Induction Report

Duration: 27-Jul-16 to 25-Aug-16

By Jagannathan G.

■ Company Confidential and Copyright ■

Contents Page No.
Self Introduction 3
Induction schedule 4
Plant process flow 5
RM stores 6
Mixing 8
Compression Molding 11
RJ Molding 14
LIMS 16
KTP/DCP 17
After cure 20
Punching 21
100% Inspection 22
QA & Shipping 23
FG Stores 25
Plant overview 26
Quality issues 28
■ Company Confidential and Copyright ■ 2
 Introduction

Name: Jagannathan G.
Designation : Asst. Manager- Sales & Marketing.
Location : Shin-Etsu Polymers India pvt. Ltd. (SD).
Work Experience : 13 years.

Experience in :

OE, After Sales & Marketing, Customer support, Key Account Management.

Previous companies:

Freudenberg-NOK, Fenner India, Fisher-Emerson, Sundaram Honda, India pistons ltd.,

Professional synopsis:

 In polymer line for last 7 years, handled polymer products such as V-Belts, Timing belts, oil
seals, Hydraulic, Pneumatic PU seals, bellows and rubber gaskets.

 Experience in Automotive & Industrial products marketing.

 Having Pan India working experience.

 Has worked with Japanese companies.

 Languages known : TAMIL, English, Hindi.

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 Induction schedule

Date Activity Trained by

27-Jul-17 Raw Material Storage [Link] Vikram

28 to 30-Jul-17 Mixing [Link]

01 to 06-Aug-16 Molding [Link]

08 to 10-Aug-16 Punching and KTP [Link]

16 to 17-Aug-16 QC [Link]

18-Aug-16 QA [Link]

22-Aug-16 Packing [Link]

23-Aug-16 FG Store [Link] Vikram

24-Aug-16 Finance and Accounts [Link]

25-Aug-16 HRD & GA. [Link]

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Plant process flow

RM Stores

Mixing RJ Molding

Sheeting & Cutting

Compression Molding KTP/DCP

After Curing After Curing

Punching

100% Inspection

Shipping inspection Lot Out

Packing &
Shipping
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 Raw Material Store
 Major suppliers are: RM
Before After After
Opening opening Mixing
Silicone
Shin-Etsu Chemicals, Japan. 2 years
KE,HG,X,DY,SE,EK,XE,TS
TOREY Dow Corning silicone ltd., Curing agent C,X93 3 Years 1 Year 3 Months
Wacker Aschi Kasei silicone ltd.,
Color pigment 3 Years
Toshiba co. ltd and Momentive.

 Lead time varies based on material from 2 months to 5 months.

 Apart from RM, tools, print screens and consumables received at RM store.
 FIFO system is followed in storage and issue of material.
 Each month has different colour for easy recognition. AUG-16
8
Material Selection:

 Rubber content (RC) file has complete information of a part from RM to inspection standards.

 Suitable material selected based on below spec. requirements of product:

 Actuation force, Return force, Life cycle, Hardness and click ratio.

 Material combinations derived based on HARDNESS requirement, SHRINKAGE,

DURABILITY, TEAR-STRENGTH, FLAME RESISTANCE etc.,

 Material Safety Data Sheet (MSDS) has safety information such as Material name,
specification, manufacturer, First aid in case of contact with skin/swallowed, action in case of
FIRE etc.
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Raw material store

Material received after Custom clearance.

Inspect the condition of the shipment. Certificate Of Analysis with standard spec.
Receiving

OK material to RM store, Hazardous material to Hazardous store. Gold pills storage.

Make GRN with PO/Invoice and received qty details.

GRN
Enter manufacturing date and Expiry date in the box.

Paste FIFO stickers.

Material request raised by Mixing, MRF have required weight of RM.

Storage

Issue material to Mixing based on Material Request Form.

Maintain room temp less than 40’ C.

FIFO

MRF To Mixing
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 Mixing
 Mixing Order Sheet have Silicone, Curing agent and pigments details with part
numbers, weight and Hardness requirement. Product code, Mixing code and
Manu number mentioned in MOS.
MOS
 Cross verify MOS weight with Weighing standard.
 Weighing is very important process. If weighing not as per requirement, issue in
product output and hardness.

 Catalyst and Colour pigments weighed separately and details printed in MOS for
Weighing future reference.

 Timer is set for blending. Blending time 20 minutes.

 Mixing machine has emergency stoppers and sensors as safety measure.

Mixing  Hardness Test: Weight of specimen :13 grams. cured at 180˚ for 10 minutes.

 Hardness checked at 5 points. Report, specimen stored for future reference.

 RJ Mold material moved to storage since sheeting is not required.

Pigments  Compression RM moved to sheeting/cutting.

 If desired Hardness or Actuation force not achieved.

Change RM mixing ratio.

 Any deviation from RC file should be done in concurrence

Hardness Test
with SJ.
Blending ■ Company Confidential and Copyright ■
8
 Sheeting & Cutting

 Sheeting & Cutting standard have Sheet thickness and length.

Set length  For Half Cut ribbons :PE films in both sides.

 For Full cut ribbons: OP film in bottom and PE film in the upper side.

 3 rolls made out of a batch.

Check thickness  Cutting standard will have ribbon width and weight requirements.

 ON the motor before starting the machine.

 Weight of the ribbons checked. First 5 ribbons will be moved to balance material
after width and weigh check.
Cutting
 Full cut ribbons should be kept in bins.

 Ribbons issued to Molding as per request and details noted.

Check ribbon weight

Roll and update Storage To Molding

ribbon ledger ■ Company Confidential and Copyright ■
9
 Mixing, sheeting & Cutting:
BALANCE MATERIAL
 Material leftover in Mixing, sheeting and cutting kept as Balance
material in bins.

 Balance material is stored with product number, mixing date, qty and
expiry date details. This is used with next batch and the details noted in
MOS.

KASTURI:
 Expired, issue material is stored at this
location.

 Expiry materials used for taking first shot

in mold which was idle for longtime.

 This will remove the dust particles in Daily Mixing Plan update
Mold.

 Product issues due to Improper mixing.

 Less ribbon weight. - Short Mold

 No curing agent. - Uncure
 Dust mix in product. - Dirt in part.
 Less/more pigment weight. - Color change
 Hardness issue - Force problem.
Ribbon stock update

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Compression Molding process

Ribbon received from Mixing to be loaded in

Product feeder table.
Loading

Arrange Contact pills and assemble in mold

Assemble Pills in Mold using pill jigs.

Keep Ribbon in Mold Keep product in Mold manually.

Start curing. Automatic.

Curing

Remove finished part from Mold.

Remove finished part

Inspection Check for tear, short mold etc.

Keep the OK part in bins.

Store in Bins

To Curing/KTP- Move to Curing/KTP-DCP as required.

DCP

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 Compression molding : Requirements
 Operation log sheet is issued by PPC for the days plan.
 Work order sheet/log sheet have LOT number which is mentioned till FG for
future reference. Eg. .
 Also contains details of shift production with qty, rejection, start time and end
time and operator details.
 Separate log sheet for each processes.
 Process control sheet has consolidated information of all logs.
Operation log sheet

Gold pills  Product ribbons and contact pills are molded in compression.
 Contact pills types : alpha-97, 40P and gold pills with
different sizes.
 Conductivity differs low to high from 40P, alpha-97, gold pills.
Carbon pills  Work instruction color differs contact pill wise.
Product Ribbon  Direct Contact Printing is with lowest conductivity.

 Temperature, curing, mold opening, closing times set in PLC.

 Curing temperature is 180˚C. Curing time: 3-5minutes (varies part to part).
 Operator does only loading and unloading of product.
 Operator should wear safety equipment's (Ear plug,mask,hand sleeve, gloves) while operating the
machine.
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 Compression molding : process

Load ribbons in tray Load Cont pills in jig ON vacuum to take pills Clean cavity with air

Spray releasing Keep pill jig in tool Check pill seating Keep ribbon
Agent (RA) and release vacuum

180’ C
Press ON in auto mode Curing for set time Unload the part Check for tear, burrs

 In each shift first 10 parts, mid 10 parts, last 10 inspected at lab.

 Rejected parts to be kept in red bins and doubtful parts in white.
 Operator will enter hourly production details with qty, rejection and downtime
details. This is consolidated by PPC.
 End of shift operator fills operation log and move the parts to curing/DCP..
On-line inspection
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 Rubber Injection molding (RJ)

RJ Machine Load tool Load RM in injector Curing at 170 C

Tool opens after curing, Unload the part Remove runner flash ON machine for next
and remove Flashes in tool from Machine cycle

 In RJ molding RM is injected into the tool through runners.

 Advantages of RJ is fast production, low wastage and accurate parts.
 Weight per RM product roll is 5kg.
 Only RM loading and unloading of molded parts done manually.
 Operating conditions are fed in PLC. Fully controlled by sensors.
 Molding and tool open/closing automatic.
 Operator has to deflash and inspect each part.
Injection process

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 Rubber Injection molding : Inspection

Inspection instructions OK and NG part display Remove inner/outer flash in Part

On line inspection Bins for rejection, doubtful parts First shot part flash thickness check

 First shot parts kept for inspection.

 5 nos cut vertically to check the inner

profile.

 Parts fell down are kept in white bins as

doubtful parts.
Part cut sample inspection OK parts to Post curing

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 Liquid Injection molding (LIMS)

RM A,B in liquid state FIFO in RM RM change records Color agent feeding

Tool

Set up in PLC Curing @ 185/195 ‘C Finished part out Inspection in line

 No Mixing for LIMS RM as it fed in liquid state.

 No After curing done for rubber ring.

 At present only one part is supplied from this

machine to Sumi-Motherson.
Move to 100% Purging and stroke
inspection details  Purging done while starting the machine after
Long gap.
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 Printing: Process

DCP Ink Mixing KTP Part received from Molding

Ink mixing is the important part in printing.

Load tool in Machine DCP Ink - carbon and Kerosene.
KTP ink – Black, overcoat.

Setting up tool and ink contact

Set up tool for Printing

Printing: Automatic.

DCP-Single printing.
DCP Black Printing
KTP – Black printing & overcoat printing.

Remove finished part Curing Curing is must after each printing.

Inspection & Curing Overcoat Printing Curing at KTP/DCP done for 30 mnts.

Store in Tray Curing

Move finished part to After cure.

To After Curing

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17
 Keypad Top Printing (KTP)

Entry thro Air shower Ink mixing using weight Mixing standard Set up screen in M/C

Set-up Squeezee, Doktor Set up Jig /Screen Load product and ON Key Top Printing

Curing 30 mnts @ 200 C Ink life monitoring Overcoat printing Finished part to curing

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 Direct Contact Printing (DCP)

Daily plan update Mix ink – Life 45 days Set up DCP tool in m/c Fill ink and check level

Place the part in tool Remove finished part

Part After DC Printing Mix ink once in 30 mnts
and on vacuum and check

 2 types printing at KTP. Black printing and Overcoat printing.

 Catalyst added with KTP ink, ink life reduces after adding catalyst.
 Curing after each printing is necessary. Curing @ 200 C for 30 minutes.
 KTP Ink Life is 5 hours and DCP ink life is 45 days. After the life time ink solidified, color
changes.
 Safety measure: DCP jig entry controlled by sensors.

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 After curing

Operation log- Aftercure Load received parts in trays Keep resistance sheet

Load parts in oven Set time, temperature Part # start time display Cooling off with Air

 Post curing is done to remove moisture from parts.

 Curing time will vary part to part. Temperature is 200˚C.
 Parts with 40P and without carbon cured for 60 minutes and parts with Alpha 90 is
cured for 120 minutes. Protectors cured for 240 minutes.
 Partwise curing procedure is available at Curing bay.
 White Resistance sheet is kept along with material while curing. Paper turns to dark
grey after curing. If it turns pale grey or black, there is problem in temperature.

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 Punching

Punch tool rack Tool loading Place part in lower tool, ON both buttons

Remove finish part Check for flash rejected part in red bin Clean with AIR

 Punching is done to remove excess material and flashes in molded part.

 Punching tool is set by Engineers.
 All the parts checked visually after punching.
 Punching not required for RJ Mold, LIMS parts.
 Parts moved to 100% inspection area after punching.
 Safety measure: M/c will not operate if fingers in between tool, sensor control.

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 100% Inspection (QC)

Inspection plan Inspection table Inspection method display Before Inspection

Conductivity calibration Conductivity test Flash gauge check Visual Check

 QC takes care of On-line inspection and 100% inspection of parts.

 QC checks only conductivity and visual attributes.
 Incoming inspection of RM is done by QC.
 QC maintains defect records and communicates the same to production.
 QC takes care of EMS, Measurement system audits.
 Every operator undergo R&R once in 4 months.
On-line check list

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 Quality Assurance (QA)

Start-up, shipping inspection Operation log Sampling qty chart Shipping inspection

Dimension check Ink Thickness checking Force checking Resistance checking

Thickness checking Life cycle testing Life cycle test set-up Water leak testing m/c

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 QA Packing

Daily plan Shipping instructions Counting and arranging Weighing of pack

Sealing of pack Arrange packs in carton Label with lot# Balance material

 After 100% inspection all lots checked as per lot sampling at shipping inspection. Even if a
single rejection, the whole lot will be LOT OUT and re-checked at 100% inspection.
 QA does start-up inspection and shipping inspection.
 Test lab checks thickness(flash/part), dimensions, Force(CP) and resistance.
 QA manages the RC files. RC has details of parts from RM to inspection.
 Life cycle and water test done during initial development stage.
 QA handles PPAP(PSW, dimensions, control plan) and new product trials and 4M changes.
 QA handles ISO, TS certification audits (process, product).
 QA handles customer claims.
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 Finished Good store

Box weight checked Move to FG stores Box sealed and signed FG storage
and stamped

FIFO stickers Invoice copy Shipping Bill Despatch

 FG stores receives the material from packing.

 Each labels checked and signed by FG store in-charge.
 Once invoicing is done FG arrange for despatch and maintains
record of FG stock, warehouse daily movements.
 FG stores consolidates all op-log sheets and update in system.
 As SD in SEZ each invoice has to be attached with SEZ cargo gate
pass, Shipping bill and packing slip.
FG stock update
 SD exports directly to customers and supports SE warehouse.
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 Customers & Machines

Customer Name Compression RJ LIMS [Link]. Machine/Equipment name Location No. of

India
1 Compression molding Production 31 (26+5)
Sumi Motherson
2 RJ molding Production 5
Hitachi Automotive systems, 3 LIMS Production 1
Jay-Ushin Ltd., 4 Mixing m/c Mixing 3
Mindarika India Ltd., 5 Sheeting Mixing 2
De Diamond Electric. 6 Cutting Mixing 3(2+1)
Overseas 7 Keytop Printing Production 6
8 Direct contact printing Production 4
Preh GMBH
9 Punching Production 21 (16+5)
Marquardt GMBH 10 Curing ovens Production 9 (6+3)
Nespresso 11 Quick vision Dimenson check QA 3
Hella 12 Force checking QA 2
Continental 13 Ink thickness microscope QA 1
14 Thickness gauge QA 1
Delphi
15 Resistance check QA 1
Valeo 16 Life cycle QA 3
ZF TRW 17 water leak tester QA 1
Standard Keys (OE) 18 Navithas inspection QC 1

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 Capacity and Expansion

2016-17 Compression Rubber Injection

Capacity 10 shots/hr 6 shots/hr

No. of parts 141 (Jul'16) 5 (Jul'16)
Part type Key switches, Protector
Standard keys Rubber, cover
Application HMI Auto-Electric
No. of machines 31 (26+5) 5
Additional plan 10 (end 2016) 6
capacity utilization 87% (Jul'16) 47% (Jul'16)
Future Expansion With addition of 15 more machines, As new machines coming up,
Capacity will increase by 57%. Will have RJ will be moved to new plant
dedicated line only for compression by Q2-2017. Capacity will
molding machines. increase by 3 folds.

Target segments Medical Medical

Automotive gaskets Auto ignition coil.
Input devices Plug type parts.

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 Quality Issues

Issue Reason
Tear Excess RA sprayed
Burr Improper cleaning of tool
Excess Flash Excess material
Damage Forceful removal from tool
Short Mold Low Ribbon weight/ Improper
flow of material
White/Black marks Mixing issue
Dent/Dirt Dust in tool
Uncure Flash in tool
Mix-up Handling issue
No carbon/ double Pill Pill loading problem
Pill offset/Damage Pill loading problem
Fitment problem(Dimension) Tool/RM problem
Force issue Hardness problem

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 Observations
Sl. No Area Existing process Question / Sugesstion

1 Mixing Sheeting and cuting done as two processes. Can we do cutting as a sequence to sheeting.

2 Mixing Balance material FIFO Make mandotory to check balance material

while sheeting.

3 Mixing cutting of RM Done manually

4 Molding No Mark on Pill jig Mark operater side for easy fitment

5 Molding Operator removes the part with help of air gun Ejact Pins in tool for easy removal. Pins has to
like peeling off. Part might tear off if removed come out while tool is open will remain inside
faster when tool is closed. This might be achived
with spring tension. We shall check the
possibility.

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 6 Molding No separate record maintained for ribbon receipt
7 After cure No FIFO week FIFO to be maintained as molding to
curing time is just 48 hours.
8 After cure Oven open during curing Possibility of temperature loss. Oven can be
opened only if m/c working is stopped.
9 RJ Deflashing table Layout of deflashing table to ease access to
curing trolley.
Tray

Trolley
Location

10 RJ SEQUENCE CELL concept.

11 RJ GLOVE / TOOL FOR REMOVAL
12 DCP Ink mix date on bucket Only recorded in paper. On bucket will be
easy for referance.
13 Punching NO FIFO FIFO to be introduced.
14 Prodution Cleaning schedule Scheudle for machine cleaning to be followed.
15 Prodution Tool room, condition monitoring Specified location for tool storage and
monitor conditions, small repairs if feasible.
16 Prodution Ok tag Exisitng Proposal

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17 Prodution Single log sheet. Shall Modify proces control sheet to
accommodate all processes as single log
sheet. make new OK tag to have rejection
information and keep operation logs at
concerned departments it self.
18 Inspection Conductivity& visual As a sequence Visual inspection table to be
adjacent to conductivity check table. This will
save time.

19 Inspection Rejection material monitoring No proper monitoring of rejections. Process to

be streamlined to meet minimal rejection at
production itself. RA/Pins.
20 Inspection Before inspection storage No proper space for storage before
inspection, hence no FIFO followed.
22 QA No Defectwise trend and root cause analysis Defectwise trend in customer claim and
rejection to be monitored to concentrate on
Defect Trend
repeated issue.
6
4
2
0
Jan'17 Feb'17 Mar'17 Apr'17 May'17 Jun'17

Tear Short mold Dent Uncure

21 Shipping Packing Layout Packing layout should be in concurrance to FG

receiving area. Movement of trollies to be
eliminated.
23 FG Roller conveyor table. Roller conveyor table shall be installed from
packing table to FG receiving. This will
eliminate movement of trolles and ease
weighing and sealing of boxes.
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24 FG Despatch part location. Identify loacation near loading area to keep
day's despatch parts.

Despatch
material
location

25 QA Assembled units or drawings Partwise/part type wise assembly units or

assembly drawings to be installed at QA for
better understanding of product.
26 QA Application details Partwise application details has to be
maintained for better understanding of
products.
27 QA Customer claim communication Customer claim communication/form with
details of nature of defect, stage and solution
with CFT.

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 Existing Cell concept
RJ RJ Molding
To FG
Machine
area De-flashing and
loading in trolley Shipping
De-flashing
inspection

Curing
area After curing 100%
Loading
Inspection

Inspection
area 100% inspection
Curing

Shipping
area
Shipping & Packing
Single machine molding to
packing can be handled only by
FG 2 operators.

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 Existing Roller conveyor

Packing
Packing table Packing
table
Table
Packing

Packing Weighing of boxes

Ground
conveyor

FG
FG Stores
FG receiving area
Ground

Storage Packing to FG can be handled

Pallets
by 3 operators per line

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 நன்றி

ありがとうございます

Thank you

■ Company Confidential and Copyright ■