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Time delays in automatic GT loader-Curing section (AKM).

By Keerthi Kumar H.M 52 BTTP Nov2011 Industrial Engineer - Medak
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Assignment snap shot

 Section name - Curing Section

 Tyre type

- Considered only Radial tyres.

 Machine

- Automatic GT loaders.

Objective of the assignment : To reduce the time differences found in automatic loaders to the level of ideal time found in same group.

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Scope of the assignment:

 By collecting data regarding timings observed for automatic loader operation, we can compare the differences found in each mould with respect to ideal time to complete that process.  With this data collection, we can make a priority analysis to reduce the excessive time consuming in set of moulds.  As curing time is constant, only way to increase curing production is by reducing the excessive time found in GT loader operation.  As the short delays are repeating in each cycle of operation, there is a much scope to reduce large loss in longer run.
 By reducing the time difference, we can increase the tyre curing capacity of existing moulds.

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ABSTRACT:
 The assignment was based on conducting the time study on various moulds for loading/unloading operation of automatic GT (green tyre) loader. When we compiled this data its found that each automatic loader is taking different time to do the same operation in similar tyre type.  In this assignment considered 50 mouls(100 cavities) which are producing radial tyre curing for our study purpose. Out of 50 moulds categorized the moulds which are producing same type of tyres into one group. The minimal time found in each group had been considered as ideal time/ Bench mark time for reducing excessive time found in other moulds due to various reasons.  From the differences found in each mould, we have analyzed the most probable reasons for the existence of these delays.

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The process:
 Green tyre will be loaded on the GT stand with alignment with side walls joining point.  Switch on the auto pick up button of loader. So that it will pick the tyre by hydraulically operated one way cylinder arrangement.  The collapse/Expand action of the loader will be controlled by pneumatic cylinder.  The GT will be loaded into the lower bladder ring by hydraulically controlled (cold water with pressure of 250 PSI) two way cylinder for IN/OUT movement.  Same Sequence will be repeated during bringing back the loader to original position.  The sensors had been provided to receive the signals for bottom & top position reached during both loading & unloading cycle.  The entire automatic loading system will be controlled by instrument air with pressure of 40 PSI.
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Methodology Followed:
 With the help of stop watch study, captured the loading/unloading time observed in each mould. Considered 04 readings in each mould for arriving at average time.  Captured the data in prescribed format which is covering all the required data.  The attached excel sheet will indicate the different data's had been collected for fulfilling the purpose.  Total time required for automatic loading of GT loader had been arrived by considering summation of mould open time, loading/unloading time & mould closing time.

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Data Collection:
 In the similar type of tyre curing moulds, we have compared the differences by considering minimal time found in same group as a benchmark.  The time delays had been projected to one year to get the importance of the minimal delays in repetitive manner.  Formula used are, 1.No. of cycles per day= available time / (curing time+ideal time for L/UL) 2. Total time delay per year = Individual time loss * No. of cycles per day * 365. 3. Projected production loss per/year = Total time delay / (curing time+ideal L/UL time).
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Data Interpretation:
Comparison of loader timings v/s different moulds-140/60 R17 REVZ.
120 100 80 60 40 20 0 161/162 163/164 171/172 187/188 189/190 195/196 199/200 73 107 100 89 95

93

Ideal time - 73 sec

75 Total ti me (sec)

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Calculation:
 Max. % of deviation in time delay:
 Example taken in case of 140/60 R17 REVZ  Max. time found in mould # 161/162 106 sec  Min.time found in mould # 171/172 -73 sec  = (Max. time - Min. time)/Min. time * 100  = 106-73/73 * 100  Max. % of time delay = 45.20 %.

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Comparison of Diff. in time WRT minimal time found in mould # 171/172.(140/60 R17 REVZ)
40 34 35 30 25 20 15 10 5 0 -5 161/16263/16471/17287/18889/19095/19699/200 1 1 1 1 1 1 3 0 16 28 21 23 Di ff. i n time WRT Ideal ti me.

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Projected Mouldwise loss of Tyre curing production/year. (140/60 R17 REVZ)

199/200 195/196 189/190 187/188

76 648 591 467 Projected loss of Tyre curing production/year. 791 972

171/172 0 163/164 161/162

-200

200

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Observations:
 The difference in automatic loading timings are due to combination of following reasons:
 Drop in hydraulic pressure due to air leakages found in smaller pipes. (leakage may be due to small hole in the pipe or improper joints).  Due to hardness of water, scaling will be developed inside the pipes after used it for quite longer days. These scaling (sulphur oxide) will black the valve, hence by reducing the water flow rate.  Whenever cylinder had been replaced with newer one, piston movement will be slower WRT to older cylinder in other side of the arm. (due to restricted movement of piston disc).

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Continued..
 The Cylinder piston disc might have damaged slightly / wear out , it will be affected in cross passing of pressure so that reducing the final output pressure exerted on the cylinder.  Drop in instrument air pressure(40 PSI) due to leakage problem will also result in insufficient/partial opening of valve gate.  Sometimes, water inlet valve will be partially closed during operators handle it manually. No visual proof for identifying the correct position of hand valve at fully open condition.

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Continued..
During returning of cold water, it may contain with any minute foreign particle which will obstruct in outlet valve. This may also affect out flow rate of water hence by delaying downward movement. ( Strainer is provided for inlet pipe to filter foreign material).  Due to any one of these reason/ combination of reasons, water pressure will be different at both the sides of the arm (left & right), as we are having common return valve, the cylinder which is having higher pressure will move fast thru the common return valve by restricting movement of water from other cylinder.
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CONCLUSION:
 Whenever considering practical difficulties, its highly cost effective to completely avoid these variations. But by attacking on the most probable reasons by preventive maintenance can solve the problem to acceptable level / within the tolerance.

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LIMITATIONS:
 Due to non availability of sufficient time, only 3 major groups of similar types tyre had been considered for analysis.  Also no. of readings taken in each mould to arrive at average time is not sufficient so that final time may not accurate enough.  Although we have found out various causes & its effect on GT loader performance, but we are not able to find out root cause in each loader. (Because it needs further mouldwise breakdown of analysis)

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Thank You.
ANY QUERIES?

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