CHAPTER – 1

COMPANY PROFILE
1.1 HISTORY OF TVS
TVS was established by Thirukkurungudi Sundaram Iyengar. He began with
Delhi's first bus service in 1911 and founded T.V. Sundaram Iyengar and Sons
Limited, a company in the transportation business with a large fleet of trucks
and buses under the name of Southern Roadways Limited.

1.2 GROUP OF COMPANIES

TVS is one of India's largest diversified industrial conglomerates with its
principal headquarters located in Madurai and international headquarters
in Chennai. It has a presence in 129 countries with 73 holding group companies.
The largest and most visible subsidiary is TVS Motor Company, the third-
largest two-wheeler and three-wheeler manufacturer in India. TVS Group, with
group revenues of more than US$7.2 billion, is an automotive conglomerate
company, specializing in the manufacturing of two-wheelers, three-wheelers,
auto-components, hardware electronics, high tensile fasteners, die casting
products, brakes, wheels, tires, axles, seating systems, corrosion management,
fuel injection components, electronic and electrical components and many
more. It also owns vehicle dealerships also. Some major companies of TVS
Group are in the following:

 AXLES INDIA LIMITED

Axles India is a joint venture of wheels India, sundaram finance and Dana
holding corporation, USA. Axles India has the capability to provide axle
housings for the entire range of medium and heavy commercial vehicles. Started
in 1983, the production of pressed axle housings is at an annual level of 280,000
pressed axle housings with 30% to export market, manufactured in plants at
sriperumnudur and cheyyar.

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  BRAKES INDIA LIMITED
Brakes India was incorporated in 1962 as a joint venture between TV sundaram
lyengar and sons Ltd., and Lucas industries Ltd., UK (subsidiary of TRW inc.
USA) to manufacture braking equipment for automotive and non-automotive
applications. It caters to over 60% of the domestic OEM market besides
exporting its products to over 35 countries worldwide.

 HARITA GRAMMER LIMITED

Harita Grammar limited is a public incorporated on 20 February 1986. It is
classified as non-government compact and is registered at registrar of
companies, Chennai. Its authorized share capital is Rs. 15,000,000 and its paid
up capital is Rs.0. it is involved in Extra Territorial Organizations And Bodies
Harita crammer limited’s annual general meeting (AGM) was last held on N/A
and as per records from ministry of corporate affairs (MCA), its balance sheet
was last filed on N/A.

 INDIA MOTOR PARTS AND ACCESSORIES LIMITED

India Motor Parts & Accessories Limited (IMPAL) a TVS Group Company was
incorporated on 12th July 1954. The Company is engaged in the distribution of
automobile spare parts and accessories through its 50+ branch network
representing over 50 manufacturers. IMPAL is one of the few all India
distributors of motor parts and deals in engine group components, brake
systems, fasteners, radiators, suspensions, axles, auto electrical, wheels, steering
linkages, instrument clusters etc.

 INDIAN NIPPON ELECTRICAL LIMITED

India Nippon electrical limited was incorporated in 1984 and converted into a
joint venture in 1986 between Lucas Indian service limited, a wholly-owned
subsidiary of Lucas-TVS limited and MAHLE Electric drives Japan
corporation, Japan-a company of MAHLE Group, Germany, to manufacture

2
electronic ignition system for two-wheelers, three wheelers and portable
engines.

 LAKSHMI AUTO COMPONENTS LIMITED

Lakshmi Auto Components Limited is a Public incorporated on 13 October
1986. It is classified as Non-government Company and is registered at Registrar
of Companies, Chennai. It is involved in Manufacture of transport equipment.

 LUCAS INDIAN SERVICES LIMITED

Lucas Indian Service Limited (LIS) established in 1930, is an aftermarket
organization providing solutions to a range of vehicle manufacturers from 2
wheelers, cars, trucks/buses as well as off-highway vehicles. LIS also
manufactures Ignition coils and Solenoid switches and distributes wide range of
Auto-electrical parts, diesel fuel injection spares, Automotive Batteries,
Radiator Fan Motor Assemblies, Glow plugs, Synthetic & Semi Synthetic
Lubricants and Engine Coolant.

 SOURTHERN ROADWAYS LIMITED

TVS Southern Roadways Ltd. provides goods transport and parcel delivery
services in South India. It serves individuals and householders, merchants and
professionals, manufacturers, and distributors. The company was founded in
1946 and is headquartered in Madurai, India. TVS Southern Roadways Ltd.
operates as a subsidiary of T V Sundram Iyengar & Sons Ltd.

 MADRAS AUTO SERVICES

Madras auto service is popularly referred to in the automobile industry, came
into the TVS fold as early as 1936. It has set the pace for the spare parts and
components industry in many avenues.Today MAS represents more than 70
ancillary manufacturers. In addition to marketing spares for trucks and cars,
tractors, earthmoving equipment, genset and IC engines, MAS is one of the
largest wholesalers of spare parts, with a network of over 7,500 dealers.
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  SUNDARAM BRAKE LININGS LIMITD
Sundaram brake linings limited was established in 1976 as a joint venture with a
world famous friction materials manufacturer, sundaram brake linings (SBL) is
now a fully Indian owned company manufacturing automotive, non-automotive,
railways and industrial friction materials. SBL products are extensively used in
commercial vehicles, passenger cars, tractors (agricultural), railways and two
wheelers.

 SUNDARAM FASTENERS LIMITED

Started in 1966, Sundaram fasteners limited have grown into a global leader,
manufacturing critical, high precision components for the automotive,
infrastructure, windmill and aviation sectors.Our varied range of productions
encompasses fasteners, power train components, sintered metal products, iron
powder, cold extruded parts, radiator caps, water pumps, oil pumps and wind
energy components.An unwavering focus on delivering quality has won
sundaram fasteners limited the trust of both OEM and aftermarket customers in
highly competitive markets like India, china, Germany, USA, UK, Italy, France
and Brazil.

 SUNDARAM FINANCE LIMITED

Sundaram finance limited is a financial and investment service provider in
India. It is based in Chennai and has more than 640 branches across the country.
The company offers vehicles loan, construction equipment loan, consumer
loans, wealth management, commercial finance and infrastructure finance
among others.

 SUNDARAM INDUSTIES
Sundaram industries private limited is a group company of the illustrious TVS
group in south India. The TVS group is India’s leading supplier of automotive
components and one of the country’s most respected business groups – a name

4
to reckon with when it comes to value-based businesses. Today this 100 year
renowned business conglomerate remains faithful to its core ideals of TRUST,
VALUE, SERVICE and ETHICS.

 SUNDARAM MOTORS
Sundaram motors, is a division of TV sundaram lyengar and sons private
limited, and is an authorized dealer for Honda cars operating as sundaram
Honda.TV Sundaram lyengar and sons private limited, Madurai, the holding
company of the TVS group, began passenger bus transport operations in 1911.
Over the past nine decades, the TVS group ventured into vehicle sales and
service, spare parts distribution, manufacture of automobile components, two
wheelers, computer peripherals including printers, hire purchase financing,
leasing apart from general insurance. The TVS group comprises including
printers, hire purchase financing, leasing apart from general insurance. The TVS
group comprises of 45 companies with over 30,000 employees and a group
turnover exceeding US$ 4 billion.

1.3 ABOUT THE COMPANY

Sundaram industries are a part of 8.5 Billion USD TVS group established in the
year 1961 at Madurai for the manufacture of moulded rubber products. Own
compound mixing, mould design and development with state of the art
manufacturing facility. Compound design and development offers wide range of
polymers NR, Butyl, SBR, NBR, CR, EPDM, HNBR, FKM, ACM, VMQ and
other high end polymers on specific request and application. Supports product
design to customers through CAE wherever required. Product traceability
system through “Bar codes” starting raw material and up to finished products.
Segments of business which includes automotive, Defense, Railways, Textile,
Mining, Construction and off Highway equipments and many more.
Manufacture of safety critical technical parts with grate focus on quality
consistency and service. Provides elastomeric solution to many customers for
5
the existing and future parts with home grown technology in compounding,
design and development. Employs round 1,000 persons with service network
spread in all the regions in India as well as in Europe and America. World
leaders in the component industry who are in the manufacturing of Braking,
Steering, Chassis and many more automotive systems are the key customers.

1.4 SEAL FENDER

Seal fender which product your vehicle protect your vehicle from dirt, mud, and
dust with these first-rate AND seals. Manufactured to original factory
specifications, they provide the same function as the seals from the dealer. The
sealing will be obtained due to interference pressure between the seal seat and
seal and also behind the seal in space between the seal base plates. These seals
may be used as top, bottom and side seals either by using them with water
pressure acting which is withdrawn before the gate is moved to reduce /
eliminate friction load or they may be used with metal or fluorocarbon film to
achieve the same purpose. On heavy gates is moved to reduce / eliminate
friction load or they may be used with metal or fluorocarbon film to achieve the
same purpose. On heavy gates such seals may be well bottom seals where
enough mechanical compression becomes available to make a good seal.

6
1.5 MAJOR POLYMERS AND THEIR COLOUR CODES
 EPDM - Yellow
 Neoprene - Orange
 Natural - White
 Nitrile - pale blue
 SBR - Pale green
 Silicones - Green
 Poly acrylic - Light orange
 Other polymers - Gold

1.6 METHODS USED IN INDUSTRIES

 KAIZEN
From the Japanese words “kaizen” which means “Change for Better”. The
popular meaning from Toyota is “continuous improvement” or “small
incremental improvements” of all areas of a company, not just manufacturing.
Kaizen means all personnel are expected to stop their work when they encounter
any abnormality and, along with their supervisor, suggest an improvement to
resolve the abnormality.

 5S
5S is a system for organizing spaces so work can be performed efficiently,
effectively, and safely. This system focuses on putting everything where it
belongs and keeping the workplace clean, which makes it easier for people to do
their jobs without wasting time or risking injury.

 POKA-YOKE
Japanese approach to ‘mistake proofing’ in all aspects of manufacturing,
customer service, procurement, etc. It employs visual signals that make
mistakes clearly stand out from the rest, or devices that stop an assembly line or

7
process if a part or step or step is missed. Its older name is baka yoke (fool
proofing).

 SIX SIGMA
Six Sigma is a disciplined, statistical-based, data-driven approach and
continuous improvement methodology for eliminating defects in a product,
process or service. It was developed by Motorola and Bill Smith in the early
1980’s based on quality management fundamentals, then became a popular
management approach at General Electric (GE) with Jack Welch in the early
1990’s. The approach was based on the methods taught by W. Edwards
Deming, Walter Shewhart and Ronald Fisher among many others. Hundreds of
companies around the world have adopted Six Sigma as a way of doing
business.

1.7 QUALITY JOUNERY-6M APPORACH

 Manpower: People issues fall into this area. Note that many people
issues are really methods, machine, or material issues. Also note that
“manpower”, being gender specific, can be perceived as being
insensitive. Some people replace the term with “People Power”.
 Machines: Tools and equipment used to complete production task.
Facility systems also fall into this category.
 Materials: Raw materials, components, and supplies used for
production. General materials used for business operations (i.e. cleaning
supplies, 5S supplies, etc.) also fall into this
category.Methods: Production and support processes.
 Measurements: Measurements include physical measurement,
automatic sensor readings, and inspections. Note that there may be
overlap with machines regarding the measuring devices.

8
  Environment: Weather and other natural, uncontrollable events fall into
this category. Environmental systems (i.e. AC, heating) would likely fall
into machines.

1.8 DEPARTMENTS AVAILABLE

1.8.1 RAW MATERIAL DEPARTMENT

Materials management is a core supply chain function and includes supply
chain planning and supply chain execution capabilities. Specifically, materials
management is the capability firms use to plan total material requirements. The
material requirements are communicated to procurement and other functions for
sourcing. Materials management is also responsible for determining the amount
of material to be deployed at each stocking location across the supply chain,
establishing material replenishment plans, determining inventory levels to hold
for each type of inventory (raw, WIP, Finished Goods), and communicating
information regarding material needs throughout the extended supply chain.

1.8.2 DESIGN DEPARTMENT

Design management is a field of inquiry that uses project management, design,
strategy, and supply chain techniques to control a creative process, support a
culture of creativity, and build a structure and organization for design. The
objective of design management is to develop and maintain an efficient business
environment in which an organization can achieve
its strategic and mission goals through design.

1.8.3 MILLING DEPARTMENT

Milling is the process of machining using rotary cutters to remove material by
advancing a cutter into a work piece. This may be done varying direction on one
or several axes, cutter head speed, and pressure. Milling covers a wide variety
of different operations and machines, on scales from small individual parts to

9
large, heavy-duty gang milling operations. It is one of the most commonly used
processes for machining custom parts to precise tolerances.

1.8.4 STORE HOUSE AND SLUG PREPARATION

Slugs is the glass-like by-product left over after a desired metal has been
separated (i.e., smelted) from its raw ore. Slugs is usually a mixture of
metal oxides and silicon dioxide. However, slag’s can contain
metal sulfides and elemental metals. While slugs are generally used to remove
waste in metal smelting, they can also serve other purposes, such as assisting in
the temperature control of the smelting, and minimizing any re-oxidation of the
final liquid metal product before the molten metal is removed from the furnace
and used to make solid metal.

1.8.5 QUALITY
Product quality means to incorporate features that have a capacity to meet
consumer needs (wants) and gives customer satisfaction by altering products
(goods) to make them free from deficiencies or defects.

1.8.6 MAINTENANCE DEPARTMENT

The technical meaning of maintenance involves functional checks, servicing,
repairing or replacing of necessary devices, equipment, machinery, building
infrastructure, and supporting utilities in industrial, business, governmental, and
residential installations. Over time, this has come to often include
both scheduled and preventive maintenance as cost-effective practices to keep
equipment ready for operation at the utilization stage of a system lifecycle.

1.8.7 FINANCE DEPARTMENT

Finance is a field that is concerned with the allocation (investment)
of assets and liabilities over space and time, often under conditions of risk or
uncertainty. Finance can also be defined as the art of money management.

10
Participants in the market aim to price assets based on their risk level,
fundamental value, and their expected rate of return. Finance can be split into
three sub-categories: public finance, corporate finance and personal finance.

1.8.8 PACKAGING AND DISPATCH

Dispatch is a procedure for assigning employees (workers) or vehicles to
customers. Industries that dispatch include taxicabs, couriers, emergency
services, as well as home and commercial services such as maid services,
plumbing, HVAC, pest control and electricians.

1.9 PROCESS FLOW IN TVS RUBBER FACTORY

Store And Raw

Material

Milling

Rubber Cutting
Compression Injection
Moulding Moulding

Moulding

Transfer Mounting (or)

Moulding Bonding
Deflashing

Final Inspection

Logistics

Customer

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1.10 MATERIAL USED IN COMPANY
 Poppet valve
 Reaction Disk
 NRV – Grommet
 Baffle
 O-Rings and Sealing Ring
 Dust Covera
 Front Seal
 Piston Boot
 Pin Boot
 Sliding Bush

1.11 PRODUCTION APPLICATION

 Gear Shift Bull Joint
 Rack And Pinion Type Steering For All Passenger Gear
 Center Line Assembly
 Tie Rod Assembly
 Drag Link Assembly
 Suspension Bull Joint
 Stabilize Link Joint
 Lower Control Arms
 Outer Ball Joint

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1.12 TYPES OF UNITS

1.12.1 Injection Molding Unit

Injection molding is the most commonly used manufacturing process for the
fabrication of rubber parts. A wide variety of products are manufactured using
injection molding, which vary greatly in their size, complexity, and application.
The injection molding process requires the use of an injection molding machine,
raw rubber material, and a mold. The rubber is melted in the injection molding
machine and then injected into the mold, where it cools and solidifies into the
final part. Injection molding is used to produce thin-walled rubber parts for a
wide variety of applications, one of the most common being rubber housings.
Rubber housing is a thin-walled enclosure, often requiring
many ribs and bosses on the interior.

1.12.2 Vacuum Compression molding unit

Compression Molding is a method of molding in which the molding material,
generally preheated, is first placed in an open, heated mould cavity. The mould
is closed with a top force or plug member, pressure is applied to force the
material into contact with all mould areas, while heat and pressure are
maintained until the molding material has cured. The process employs
thermosetting resins in a partially cured stage, either in the form of
granules, putty-like masses, or performs.

1.12.4 Mixing Units

The type of operation and equipment used during mixing depends on the state
of materials being mixed (liquid, semi-solid, or solid) and the miscibility of the
materials being processed. In this context, the act of mixing may be
synonymous with stirring-, or kneading-processes.

13
1.12.5 Post Curing Ovens
An Oven is a thermally insulated chamber used for the heating, baking, or
drying of a substance and most commonly used for cooking. Kilns and furnaces
are special purpose ovens used in pottery and metalworking, respectively.

1.12.6 Boilers
The main function of a boiler is to heat water to generate steam. Steam
produced in a boiler can be used for a variety of purposes including space
heating, sterilisation, drying, humidification and power generation. The steam
generated by steam boilers is used for driving various type of steam turbines
which further drives various types of pumps compressors generators etc.

1.13 PRODUCTS
Supply tailor made quality products to automotive, defense, railways, textile,
mining, construction and other industrial sectors. TVS Rubber, Sundaram
Industries products are tested and verified with a state of the art laboratory and
testing equipments.

14
 Products Image
Air Brake System
(Bonded 4 way Valve,
Grommets, Fabric
Reinforced Diaphragm)
Anti Vibration Mounts
(Engine Mounts, Exhaust
Mounts, Bump Stops,
Suspension Bushes, Strut
Mounts)
Hydraulic Brake
system
(Booster Diaphragm,
Brake Chamber
Diaphragm, Pin Boot,
Piston Boot, Reaction
Disc)
HVAC Systems
(Seals, Cut Gaskets for
Ducts, Grommets,
Radiator Gaskets, Frame
Gaskets, Mounting
Bushes, Washers and
other Seals)
Wiring Harness System
(Door Grommets, Wire
Grommets, Boots in
large numbers and
varieties.)

15
Parking Brake System
(long critical Bellows,
Grommets, Bushes,
Pedal Pads and many
more)

Gear Shift Leaver

Boots
( offered in various sizes
and shapes with metal or
plastic bonded or plain
rubber for key account
customers.)
Steering System
(steering boots, bellows,
dust covers, CVJ boots
and Seals)

Automotive Spare
Parts
(Front Fork Suspension,
Steering and other
Sealing applications)

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 CHAPTER - 2

LITERATURE REVIEW

1. Nitin Pandhia and Sanjeev Vermaa introduced Value Stream Mapping

(VSM) is an important tool for implementing lean philosophy. VSM is a
method to describe the flow of material and information through the production
system. The ratio of value added to total lead time is determined by
documenting the current lead time, inventory levels, and cycle times. Value
added activities make the product more closely to the customer requirement.
Non Value added activities do not create customers value, and anything that
does not constitutes to value is defined as Waste.

2. J Dinesh et. Al introduced VSM is a useful tool for process analysis and
improvement by identifying and eliminating time spent on non-value-added
activities. By using Value Stream Mapping the process time and value added
and nonvalue added activities are identified. Lead time is reduced by
improvement made in the pump industry. VSM have been proven to be a greatly
useful tool to eliminate some waste in a cycle and find there are more waste for
you to eliminate in next cycle, during which lean becomes a habit or culture.

3. Muhammad Abdus Samad et. al introduced Value Stream Mapping (VSM) is

a Special type of flow chart that uses symbols known as "the language of Lean"
to depict and improve the flow of inventory and information. Value Stream
Mapping Purpose is to provide optimum value to the customer through a
complete value creation process with minimum lead time. For this purpose they
have tried to show how the lead time can be reduced by using lean tools
properly.

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4. Rumbidzayi Muvunzi et. al Inroduced Using the VSM, Productivity
increased from 20,220 tiles per month to 28,350 tiles per month, In the tile
manufacturing industry. There was reduction of defects from 245 defective tiles
per day to 10 defects thus saving the company up to $4419.9 per month. Raw
materials were saved which contributed to 168 tiles per day which translates to
$2993.76 per month. Lead time reduction from 8467 seconds to 5657 seconds,
that is by 46.8 minutes, which contribute up to 12% of production time.

5. Rahani Ar, Muhammad al-Ashraf described a case where Lean Production

(LP) principles were adapted for the process sector of an automotive part
manufacturing plant. Value Stream Mapping (VSM) is one of the key lean tools
used to identify the opportunities for various lean techniques. The contrast of
the before and after the LP initiatives in determine managers potential benefits
such as reduced production lead-time and lower work-in-process inventory. As
VSM involves in all of the process steps, both value added and non-value
added, are analyzed and using VSM as a visual tool to help see the hidden waste
and sources of waste

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 CHAPTER - 3

PROJECT INTRODUCTION
In this project, we are going to do reducing the cycle time on injection moulding
to achieve higher production output. Before, getting start into to the project. We
have to know each and every aspects and information about Injection Moulding.

3.1 INJECTION MOULDING

Injection moulding is a method to obtain moulded products by injecting rubber
materials molten by heat into a mould, and then Curing and solidifying them.
The method is suitable for the mass production of products with complicated
shapes, and takes a large part in the area of rubber processing.

3.2 INJECTION MOULDING MACHINE

Fig 3.1 INJECTION MOULDING MACHINE

Injection moulding machine moulds can be fastened in either a horizontal or

vertical position. The majority of machines are horizontally oriented, but
vertical machines are used in some niche applications such as insert moulding,
allowing the machine to take advantage of gravity. Some vertical machines also
do not require the mould to be fastened. There are many ways to fasten the tools

19
to the platens, the most common being manual clamps; however, hydraulic
clamps and magnetic clamps are also used. The magnetic and hydraulic clamps
are used where fast tool changes are required.

3.3 MOULD
A mould is a hollow metal block into which molten rubber is injected to from a
certain fixed shape. Although they are not illustrated in the figure shown below,
actually there are many holes drilled in the block for temperature control by
means of hot water, oil or heaters. Molten rubber flows into a mould through a
sprue and fills cavities by way of runners and gates. Then, the mould is opened
after Curing process and the ejector rod of the injection moulding machine
pushes the ejector plate of the mould to further eject mouldings.

3.4 MOULDING
A moulding consists of a sprue to introduce molten resin, a runner to lead it to
cavities, and products. Since obtaining only one product by one shot is very
inefficient, a mould is usually designed to have multiple cavities connected with
a runner so that many products can be made by one shot. If the length of the
runner to each cavity is different in this case, the cavities may not be filled
simultaneously, so that dimensions, appearances or properties of the mouldings
are often different cavity by cavity. Therefore the runner is usually designed so
as to have the same length from the sprue to each cavity.

Fig 3.2 Moudling Parts

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3.5 USE OF REPROCESSED MATERIALS
Sprues and runners among mouldings are not products. These portions are
sometimes discarded, but in other cases they are finely reground and reused as
materials for moulding. These materials are called reprocessed materials.

3.6 MOULDING CONDITION

Moulding condition means cylinder temperature, injection speed, mould
temperature etc. set in a moulding machine to obtain required mouldings, and
the number of combinations of conditions is innumerable. Depending on the
Conditions selected, the appearances, dimensions, and mechanical properties of
the moulded products change considerably. Therefore, well-tried technology
and experience are required to select the most suitable moulding conditions.

3.7 BASIC PROCESS OF INJECTION MOULDING

The various stages of the injection moulding process are carefully
considered when analyzing part design, tool creation and efficient
production of molded rubber products.
Step 1: The Mould Closes
The Injection Moulding cycle timer begins when the mold closes.

Step 2: Injection
The heated rubber is injected into the mold. As the melt enters the mold, the
displaced air escapes through vents in the injection pins and along the parting
line. Runner, gate and vent design are important to insure the mold is properly
filled.

Step 3: Curing
Once the mold is filled the part is allowed to cool for the exact amount of time
needed to harden the material. Curing time is dependent on the type of rubber
material used and the thickness of the part. Each mold is designed with internal
Curing or heating lines.
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Step 4: Feeding raw material
While the part cools, the barrel screw retracts and draws new rubber into the
barrel from the material extruder. The heater bands maintain the needed barrel
temperature for the type of resin being used.

Step 5: Ejection
The mold opens and the ejector rod moves the ejector pins forward. The part
falls and is captured in a bin located below the mold.

Step 6: Removing The Runner And Packaging

Although the injection molding machine’s cycle ends on Step 5, the process
continues. Periodically the machine operators or robots separate the usable parts
from the left over runner. The runner is the pathway that the rubber takes to fill
the mold cavity. In many cases the runners are ground and recycled to reduce
costs and environmental impact. The usable parts are then weighed, counted
and packaged for assembly or shipping.

22
 CHAPTER – 4

PURGING FLASH REDUCTION

4.1 PURGING

In injection moulding process , the rubber is given to the extruder and the
extruder sends the rubber to the end of the injector ,the injector gives pressure
of 2000 to 3000 psi and injects the rubber into the mould through the nozzle .

Since the nozzle is in continuous contact with the mould top plate which
is of 180°c ,the nozzle takes some parts of temperature and the rubber which is
entering through the nozzle gets cured, before it enters the mould.For this, the
operator removes the cured rubber by doing the process called purging.For each
cure, the operator removes the cured rubber from the nozzle to prevent the
mixing of cured rubber to the product and also for huge rejection in the number
of products. The process of removing the cured rubber is called purging.

4.2 PURGING PROCESS

During the injection moulding process the rubber gets cured in the nozzle,
due to the transfer of temperature between the heater plate and nozzle .The
Process of removing those cured rubber is called Purging process.If the rubber
doesn’t removed by the operator, it will damage the product .In this industry
different kinds of rubber is used for making different products .Some rubber’s
curing time is less and it is cured in short span of time and some rubber’s curing
time is more and it takes long span of time for curing.Curing also depends on
the property of the rubber. In TVS Rubber Industry Purging process plays the
major role in the wastage of rubber. The rubber once cured cannot be used in
furthur process for making products.The cured rubber is considered as a waste
and it is collected separately.

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4.3 PROBLEM DEFINITION

1) What is the Problem?

Wastage of rubber due to purging process.

2) Where is the Problem Occuring?

In Injection Moulding Machine,in between heater plate and Upper
Plate Die.
3) When is the Problem Occuring?
During the moulding process in the moulding Machine.
4) How do we get to know the problem?
From Moulding and Final inspection and Visual inspection in all parts.
4.3.1 IMPACT OF THE PROBLEM
1) Failure Of Product
2) Complaints from the Customer
3) High Scrap Value
4) Inspection Carried out
5) Extra time consumption
4.3.2 BRAINSTORMING
1) Cure Bit Rejection
2) Temperature Variation
3) Stopping of Machine
4) Mould Change
5) Depends on the type of rubber
6) Efficiency of Machine
7) Arrangement of machine
8) Depends on the Mix
9) Timing
10) Depends on CRB 11) For Fast Flow

24
 4.3.3 ALL POSSIBLE CAUSES

25
 4.3.4 PURGE LEAK FOR 6 DAYS

Average purge leak for 6

Sl No Press No days % Cum %

1 Press 12.400 1050.0 15.3 15.3

2 Press 12.392 1015.0 14.8 30.1

3 Press 12.396 710.8 10.3 40.4

4 Press 12.302 683.3 9.9 50.4

5 Press 12.391 593.3 8.6 59.0

6 Press 12.401 550.0 8.0 67.0

7 Press 12.393 526.6 7.7 74.7

8 Press 12.228 471.6 6.9 81.6

9 Press 12.394 453.3 6.6 88.2

10 Press 12.402 316.6 4.6 92.8

11 Press 12.397 298.3 4.3 97.1

12 Press 12.395 116.6 1.7 98.8

13 Press 12.398 83.3 1.2 100.0

TOTAL 6868.7

26
 4.3.5 PARETO CHART FOR PURE LEAK

27
4.3.6 SUGGESTION
1) ALARM FOR EXTRUDER
In the extruder , a proximity sensor is placed in the mouth of the
extruder to detect the presence of the rubber. when the operator does not
insert the rubber into the extruder after the finishing of curing time in the
machine ,the sensor will detect it and the alarm will alert the operator to
insert the rubber into the mouth of the extruder.
2) COOLANT SETUP FOR THE NOZZLE
Since the temperature from the heater plate passes to the mould and
machine nozzle it causes the curing of the rubber in the nozzle and it
causes damage in the product.To prevent the curing of rubber we suggested
a coolant supply for the nozzle .
3) NOZZLE UNIT UP/DOWN
During the moulding process the nozzle is in continuous contact with
the heater plate hence this causes the transfer of heat from the heater plate
to the nozzle and this cause rise in the temperature .Due to this rise in the
temperature the rubber which is passed through the nozzle gets cured.we
suggested to lift the nozzle for each cure which will minimize the curing of
rubber.
4) OPERATOR AWARENESS
In B-54 type injection moulding, each machine had a purge leak and
the amount of leak which is removed by the operator plays a main role in
wastage of rubber. Trained Operator will remove a less amount of purge
leak whereas untrained operator will remove large amount of purge leak.
So the Untrained Operator should aware about this, and operate the
machine properly.
5) CRB MAINTENANCE
Cold runner block which is present inbetween the mould top plate
and heater plate should undergo a weekly maintenance .
28
 6) SYNDANIO SHEET
By using the syndanio sheet we can reduce the heat transfer between
the nozzle and the mould .The syndanio sheet is placed in the top of the
mould where the nozzle is in contact .This will control the heat transfer
between the mould and nozzle.
7) MOULD TEMPERATURE CONTROLLER
Mould temperature controller is used to control the temperature of
CRB by supplying the oil from the controller .CRB temperature is
maintained at the range of 55±10 °c , If the temperature exceeds the limit
MTC will start to cool and if the temperature goes below the limit It will
supply heat.
4.4 IMPLEMENTATION
1) MOULD TEMPERATURE CONTROLLER

29
 MTC is an upcoming technology in the field of injection moulding which
can heat and cool the cavity surface during the injection moulding process. In
this research, the heating and cooling systems consist of a mould temperature
controller, a heating system, and a mould plate.
MTC is used to maintain the temperature of the CRB which is 60°c by
suppling the oil to the CRB.If the temperature exceeds 60°c MTC will starts to
supply coolant to the CRB and brings back to the temperature of 60°c .If the
temperature goes below 55°c it will stop the oil supply By this process it
maintains the temperature inbetween this range.

By connecting the Mould temperature Controller with injection moulding

machine ,We had a reduction of 20 -25% in the Purging process .
2) SYNDANIO SHEET (Heat resistance sheet on mould)
Syndanio-350 having good insulation & very high compressive strength
can withstand 350o continuous temperature

This is high strength machinable Non- Asbestos grade thermal and

electrical insulation board suitable for applications requiring high mechanical
strength at high temperature.It has two types of sheets,

30
 ▫ Syndanio – 350:-With stands 350 °C Continuous Temperature
▫ Syndanio – 550:-With stands 550 °C Continuous Temperature.
ADVANTAGES OF SYNDANIO SHEET :-
 High Mechanical strength

 Precise to machine and work

 Various grades available up to 550 °C
 Thermal Insulating
 Non-Combustible & Non-ignitable
 High electrical strength and arc resistance
 Safe in terms of working hygiene
AUTOCAD DESIGN :-

OLD DESIGN

NEW DESIGN

31
3D CREO MODEL:-

OLD MODEL

NEW MODEL

32
We are going to place the syndanio sheets Which is a heat resistant material
look like Aspectos in the top layer of upper plate. This Sheet Will prevent the
entering of heat to the nozzle And also prevents the curing of rubber in the
Nozzle.This accounts for the reduction in the wastage of rubber

FINAL MOULD

33
 4.5 RESULT:

S Purge Leak Before Purge Leak After

no Implementing(in Grams) Implementing(in grams)
1 1200 755

2 1260 780

3 1275 745

4 1315 785

5 1240 740

6 1235 685

7 1135 780

4.6 CONCLUSION:

After the implementation of these mould in machine number

12.396 the purge leak had reduced upto 40-45% in that machine.If we
implement this mould in all b-54 type injection moulding machine, the
production rate will increase to the higher level.

4.7 FUTURE WORKS:

For the Complete rejection of purging we should go for nozzle

coolant setup. If we implement these nozzle coolant setup there is a chance for
complete rejection of purging process.

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COOLANT SETUP:

This is the machine nozzle with the coolant setup.For implementing this
setup we need another thermocontroller to supply the coolant to the nozzle
setup.Since we have to alter the B-54 Injection moulding machine setup this
will become a complex process.But if we alter the machine design and
implement this coolant setup there is a chance for the complete rejection of
purging process

35
 CHAPTER – 5

CYCLE TIME REDUCTION

5.1 CYCLE TIME

The total time from the beginning to the end of your Process, as defined by you
and your customer. Cycle time includes Process time, during which a unit is
acted upon to bring it closer to an output, and delay time, during which a unit of
work is spent waiting to take the next action. In a manufacturing company,
involved in large capital Products, the cycle time may similarly be the time from
raw material receipt through to the time the item of Production finishes final
inspection.

5.1.1 Cycle Time calculation in a continuous Process

In the vast majority of instances, there will be numerous Products or services
being Processed at any one time, therefore the cycle time calculation needs to be
as follows:
Cycle time = Time for completion of a unit

.5.2 TIME STUDY

Time study is a structured Process of directly observing and measuring human
work using a timing device to establish the time required for completion of the
work by a qualified worker when working at a defined level of Performance.
It follows the basic Procedure of systematic work measurement of:

36
  analysis of the work into small, easily-measurable components or
elements
 measurement of those components and
 Synthesis from those measured components to arrive at a time for the
complete job.
The observer first undertakes Preliminary observation of the work (a Pilot
study) to identify suitable elements which can be clearly recognised on
subsequent occasions and are of convenient length for measurement.

Time study is a very flexible technique, suitable for a wide range of work
Performed under a wide range of conditions, although it is difficult to time jobs
with very short cycle times (of a few seconds). Because it is a direct observation
technique, it takes account of specific and special conditions but it does rely on
the use of the subjective Process of rating. However, if Properly carried out it
Produces consistent results and it is widely used. Additionally, the use of
electronic data captures devices and a Personal computer for analysis makes it
much more cost effective than Previously.

5.2.1 Online Time

Activity or a Process which is carried out during the machine is at non-
running state. Then, the time is said to Online Time.

5.2.2 Idle Time

Activity or a Process which is carried out during the machine is at
running state. Then, the time is said to Idle or Offline Time.

5.3 ACTIVITY LOG

An Activity Log (also known as an Activity Diary or a Job Activity
Log) is a written record of how you spend your time.Activity Logs are useful
tools for analyzing how you use your time. They help you track changes in your

37
energy, alertness and effectiveness throughout the day, and they help you
eliminate time wasting activities, so that you can be more Productive.
Once you've analyzed your Activity Log, you should be able to boost your
Productivity by eliminating or delegating low-value activities, scheduling
challenging tasks for the time of the day when you feel your best, minimizing
the number of times that you switch between types of tasks, and reducing the
time you spend on Personal activities.

38
 CHAPTER – 6
PROBLEM IDENTIFICATION

In New Injection Cell, Products are mentioned in Part name and number. We
obtained Production rate data for all the Parts of Past three months duration. We
Picked out the Parts which doesn’t achieve the stipulated cure.
In injection moulding, number of Production is expressed in cure. A cure may
has one or more number of Product, this depends up on the design of the mould.

6.1 STIPULATED CURE (STP CURE)

In moulding, a raw material which is converted into Products is said to be cure.
Like this, the Planned Production output for specific Period of time is said to
stipulated cure in this Process.

6.2 ACTUAL CURE

The number of cure which is Produced in a sPecific Period of time or shift at
real time is known Actual Cure.

6.3 PARTS LACK ON ACHIEVING STP CURE

By analyzing, last three month Production data. There are nearly 24 Parts which
doesn’t achieve the stipulated cure. In this list of Parts, Only few of the Parts are
on Production now. As Per the customer’s demand and requirements, each and
every Part is to be manufactured. In the short listed Parts, few of the Parts are
manufactured by using different mould. Some mould may vary in cavity, size
etc., it’s depend upon its design. So, mould number are to collected for same
and different Parts.

39
 TABLE 6.1 PARTS LACK TO ACHIEVING STP CURE
STP
Sl.no Parts Mould Cavity Cure Actual Cure
1 Seal RH a 1 6 22 18
2 bellow small 1 16 90 65
3 Seal RH b 1 56 22 18
4 link 1 31 60 52
5 Grommet 1 24 60 47
6 Bellow Big 1 8 55 52
7 Gasket 1 6 120 112
8 Shield fuel tank 1 4 90 45
9 Hose 1 16 60 45
10 Tank Packing A 1 60 24 22
11 Tank Packing B 1 56 24 22
12 Tank Packing C 1 66 24 21
13 Tank Packing D 1 66 24 21
14 Tank Packing E 1 56 24 22
15 Tank Packing F 1 60 24 22
16 Tank Packing G 1 60 24 22
17 Tank Packing H 1 56 22 11
18 Tank Packing I 1 56 24 23
19 bumPer 1 48 70 56
20 Tank Packing 1 56 24 22
21 PAD RR BPG AM-1 1 8 70 67
22 Bellow 1 24 60/75 75
23 Bush 1 24 120 112
24 Front engine mounting 1 2 29 28
25 Grommet 1 120 119
26 PAD RR BPG AM-2 1 8 70 57
27 Bellow 1 16 50 40

40
In the above table, there are nearly 27 Parts which is lack on achieving STP
cure. On these Parts, there are only three of them are under Production in
Present which is listed in the below table.

TABLE 6.2 SHORTLISTED PARTS AT PRESENT

STP
Sl.no Parts Mould Cavity Cure Actual Cure
1 PAD RR BPG AM-1 1 8 70 67
2 Bellow 1 24 60/75 75
3 PAD RR BPG AM-2 1 8 70 57

From the above table,we are going to work on one of the Parts to achieve STP
cure. Because, these Part are on lacks in achieving STP cure at Present.The Part
we are going to work on is Bellow.

41
 CHAPTER – 7

DATA COLLECTION

To achieve the STP cure on the Part Bellow. The better way is to reduce the
cycle time by eliminating the activity which leads to wastage of time or else
rearrange or modify activity in order to reduce the cycle time on Production of
the Parts. We use VSM (Value Stream MaPPing) and ECRS (Eliminate
Combine Rearrange Satisfy)

At first, we have study the Activity Log. Activity Log helPs to identify the each
and every activity which is carried out during Production.

7.1 ACTIVITY LOG

Activity Log of the Part are noted by observing the oPerator’s Process, stePs,
and activities which is undergone during the Production of the Part.

In this Log, Activity of these Part may also vary to oPerator’s skill and way of
learnt. So we have to standardize the Activity log as Per different oPerator’s
activities. Every cycle, the activity list may or may not be same due to its
obstacles and circumstance.

7.1.1 Bellow - ACTIVITY LOG

Activity Log of Bellow is shown below. In the listed activities, the order may
vary in some cases. Sometimes, some activity is not carried out. It is already
done in idle time.

42
 TABLE 7.1.1 BELLOW- ACTIVITY LOG

Activity No. Activities

1 Mould moves down

2 Flash removing
3 Mould moves down again
4 Mould slide out
5 Flash removing
6 Mould lift Up
7 Mould rotate (half)
8 Cleaning mould
9 Mould rotate (half)
10 Mould moves down
11 Mould sliding in
12 Checking Pressure
13 Mould moves uP
14 Disc slide in
15 Disc clam uP and hold
16 injection Extrusion curing
17 Feeding

7.2 TIME STUDY

For the Part Bellow, Time Study is taken on basis of continuous data for
duration of one hour. During the taking of time study, all the activities which is
carried out by the oPerator is noted down. There is no desired number of cycles
to observe in this hour.Time study is taken by using a digital clock or digital
stoP timer. As Per industrial standard, for time study it is must to use only
digital timer or clock in order to get the accurate duration of activities in
seconds.Time study for Bellow are given below in a Time Study Chart.

43
 TABLE 7.2.1 Bellow – TIME STUDY

44
7.3 CALCULATIONS

Man Handling Time

Providing 5% Cushion Time = ×105
100

128
Providing 5% Cushion Time in cycle time (GN15) = ×105
100

= 135 Seconds

Cycle Time = Man Handling Time(Including cushion time) + Machine

Handling Time

Cycle Time (GN15) = 135+313

= 448 Seconds

Shift Time = 7.5 hours = 450 min = 27000 seconds

Total Available Time or Shift Time

Number of cure Per shift =
Average Cycle Time

27000
=
448

= 61 Cure Per shift

45
 CHAPTER – 8

SUGGESTION
We are going to automate some of the process in injection moulding machine in
order to reduce the cycle time which is used for one cure. Sensor plays an
important role in the automation of these process . The process we are going to
automate is
1) Mould sliding in
2) Mould up
3) Mould down
4) Mould sliding out

SIDE VIEW OF SENSOR SETUP

46
FRONT VIEW OF SENSOR SETUP

47
PLC DIAGRAM FOR AUTOMATION OF THE PROCESS

48
8.1 THEORETICAL CALCULATIONS

AVG TIME TAKEN AVG TIME TAKEN

S NO PROCESS BEFORE AFTER

1 MOULD SLIDE IN 9 7

2 MOULD SLIDE OUT 9 7

MOULD MOVES
3 DOWN 4 3

4 MOULD MOVES UP 5 3

Time Consumers Before After

Selected Process Timing 27 secs 21 secs
Cycle Time 350 secs 344 secs
No. Of cure Per (Actual) 64/shift 65/shift
STP CURE 70/Shift

No of cure increased per shift after implementation : 1 cure

No of products obtained from 1 cure : 8 bellows.

No of shifts per day : 3 shifts

Increase in the number of products per day after implementation : 24 bellows.

49
8.2 CONCLUSION

This report is concluded and shows cycle time reduction is achieved by using
the sensors interfaced with PLC in Injection Moulding Unit. The methodology
helps to automate some of the injection moulding process and the machine as a
computerized and also accounts for the reduction in the time for single cure.
The Project carries genuine advantage of focusing on eliminating all kinds of
non-value added activities in the rubber industry. It focuses the cycle time
reduction by elimination non value-added time to improve the number of cure
Per shift.

50
REFERENCE

[1] Lean Manufacturing: PrinciPles to Practice (2011) by Akhilesh N. Singh

[2] WikiPedia: httPs://en.wikiPedia.org/wiki/Molding
[3] R S Khurmi, J.K GuPta (2005), A text book of Machine Design.
[4] An Introduction To The Injection Moulding Of Plastics (2008) by EIRI
Board.
[5] The Toyota Way to Service Excellence: Lean Transformation in Service
Organizations (2016) by Jeffrey K. Liker

51