SMART RECOGNITION AND CONTROL OF CALENDERING SCRAP

Albherd Ramadhan Putra

21952017 - Engineering Management
Master of Mechanical Engineering – Swiss German University
 01 Introduction
Presentation

02 System in Thesis

New System by
03
Digitalization
 INTRODUCTION SYSTEM DIGITALIZATION

Calendering a process to calendering nylon with compound

sheet.

Figure 3 Rubber Compound Sheet Figure 4 Nylon

Source : http://www.sanjung.com.tw/en/product/tirecords Source : https://www.csicalendering.com/rubber/

Figure 5 Rubber Coated Cord (Treatment)

Source : http://www.sanjung.com.tw/en/product/tirecords
 INTRODUCTION SYSTEM DIGITALIZATION

System in Thesis
Input : Scrap of Topping Process :
Calendering Process 1. Scrap Collecting = owner process (calendering
section) & next process (cutting section) collect data of
scrap treatment.
2. Scrap Stratification = classifying scrap according
limit sample and manufacturing standard
3. Check daily production report / quality records.
4. Focus to one problem (largest or achievable)
5. Observe the 4M factors of problem.
6. Propose action to decrease the factor of problem.

FMEA
Figure 6 Scrap of Topping Calendering Process

Figure 7 Processing Data

 INTRODUCTION SYSTEM DIGITALIZATION

System in Thesis (continue)

Output : Reccomended Action Boundaries

1. Correction This research is only conduct in Calendering

2. Corrective Action (Visualization of Work Process of a Leading Bias Tyre
Guidance / process parameter change Manufacturer at Indonesia.
/ maintenance schedule change )
 INTRODUCTION SYSTEM DIGITALIZATION

Calendering Scrap Collection

Collected in Next Process

Collected in Topping Calender
(Bias Cutting)

Cut the defect Rubber Coated
Cord (treatment)
Before it get into liner.
Scrap is written in scrap
checksheet
After the defect rubber coated
cord (treatment) is selected by
bias cutting operator.

Figure 8 General Flow Process Collecting Calendering Scrap

 INTRODUCTION SYSTEM DIGITALIZATION

FLOW PROCESS TOPPING CALENDER

INPUT : OUTPUT :
Compound Milling
1. Production 1. Objective
schedule achieved
2. Process & 2. Customer
Product Wind Satisfied
Calendering Cooling
Requirement Up 3. Treatment
3. Customer comply with
Requirement standard
Treatment
4. Minimum
Nylon Let Off Splicing Drying
scrap

Figure 9. Process Flow Chart

 INTRODUCTION SYSTEM DIGITALIZATION

SMART RECOGNITION AND CONTROL OF

CALENDERING SCRAP
Description :
Calendering defect / scrap data collection system using cameras and
programming algorithms and a wireless connection to the database. The camera
can scan scrap in treatment, move the actuator to mark scrap area, enter scrap
data to the database, analyze the causes of scrap based on historical data (big
data), and adjust the parameters of the calendar process that cause scrap.

New System Purpose :

1. Increase speed of scrap detection.
2. Increase Speed of the flow of information related to existing scrap, and
prevent temporary repetitive scrap (correction).
3. Reducing data entry jobs.
4. Transferring human resources who previously served as scrap collectors and
data entry to areas where production lacks human resources.
INTRODUCTION SYSTEM DIGITALIZATION

Quality Function Deployment

Most Important
 INTRODUCTION SYSTEM DIGITALIZATION

System Architecture Modelling : Mind Map

Scan
Scrap Definition
scorch Treatment
Product Information
Camera Database
Nylon split
Big Data Scrap Causes
Recognition
Over side
gum Thickness

Width
Less press Smart Calendering
Scrap Scrap Recognition Dimension of
calendering Type
and Control Quality Product Ends cord
Folded
treatment Appearance
Controlling Process of
Foreign Calendering
Crossing cord Cord splicing
material
Process Parameter
in Calender Compound milling
Exposed cord
air blister
Calendering
Cold
compound temperature tension line speed Wind up brake
Winding up

Calender roll Cooling drum Cold Feed Extruder

Figure 9. Research Mind Map

 INTRODUCTION SYSTEM DIGITALIZATION

System Architecture Modelling : IDEF1

Scrap database

Scrap causes Controlling Illustration

Treatment
Scanning database

Process Parameter and

scrap product specification
Searching database
Camera / Scanner

Scrap
Processor /
Causes Correction
Computer Controlling

Scanning Illustration Searching Illustration Actuator

 INTRODUCTION SYSTEM DIGITALIZATION

System Development Methodology : Waterfall

Requirements The stage of gathering information related to the smart scrap recognition and
Definition control program through discussion.

System and Algorithm, system and application design stage to translate the required
Software Design requirements.

Development Program code development phase based on design.

Implementation The stage of combining software with hardware

and Testing

Deployment The system deployment stage to all machines.

Operation and The software stage has been used

Maintenance including maintenance.
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