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 : [Link] Source : [Link]
Figure 5 Rubber Coated Cord (Treatment)
Source : [Link]
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 After the defect rubber coated
Cord (treatment) cord (treatment) is selected by
Before it get into liner. bias cutting operator.
Scrap is written in scrap
checksheet
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.
THANK YOU