer efficiency for such a small physical size has increased the domestic hot water (DHW) flow rate of combination boilers. The small plate heat exchanger has made a great impact in domestic heating and hot-water. Larger commercial versions use gaskets between the plates, smaller version tend to be brazed.

Figure 2.3.1 Plate heat exchanger

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The EPDM gaskets used in plate heat exchangers have Weather Resistant property & NBR gaskets have Oil Resistant property. Also NBR have heat resistant in different Temperatures (80C-800C). The gaskets of 63830 material of NBR can be used food applications such as Yogurt, Cheese, Souse, Bear and Milk Temperature 90C). Also the gaskets of 70840 & 70817 materials of EPDM are used to food applications.

2.3.3 Gasket production process

Deal with GGAB Receive compound from GGAB Not ok Inspection Ok Stores Deal with GGAB Expired CPD Ok Transport to extrusion Cutting according to required length Extruding Ok Inspection CPD strip cutting Compound mix in ETEC Not ok Inspection

Not ok Deal with control of NCP

Ok Blank stacking Transport to moulding Moulding In process inspection & correction Ok

Not ok Inspection

Transport to FGS Not ok

Bundling

Post curing

Transport to post curing

Sample inspection Ok

Handling through NCR

Packing &Final inspection

Labeling

Dispatch

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2.3.4 Blanking
Blanks are made by extruding. Elastomeric has 3 extruders. All the extruders are cold feed extruders. Final black is long cylindrical rubber piece. Dimension of blank are diameter, length and weight. Blank dimension varies according to gasket type. Table is given to operators which has dimension of blank according to gasket type. Blank dimension can controlled by changing die diameter, Extruder speed, conveyor speed, cooling temperature, traveling time and traveling speed. These details are available to operator as chart.

2.3.5 Extrusion method

Blank of the gasket is getting by extrusion. Extrusion method is cold extrusion. Cooling system is water cooling. Required dies are manufactured in tool shop. There three extruder machines. All machines are pin type extruder machines. Specific extrusion temperature is available for each specific rubber compound. Weight of the blank is control by the speed of the belt and ram. If blank weight is not up to required weight they are reprocess with new compound.

Figure 2.3.2 Extruder 1

2.3.6 Moulding and post curing

Gasket moulds are prepared in tool shop. Tool shop use CNC machines for that. Gasket drawing is given by customer. There are more than 60 presses in whole factory. 40% of gasket cures in press balance 60% complete in oven. It is called post curing. Compression moulding is used in gasket press. Post curing is done in nitrogen or oxygen media. It is select according to customer requirement.

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2.3.7 Quality Inspection

Gaskets are checked before packing. In inspection the gasket that has major defects are totally rejected. Major defects are as follows. 1. Broken T Causes Carelessness of worker Remedies Training workers for gasket remove. Apply mould releasing agent properly.

2. Curing mark

3. Short moulding This occurs when the compound is not enough. Training should be given to workers.

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4. Tearing

Causes Increasing mould temperature. The lack of training The reduction of ability to remove spew.

5. Air trap

6. Spew at mould

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7. Dirty mark

Figure 2.3.3 Mould defects

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4. Observations at the organization

2.4.1 Fire protection and prevention procedures

Elastomeric has prior experience in fire. So they have good fire protection system now. Fire sensors are placed in many places. Company is well equipped with fire extinguishers. They have proper plan to work out if fire occurs. Training is given how to act when fire occurs to all employees. Special firefighting training is given to selected workers from every shift. According to the plan everyone has place to go and stand in front of the factory. Fire evacuation plan is drawn and published in many places. Sometimes fire alarm is activated to check whether employees work according to plan. I had two experiences after I came here. Following chart is displayed where fire extinguishers placed.

Figure 2.4.1 Fire extinguisher chart.

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2.4.2 Quality standard systems

Elastomeric has got ISO: 9001 quality management certificate and ISO: 14001 environmental management certificate. They organize workshop to give knowledge to workers about these standards. 5 S system is launched every department in elastomeric. 5 S Posters are displayed everywhere in the factory to educate workers about it. Workers are encouraged to follow it. Workers are well aware about KAIZAN. Workers are given many Kaizan ideas. Company has given price for every valuable kaizan.

2.4.3 Safety procedures

Every worker in elastomeric has safety shoes, gloves and dust mask. Special dust mask is given to chemical weigh men. Accidents are minimized within the factory premises. Mill operators have special procedures to work out before starting work.

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5. Projects.
1. Comparison between EVR and DVR on tread compound.
Procedure: Two rubber pieces of same mass was obtained from first stage batch. Required amount of EVR and DVR were measured to paper plates separately by using lab scale. Two set of other chemical ingredients were measured to metal cup separately by using lab scale. One rubber piece was cut into small pieces. These pieces were added lab two roll mill one by one. Then allowed to form band around front roll of mill. Mill was operated until band become soft smooth and well grip on front roll. Then half of EVR was added between nip of the roll and allowed to mix. Then remain half of EVR also added and mixed until band surface become free from EVR. Band was cut many times using mill knife for better mixing. Then one set of measured chemicals were added between nip of the rolls and allowed to mix. Again band was cut by using mill knife and rolled for better mixing. Then allowed to form band with smooth surface. Compounded rubber band was removed from mill. Hardness buttons, abrasion test piece and tensile test piece were prepared. Same procedure was carried out for other rubber piece and DVR was used except EVR. Results were compared.

Table 2.5.1 Physical properties comparison of EVR and DVR EVR MH (dNm) ts2 (m:s) tc90 (m:s) Hardness ( Shore A) Resilience (%) Force @ 300% elongation Maximum force 11.64 1.19 2.27 53 41 8.793 18.216 9.89 1.22 2.29 58 41 7.632 13.867 DVR

See Annexes & Appendices for MDR & tensile result sheet.

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2. Trial was carried out to observe behavior of physical properties upon EVR1000. Chemicals were weighed for 2 trials. One formulation consist 36g ( 20Phr) of EVR and other 54g (30Phr) of EVR. Same vulcanising system was used for both of them. Binary accelerator system was used. DPG and TBBS were used. TBBS was used as primary accelerator and DPG was used as secondary accelerator. Table 2.5.2 Physical properties comparison for two systems EVR 20Phr Hardness (Shore A) Resilience (%) S.G MH (dNm) ts2 (m:s) tc90 (m:s) Maximum force (MPa) Extension @ break (%) Modulus (MPa) 71 46 1.23 24.06 0.28 1.21 16.704 341.6 14.821 EVR 30Phr 73 48 1.23 25.20 0.26 1.16 15.98 313.9 15.408

See Annexes & Appendices for MDR & tensile result sheet. 3. Colour compound was compounded on lab mill. SBR rubber was masticated. Then deactivation agent is added to rubber. Silica was used as filler. Because of bound water layer around silica particles curing time increases. It was due to H bond formation between water layer and N atoms of accelerators. Deactivation agent was used to avoid that. Coupling agent was added to silica before adding it to rubber. Coupling agent has both hydrophilic and hydrophobic part. So these chemicals couple the silica particles and the rubber molecules respectively. This helps unioform filler dispersion. China clay also used as filler. Whitening also used as filler. Titanium oxide was used to get light colour. Mill was not cleaned before starting the mixing because of that light black colour was appeared in some areas of rubber sheet. Colouring agent was added before adding vulcanising system. Test pieces were prepared and results were taken. Table 2.5.3 Results Hardness (Shore A) Resilience (%) tc90 (m:s) ts2 (m:s) 62 46 2.25 1.23

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Maximum force (MPa) Extension @ break (%) Modulus @ 300% elongation (MPa)

9.333 441 5.743

See Annexes & Appendices for MDR & tensile result sheet.

Resilience was not up to required % value. So to increase resilience NR (FAB) and BR was introduced to previous day formulation rather than using SBR alone while other chemicals remain same Phr value. SBR has lower level of unsaturation so longer cure time is needed. Resilience also lowers due to lack of bonds. But NR and BR has unsaturation so it helps to reduce cure time and as well to increase resilience. Lab mill was cleaned before start mixing. Other chemicals were added as same as previous day. Test pieces were prepared and results were taken. Table2.5.4 Results Hardness ( Shore A) Resilience (%) tc90 (m:s) ts2 (m:s) Maximum force (MPa) Extension @ break (%) Modulus @ 300% elongation (MPa) 61 56 1.47 0.59 7.5 340.9 6.29

See Annexes & Appendices for MDR & tensile result sheet. SBR was totally removed from formulation. BR and FAB were used while other chemicals at same Phr value. Test pieces were prepared and results were taken. Table2.5.5 Results Hardness ( Shore A) Resilience (%) tc90 (m:s) ts2 (m:s) Maximum force (MPa) Extension @ break (%) Modulus @ 300% elongation (MPa) 65 53 1.17 0.46 10.23 390.4 7.19

See Annexes & Appendices for MDR & tensile result sheet.

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Finally BR also removed from formulation and rubberplast reclaimed was introduced. Other chemicals remain at same Phr value. Test pieces were prepared and results were taken. Table2.5.6 Results Hardness ( Shore A) Resilience (%) tc90 (m:s) ts2 (m:s) Maximum force (MPa) Extension @ break (%) Modulus @ 300% elongation (MPa) 65 55 1.08 0.43 11.67 359.8 8.97

See Annexes & Appendices for MDR & tensile result sheet 4. Compare old and new antioxidant and antiozonant New antioxidant and antiozonant samples were sent by supplier to us. It was needed to check there quality. There was raw material testing formulation. I had to compound rubber sample for antioxidant and antiozonant separately according to that formulation on lab mill. Compound rubber batch for antioxidant First I had to decide to compound mass. I was decided to compound 1Kg of master batch. Mater batch consisted RSS rubber, koshyn, ZnO, PEG4000, Silica filler, stearic acid, coumarone resin and PVI. Calculation was carried out to find out quantity needed from each of above chemical. Then master batch was compounded on lab mill. Mass of compounded batch was measured. It was separated to two pieces. According to mass of piece other chemicals were measured separately. Other chemicals are DPG and sulphur. Same mass of old and new TDQ (antioxidant) were weighed separately. Then for one piece of mater batch was taken and old TDQ was added. Finally DPG and sulphur were added and mixed. Then other piece of master batch was taken and new TDQ was added and mixed. Finally sulphur and DPG were added and mixed. Hardness buttons, S.G buttons and 2 set of tensile test pieces were prepared from each compounded batches (new and old TDQ).

Compound rubber batch for antiozonant Same procedure was followed as above. Old and new 6PPD was used except old and new TDQ. Hardness buttons,S.G buttons and 2 set of tensile test pieces were prepared. Page 43

Another batch was compounded same as above. But antioxidant or antiozonant were not used. Test pieces were prepared same as above. Dumbbell shape tensile test pieces were cut from each tensile set. Tensile test was carried out for one tensile set after 16 hours of preparation from each batch. Other test pieces were placed inside oven at 70C for 1 week. After one week test pieces were taken out from oven and kept more than 16 hours at room temperature. Then tensile test were carried out for each set. This was done to find out ageing of each sample Table 2.5.7 Results Normal Hardness(Shore A) Resilience (%) S.G 54 67 1.05 Old TMQ 56 69 1.05 New TMQ 56 70 1.05 Old 6PPD 54 70 1.05 New 6PPD 54 68 1.05

Table 2.5.8 Ageing

Chemical

Tensile strength

Tensile strength

Ageing

Age Resistance

Before ageing(Mpa) after ageing(Mpa) NORMAL TMQ(OLD) TMQ(NEW) 6PPD(OLD) 6PPD(NEW) 20.49 21.61 22.00 24.52 21.29 18.037 21.28 21.86 22.13 21.45 11.97 1.53 0.64 9.75 0.75

0.08 0.65 1.57 0.10 1.33

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Antiozonat test To check the action of antiozonant we have to use ozone chamber. But it was not available in here. Another practical method was used to check it. Aged dumb bell shape test pieces were stretched and set on wood surface using nails. Every test pieces were stretched to same length. Dumb bell shape test pieces were prepared from normal batch also stretched to same length and placed on same wood surface. Then it was placed outside the factory. After that it was checked daily. Test pieces were aged one week. (05/06/12 12/06/12) Antiozonant test was started on 19/06/12 Normal test pieces were broken within one week. Table 2.5.9 Antiozonat test observation

Date 27/06/12 29/06/12 04/07/12 06/07/12 11/07/12

Observation One test piece was broken from new TMQ. One test piece was broken from old TMQ. Another old TMQ and new TMQ test pieces were broken. Last test piece from new TMQ was broken. One test piece from new 6PPDwas broken More fractures were observed in last old TMQ test piece.

13/07/12 16/07/12

Another test piece from new 6PPD was broken. Last test piece from new 6PPD was broken. Last test piece from old TMQ was broken. Cracks were observed in old 6PPD.

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19/07/12 20/07/12 23/07/12

One test piece from old 6PPD was broken. More cracks were observed in other test pieces of old 6PPD Last two test pieces from old 6PPD were broken.

5 Heat resistance color batch compounded. EPDM 512*50 rubber was used compound heat resistance color batch. This rubber contain 50 parts of paraffinic oil. Due to this reason we do not need to add oil as softner. This rubber also can accept higher filler loading. EPDM rubber was masticated easily and stick to mill surface. SI 69 was used as coupling agent. It was added to silica before adding silica to compound. Also it improves tensile strength, reduce compression set and improve abrasion resistance. Deoflows were added to improve processing. Vulkadur RB also added with silica. TDQ was added to improve age resistance.MB2 was used as secondary antioxidant and antiozonant. HMT was used and it was cross linked with rubber. MBT was used as accelerator. Finally colouring agent was used to colour the batch. In second trial silica Phr level was reduced and SI69 Phr level increased. CBS was used rather than MBT. Test pieces were prepared for both trials. Physical tests were carried out. Compression test buttons were prepared using mould. Table 2.5.10 Results MH (dNm) Trial1 20.29 Trial2 10.24 ts2 (m:s) 2:21 1:11 tc90 (m:s) 20:23 6:35 Hardness (ShoreA) 78 65 Resilience (%) 51 55 tensile strength(Mpa) 11.643 11.705 Elongation at break (%) 458.6 416.6 Modulus (Mpa) 6.872 7.539

Table 2.5.11 Compression set. Test No Trial1 1 2 3 Trial2 1 2 3 Thickness before(mm) 12.31 12.33 12.21 12.5 12.59 13.08 Spacer Thickness(mm) 9.60 9.60 9.60 9.60 9.60 9.60 Thickness after(mm) 11.7 11.6 11.6 11.77 11.75 12.08 Compression set(%) 22.51 26.74 23.37 25.17 28.09 28.74

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6 Heat resistant black compound EPDM rubber was used. N375 carbon black was used as filler. Higher loading of N375 consist in 1st formulation. It was bit difficult to mix large amount of carbon black at once. So it was added several times as small quantity. Carbon black which was dropped on tray was collected and put on rubber sheet. TDQ and some amount of deoflows were added to rubber sheet before adding carbon black. Rest of deoflows and stearic acids were added to compound by time to time. Deoflows were added to compound to give good flow properties. It behaves as lubricant and dispersing agent. TDQ was ammine type antioxidant and it provides long term heat and ageing resistance. Active carbon black was added to give conductive properties to compound. Finally ZnO was added. This master batch was divided to two parts. Then one part was compounded using efficient vulcanizing system and other part was compounded using semi efficient vulcanizing system. . Hardness was too high in this batch. Because of that new batch was compounded for new formulation. In this formulation lesser amount of N375 was used while other chemicals remain at same Phr levels. Table 2.5.12 Results Compound 1 E.V.S MH(dNm) 29.06 Hardness (ShoreA) 91 Resilience(%) 29 S.G 1.17 tc90 (m:s) 2:05 Compound 2 S.E.V.S 31.01 91 29 1.17 2:15 21.21 83 31 1.14 2:11

See annex and appendices for test results. 7 Antistatic tread was compounded Bach was compounded for antistatic tread on lab mill. SLR20 was used as rubber in 1st formulation. Structol A60 was used as processing aid. It starts to be effective in the lower temperature range of compounding and cab be used for mastication in a separate stage as well for single stage mixing. It can be used in all type of rubber. It helps to rapid incorporation of filler. Not affect to hardness of vulcanizate. N375 carbon was used as filler. Silica also used as filler. Napthanic oil also added. It helps to disperse higher filler loading. Coumarone resin also added. It behaves as processing aid. TDQ was used as antioxidant. ZnO and stearic acid were used as activator. Deoflows were added in 2nd stage to give good flow property to compound. Active carbon was added to give conductive property to final product. Pet jelly was added as dispersing agent. Finally vulcanizing system was added. Test pieces were prepared and tested. Hardness and resilience were not up to required level. So new batch was compounded for new formulation. In this formulation FAB and BR also introduce with SLR20. Page 47

Napthanic oil was removed while other chemicals remain same as 1st formulation. N375 carbon Phr level increased. Test pieces were prepared and tested. Table 2.5.13 Results. Compound 1 Hardness (Shore A) Resilience (%) S.G Tensile strength( Mpa) Tc90 (m:s) 57 30 1.11 8.34 2:12 Compound 2 67 36 1.13 13.61 2:11

8 Batches were compounded using different Phr levels for different type of carbon. Batches were compounded according to ASTM D 3192 formulation. One batch is compounded without using carbon black. Phr RSS Carbon black ZnO Stearic acid S TBBS 100.0 50.0 5.00 3.00 2.50 0.6

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Table 2.5.14 Results Without filler Phr level Hardness(Shore A) Resilience (%) S.G Ts2 Tc90 Tensile(Mpa) Elongation at break 0 41 74 0.95 0:44 1:17 10.76 640 30 61 65 1.08 0:34 1:28 23.34 448.2 50 73 50 1.13 0:31 1:40 21.66 344.1 N375 60 79 44 1.16 0:31 1:40 18:15 242.2 N550 50 71 61 1.14 0:31 1;40 20.00 331.2

9 Work study report Senior management asked to remove extra workers. But production executive tell there is no evidence to remove any body because all of them have certain work to do. To prove this work study was carried out. Production executive told me to carry out it. I was carried out it. It was difficult task for me because I had to follow all the workers within short time period. Whole day I had to stay in factory. I had to follow it in secret way without telling my work to others. If they know my work they can misunderstand it. Following report was prepared.

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Table 2.5.15 Work study report TIME INTERVALS 8.00a.m-8.30a.m A Internal mixer was operated. B Empty pallets were collected and sent to ground floor. C

Work study report D Chemicals were weighed. E Mill was operated. F Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batch was set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet.

8.30a.m-9.00a.m

Internal mixer was operated. Internal mixer was operated for B-80 first stage. Internal mixer was operated.

Weighed batches were carried to internal mixer area. Rubber was weighed for B-112. FAB was weighed Silica were weighed. for B-112. Reclaimed rubber was weighed for B-112. Oils were weighed. Buffing dust were weighed

Chemicals were weighed. Chemicals were weighed.

Mill was operated. Mill was operated.

9.00a.m-9.30a.m

10.15a.m10.45a.m

Pallets were collected.

Chemicals were weighed.

Mill was operated

10.45a.m11.15a.m

Internal mixer was operated.

Oils were weighed.

Buffing dust lot was carried to floor. EVR was weighed. Reclaimed rubber sheets were separated. Help to internal mixer operator to add rubber to mixer. Weighed for trial batch. Material weighing and store areas were swept.

Chemicals were weighed.

Mill was operated.

11.15a.m11.45a.m

Internal mixer was operated.

Reclaimed rubber was weighed.

Chemicals were weighed.

Mill was operated.

1.15p.m-1.45p.m

Internal mixer was operated.

Material weighing and store areas were swept.

Chemicals were weighed.

Mill was operated.

Batches were taken out from batch off and batches were set on pallet.

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TIME INTERVALS 2.00p.m-2.30p.m

A Internal mixer was operated.

B Code rubber was weighed.

E Mill was operated

F Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet. Batches were taken out from batch off and batches were set on pallet.

Buffing dust case was Chemicals were carried out. weighed.

2.30p.m-3.00p.m

Internal mixer was operated.

Rubber was weighed.

PR oil tank was filled.

Chemicals were weighed.

Mill was operated.

3.00p.m-3.30p.m

Internal mixer was operated.

3.30p.m-4.00p.m

Internal mixer was operated.

4.00p.m-4.30p.m

Internal mixer was operated.

Adhered rubber codes were separated and cut using bale cutter. New oil barrel was adjusted for oil weighing with help of others. Weighed rubber was carried to mixer.

Adhered rubber codes were separated and cut using bale cutter. Rubber code was weighed and bale cutter was used to cut. Code was weighed.

Chemicals were weighed.

Mill was operated.

Chemicals were weighed.

Mill was operated.

Chemicals were weighed.

Mill was operated.

A- Internal mixer operator B- Weigh man 1 C- Weigh man 2 D- Chemicals weigh man E- Two roll mill operator F- Batch off operator

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10 HOLD BATCH ANALYSATION Hold batch analysation was carried out for last 5 months. Data was collected from company batch reports and OEE. Table 2.5.16 Summary of hold batches

PERIOD :01/01/2012-31/05/2012 MONTH JAN FEB MAR APR MAY TOTAL BATCH MIXED 1887 1673 1991 979 1140 7670 HOLD 101 83 88 35 52 359 HOLD% 5.35 4.96 4.42 3.58 4.56 4.68

Table 2.5.17 Summary of hold batches Batch type B-01 B-04 B-08 B-09 B-12 B-70 B-80 B-83 B-111 B-112 A-02 OTHER Total Total hold Total mixed HOLD% L/H TOTALH/H 35 31 14 4 17 13 31 45 14 7 0 14 5 5 1 6 7 0 0 8 3 2 9 9 136 144 TOTAL L/TC90 H/TC90 0 6 0 0 0 0 0 3 14 0 0 0 5 2 0 0 0 7 0 1 0 3 7 5 26 27 SCORCH 1 1 0 1 0 2 3 0 10 0 1 2 21 OTHER 0 0 1 0 1 0 3 0 0 0 0 0 5 Hold 73 19 31 80 36 16 23 7 24 9 9 32 359 359 7670 4.68 C.hold% 20.33 5.29 8.64 22.28 10.03 4.46 6.41 1.95 6.69 2.51 2.51 8.91 100 mixed 1231 190 288 1358 976 239 451 167 279 296 617 432 Hold% 5.93 10.00 10.76 5.89 3.69 6.69 5.10 4.19 8.60 3.04 1.46 7.41

37.

40.1

7.24

7.52

5.85

1.39

See annexes and appendices for graphs.

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Chapter 3 1. Conclusion
It is great pleasure to me spent 6 months at Elastomeric technologies (Pvt) ltd as trainee. I spent my time in various section of the plant. I received valuable training in here. I studied lot of theories in university about polymer production process which were never seen. So only I had picture about process in my mind but when I came here I observed that the picture which was in my mind is not correct. Training which was received to me enhance my practical knowledge as well theoretical knowledge. I had to communicate with people who are in different work levels. So it was enable me to gain vast experience in life. Because I had to face different work cultures and disciplines. Within my training I was understood what industrial world is. I was never exposed to industrial world before my training period. From very first day I had to face new environment which was never seen before. I was the only trainee from our university to elastomeric. I think it is better because it encourage me to do work myself. So I have to face every difficulty without others. I learnt lot by it. I got lot of knowledge in R & D side. During my training I got experience in w0orkers handling. Workers are come from different cultures and different life standards so their attitudes are different. I observed workers attitudes about working environment. I think I got excellent training at elastomeric technologies (pvt) ltd. For improve in-house training it is my suggestion to organize seminars for trainees during training period. So trainees can solve their matters. They can cover the area which they not covered. Seminar should be organized 2 month times from the beginning of training. Final week of the training period should provide for preparation of report. NAITA should allocate money to pay allowance for trainees who need it. Work shop should arrange before starting training. In this work shop safety precautions and other industrially valuable things should provide to trainees. I got more training on production processes but I did not have much knowledge about cost management. If I got that knowledge it will be benefited me in future.

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Annexes & appendices.

6.00

Batch hold % VS Month

5.00

4.00 HOLD %

3.00

2.00

1.00

0.00 JAN FEB MAR APR MAY MONTH

Hold% Vs Reason
45.00 40.00 35.00 30.00 25.00 20.00 15.00 10.00 5.00 0.00 L/H H/H L/TC90 H/TC90 SCORCH OTHER Reason for hold L/H H/H L/TC90 H/TC90 SCORCH OTHER

Hold%

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25.00

Contribution to hold% Vs Batch type

B-01 B-04 B-08

20.00

15.00

B-09 B-12 B-70 B-80 B-83

Hold %
10.00 5.00

B-111 B-112

0.00 Batch type

A-02 OTHER

12.00 10.00 8.00

Hold % Vs Batch type

B-01 B-04 B-08 B-09 B-12 B-70 B-80 B-83 B-111 B-112 A-02 OTHER

Hold %

6.00 4.00 2.00 0.00 B-01 B-04 B-08 B-09 B-12 B-70 B-80 Batch type B-83 B-111 B-112 A-02 OTHER

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CERTIFICATION

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