Chapt

erIII

TechnicalAspec toftheInt ernship

Whatmakeso uri nt
ernshippr ac ti
ceatEt hioplasticindus t
ryt echnicalist hatmo stofcourses
wet ookfo rthepas t4y ear sex is
ti nt hefac tory.Fo rinstanceal lthemac hineswo rkont he
basisofhi g
ht emper ature( heat )whi chwehav elearnedab outonTher mo dynami csandheat
transferandwec analsoment iont heaut omat icrawmat eri
al( i
nt hi
sc asepo l
yethyleneresi
ns)
feederwhi chispl antedo nt heho pper so ftheb lowinjectionmac inethefi lmb lo
wingmac hines
whichwehad anawar enes so nt hec oursesIndus trialAut omat i
onand Mat erialhandling
techniquesundert het o
pic“Aux il
iaryequi pment s”.Andal sowehav es eenho ws crewconveyor
workb ot
hi nb low mold mac hineand i nj ecti
on mac ahine,which wel earned i n materi
al
handlingc ourse.And obvious l
yQual ityc ontrolactiv
iti
eswhi chwehadl earnedab outonQual i
ty
manag ement,Was te eli
mi nat i
ono nt he c o
urse Manufac t
uring 2.In Gener al,we had
experiencedont herealwo rldal mostev erythingwel earnedi nt heuniversity.

Objec
tivesoft heInter
ns hip
Asweunder standthet ec hni
calobject
iveoftheinter
ns hi
pistol
inkthetheoret
icalknowl
edge
thatweg r
asped int heuni ver
sityand thepr oducti
o nsys
tem inther ealwo rl
ds othat
experi
enc ed and wel l qual ifi
ed Pr oduc
tion Engineerscan b ec r
eated t ol ead the
manufac turingfirmofo urcountry.

Methodsandprocedureswhi
lewor
king
Observat
ionwasmyfi r
stwayo fl ear
ningand adapt i
ngt hewo rki
ngenv i
ro nmento fEt hio
plasti
cindus
try Forthefirs
tfourweekswedi dn’ttrytoex ecut
eanyki ndo ftechni
calt ask
becausewespentmo r
et i
meo nobservi
ngho ws
enioroperatorsdotheirjobs
.S tarti
ngfromt he
secondmo nt
hwewer eworki
ngasanas s
ist
antoperat
orwi t
has enioroperat
or .Oncewes t
ar ted
toadaptt heworkingenvir
onmentwemanag edt otaker esponsi
b i
li
ti
esandt echnic
alt asks
suchasquali
tycontro
lli
ngusingt
hei nst
ruments,c
orepreparationandetc etera

Ing
ener
alo
urmet
hodswer
eob
ser
ving
,as
sis
tingandwo
rki
ngt
oget
her
.

Tec
hni
calt
asks
/pr
oduc
ts

Mi
li
tar
ybo
ttl
esmaki
ngo
per
ati
on

Therear emanyb l
owmo l
dmac hi
neinthei nject
ionmo l
dfac tory,
oneo fthemus edtoextrude
bottl
esc ontinuousl
ywithsingl
ec ommandfr o moper at
or .
thesemac hinec anper fo
rmi t'
st as
k
withhi g
hqual i
ty.Dur i
ngo urinterns
hips tayatt hec ompanyweo ftenper formedo nthese
mac hine.Theb l
owmo l
dingmac hineconsi
stso fmainmac hine,electri
cs ystem,hydrauli
csystem,
pipeli
neando theropti
onalitems.Themai nmac hineinc ludesextrus i
o ndevic
e,ac c
umul ato
r
head,c l
ampi nguni t
,mac hinefr ame,b ottomb lowingdev ic
e( opt i
o nal)and mani pulato
r
(optio
nal ),etc.
Theel ectri
cs ys t
em i ncl
udest heheat ingandt emperatur econtrolsys tem ofdi eheadand
extruder ,par iso
nc ontrols ystem ( optional),PLCand s afe-guardingr elated system.The
hydr auli
csys tem includeshydr auli
cs uppl yando t
herc ontrolpartswhi chr elat
et opr essure,
directio
nandfl ow.Thepi pel i
nepar t,ino therwo rds,thedi stri
buti
ono fmac hinepi peswhi ch
containso i
l,wat erand ai rpi pes
.Thes hapi ngpr i
ncipleisfr om ex t
r udingt ob lo
wi ng .The
extruderus esi nvertertoadj ustthes peedt og etag reats peedr angei no rdertos at i
s fyt he
produc i
ng r equirement sfo r differentpr oduc t
s.Firsto f all
,t he mel t
ed pl asti
c whi ch
plastic
izedb yt heex truderwi llextrudei ntot heac cumulat orhead.Wheni treachesac ertain
volume,t hepar i
sonc ontroll
er( optional )willconstantl
yc hang etheo peni ngrang eoft hedi e.
And t hen iti si njected intomo uld and b lown outt hepr o
duc t
s.Fi nal l
yt hemani pul ator
(optional)willtaket heproduc to ut.Thusac ompletecir
c l
efi ni
shed

*****************

Bagmaki
ngoper
ati
ons
Therear etwob agmakingmac hinesi nt hepr oducti
onr oo
m.Eac hmac hinec anper for
mo nthe
samet askswithhighqual i
ty.Dur ingmyInt ernshipstayatt hec ompanyIo ftenper formedo n
thesemac hi
nes.Asthenamei mpliest hemac hinesar eusedt oproduc epo lybag s.
Firsttheb l
own-fil
m ex trusionpr o cess,smal lplast
icpellets(po lyethylener esins)aremel ted
downunderc ontr
olled condit i
onss ot hatt heyb ecomemo l
tenand pl iable.Theyar et hen
pressed( ex
truded)t hroughac irculardi eg apt oform ac ontinuo ust ubeo fpl as t
ic.Whileiti
s
sti
llinthismo l
tenstate,t hetub ei spinc hedo ffato neendandt heni nflatedands tr
etched
tot hesize(inmi l
li
met resmm)andt hicknes s( i
nmi cromet resµm)o ft hedes i
redfi ni
shed
produc t
.Theinflatedb ubb l
eo fpl asticisdr awnv ert
ical
lyupat owers ot hati thasac hanceto
coolbeforeitisfl
attenedo utandwo undo nt oroll
.Aftert hepl asti
ci so nar o l
l,itcanb ecutto
formt ubingorcentrefolds heeting.Aft ert hatwet ransformt hepl asti
ci ntopo lybags.

******************

Polyethyl
eneb ag
sar emadebyheatseal
ingand cutt
ingrol
lso
ffilm.Rol
lso
ftubi
ngo r
sheetingarefedt hr
oug
hthemac
hinet
hatdr awsmater
ialo
uttothepro
perl
eng
thassho
wn
onFi gbel
ow.

Themac hinethencycl
est oplac
eas ealont hemat er
ialandt henc utitofftomakean
indi
vidualb ag.Thes
ecretofethi
oplastici
ndustrytoproducinghighqual i
tyfi
lmisb
ecausei
t
hasgo o
dequi pmentthatmaintai
nsac o
nsis
tentflowofmat erialthroughoutt
hepro
cess
.The
company’ smodernmachinesemploys
er vodri
vemo t
orsforoptimalc o
nt r
olandacc
uracy.

@@@@@@@@@@@

Pl
ati
cco
ntai
ner
,pl
ast
icc
upmaki
ngo
per
ati
ons

Theseprodut
sar emanufact
uredb yusi
ngtheinjec
tio
nmo ldmac hine.t
hesemachi
nehav e
capabl
eofmanufacturi
ngdiffer
entproduc
tsbychangi
ngt hemo l
d. Threemaincomponents,
whic
har ethefeedhopper,t
hes cr
ew,andtheheatedb ar
r el
.Thismac hinewor
ksbyt aki
ng
plast
icpowderorgranul
esand mani
pul
ati
ngi
ttos
hapei
tint
oa par
tac
cor
dingt
othe
requi
rementsanddi
mensio
ns.

Whent hefeedho pperrec

ei v
estheplasti
cg ranules
,itthenus
esfrict
ionalac
tio
noft hescr
ew
tocreateheat.Oncethepl asti
creachesthec orr
ecttemperat
ure,itistheni
nject
edi nt
othe
moldcavit
y,whereiteventuallyco
olsandt akestheshapeacco
rdingtothemolddesi
gn.

Ifneces
sary
,adv ancedinj
ecti
onmol
dingtec
hniquessuchasr
epeatedinj
ecti
oncanbeused
toc
reatepartsoutofmulti
plemat
eri
als
.It
’sals
opo ss
ibl
etous
einsertmol
dingtoaddpl
asti
c
par
tsoverexi
sti
ngpar t
smadeoutofot
hermateri
als.

Thebasicpri
nc i
plesb
ehindt hei
nj ectionmoldingproc
essmays eemsimple,butinreali
ty,i
tisa
verycompli
catedpr ocessthatrequirestherightequi
pmentandt heri
g htexpert
ise.However
,
whenitisexecutedcorrect
ly,i
nj ec
t i
onmo l
dingc anconsi
stent
lyproduceexcell
entresult
seven
forthemo s
tchal l
engi
ngmanufac turingpr
oj ect
s.

Inj
ect
ionmo
ldmai
ntenanc
e

Knowl
edg
eandAc
quai
ntanc
esAc
qui
red
During my Seven mo nt
hso finter
nship prac
tice atTsi
nu P.L.
C I hav
e earned to
nsof
experi
encesandb enefit
s.Ihavedevel
opedteamwo rkwit
hotherempl
oyees,mos
tofallIhav
e
li
teral
lyobser
vedt hethi
ngsIlear
nedint heuniv
ersi
ty.

Materi
alHandli
ng
Int
ernalLog
ist
ics
Forkl
iftandhandtruc
ksar
eav ai
lab
lewhichareus
edi nsi
det hepl
anttotr
anspor
tvar
ious
c
ompo nentss
uchas
:rawmater
ials
,fini
shedpro
ducts,fueltanksandetcet
era.
*****pi
cs*******

Ex
ter
nalLog
ist
ics
Ther
ear
etwoc
arr
yvansfo
rdel
iver
ypur
pos
es.

******pi
cs*****

Indus
tri
alaut
omat
ion

Fi
lm BlowingMac hineisusedtomakepo l
yet
hyleneint
oplas
ticfil
m.Thi
smayb elami
nati
ng
fi
lm,pac kingfil
m,ag r
icul
turalc
over
ingfi
lm,bagsorfi
lmfortext
il
esandcl
othi
ng,andot
her
[
1]
packi
ngmat er
ial.

Part
sinclude:Scr
ewandb arrel
,mot
or,inver
ter
s,di
ehead,winderandtower.Themainmo tor
mayhav efrequencycont
rolofmotorspeedtoimpro
vespeedregul
ati
onands av
eelectri
ci
ty.
Thescr
ewandmat er
ialb
arrelmaybemadefr o
m nit
rog
entreatedchro
mi um-mo l
ybdenum-
al
umi
niumal
loy[2]

Themac hinesuckspo
lyet
hyleneresi
nsautomat
ical
lyandco
nvert
sintos
hri
nkfilm.Whenthe
produc
ti sfini
shedandr eadyforunloadi
ng,t
hemac hi
neaut
omatic
all
ycutsandchangesa
rol
li
ngcorewi t
houtahumani nt
erventi
on.

****pi
cs*****

Rec
ycl
emat
eri
als

Wehavebeenlearnedt hateverywasteofmateri
also
fpr o
dut scanbeusedagai
nasraw
mater
ialwhi
chwillreducethecostthatlos
tduetosmallpi
eces,i
ncor
rectdimens
ion
pr
oducts,
etc
..andalsoithelptocoverthe******ofrawmat eri
al

Tec
hni
calS
ki l
lsGained
Wehav egainedab r
iefknowledgeab outshri
nkfil
m,s t
retchfilmandpo l
ybagpr oduction.
Wehav egatheredt hes ki
ll
so fo peratingthemac hi
nesfr omi nit
iati
ngupt ounl oading
del
iveredproducts.
Wehav ebeenprac ti
cingonus i
nghandt ool
sandelectri
calmac hi
nes.
Wehav ethekno wledgeofwo rkpr ocedureofthec o
mpanyi .e.readingjobo r
der,c hecking
i
fthepar ameterswr it
tenont hejobo rdermatcheswit
ht heactualwo r
ko nthemac hine.
Wehav eaccomplis
hedpr oductivi
tychec kuptaskrespo
nsibl
yands el
feffici
ently.

ManagementS kil
lsGained
Wedev el
opedmyc ommunicati
onwitho therdepartment si
nt hecompanytocoordinatet
he
producti
onsystem.
We’vedevelo
pedmydec is
ionmakingwhenmac hinesstoppedwo rki
ngproperl
y.
Anothermanag ementskil
lthatweg ai nedispro b
lem solvi
ng:forinst
ancewewer eusi
ng
si
mpleflatwo o
dpi ecewhil
ewewaswo rkingontheb agmaki ngmachinetoreducemyeffo r
t
ofpull
ingthepo lybagsfro
mt hemac hine.
Las
tbutno tleastwe’vedev el
opedmymo t
iv ationandi nspi
rat i
ont oknowandpar ti
cipate
morei
nt hec ompany .

Ac
quai
ntancesAcquired
Wehadt hec hanc etomeett hegeneralmanager(owner)ofthecompanyAt
oS o
lomon
Lemma.Heenc o
uragedmewhi leIwaswo rki
nganditcreatedmoti
vat
ionandi
nspi
rati
on
formetowo r
kmo r
e.
And ofco urs
et hePr oduc
tion managerAt oAber
a Zelekegavemea l o
ngwayg oi
ng
knowl
edgeandt ipsontheproducti
onsyst
em.

Pr
obl
emsenc
ount
ereddur
ingt
heInt
erns
hipPer
iod(
limi
tat
ion)

Thepr
obl
emso
ccur
redi
nEPIi
s

Rawmateri
alsc
arce
Pro
perairc
onditi
oning
Moldmounti
ngcranes
 Excessi
ves c
raps -whenpr oduc
ingmor
escr
apsareformed
Recycli
ngas crap
Crasher
Lacko fskil
ledmanpo wer
Poorho usekeepi ng
Oldmac hineries
Costumer
Varityofpr oduc tsmeanshous
eholdmat
erial
snotpr
oduce
Nowar ehousing
Powerg enerato r

Co
ntr
ibut
ions