Final presentation

AT GAYLEY

SUMMER PROJECT

Saurabh Khurana M.S. Candidate I.E. Clemson University

About MyselfHi I am Saurabh Khurana. I am Masters student at Clemson University and I am majoring in Industrial Engineering with the focus on Quality Engineering, Six-Sigma and LEAN. I completed my bachelors degree in Mechanical Engineering from SRM University, India.Previously, I have interned in companies like Honda and Mahindra. This is my first International working experience at Sage Automotive. I am grateful to Mr. Doug Morris and Mr. Scott Colman to give me this great opportunity. During the course of last 3 months, I learned a lot about the working of an Automotive textile firm, successfully completed 2 projects, made many new friends and learnt a lot about American culture. Overall it was a great learning experience.

Currently, after completing my masters degree, I plan to work in the automotive sector for at 5 years before I go back to school to start with doctorate degree in Quality Engineering domain

Introduction

PROJECTS

1)Temperature Study of Automotive Fabric.

2)Modifying and upgrading Tenter-2 with Inspection Capabilities. (Time Study )

PROJECT-1

TITLE

“Temperature Study of Automotive Fabric”

*Three factors, No. of lots

OBJECTIVE

“To observe the pattern of the fabric- temperature behavior with respect to its zone temperature, for each fabric style running at Tenter-2, Tenter-4 and Range-6.”

METHOD

• Over a duration of 2 months, data on fabric temperature and heater’s zone temperature was collected on a daily basis, for all the fabric running on the 3 machines.

• The corresponding lot number, style number, and Pass orientation for each lot was also noted.

• The data was then classified into categories based on similar styles before analyzing relationship between the fabric’s temperature and the zone temperature over time.

FABRIC SENSOR POSITION

Zone-6

Zone-5

Zone-4

Zone-3

Zone-2

Zone-1

TENTER-2 TENTER-4 RANGE-6

Fabric In Fabric In

Fabric Out Fabric Out

*Note- Each zone on every machine has a Zone Temp Sensor.

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Zone-7

Zone-8

Zone-1

Zone-2

Zone-3

Zone-4

Zone-5

Zone-6

Zone-1

Zone-2

Zone-3

Zone-4

Zone-5

Zone-6

EQUIPMENT LAYOUT

• Each machine has been divided into 6 heat zones.

• Tenter-2 has “2 fabric temperature sensors” installed in Zone-6.

• Tenter-4 is installed with “6 fabric temperature sensors”. Zones 3,4, and 5 have “1 sensor” each. Zone 6 has “3 horizontally aligned sensors” in a SIDE-CENTER-SIDE pattern.

• Range-6 has “12 fabric temperature sensors”. Zones 2,3, and 4 have “1sensor” each. Zones 1,5, and 6 have “3 sensors” each in a similar SIDE-CENTER-SIDE pattern.

TENTER-2 DATA

TENTER-2

S.No. Date Time Lot Ornt Style NameStyle No. Speed

Zone -6 Temp ( Degree F)

Fabric Temp ( Degree F)

1 6-Jun 11:50 12336 1 Sedoso-Wide 4476 25 410 405.5 393.8 395.62 9-Jun 13:20 12344 1 Sedoso-Wide 4474 25 410 408.9 399.2 399.23 9-Jun 13:42 12352 1 Sedoso-Wide 4414 25 410 409.8 399.2 4014 9-Jun 16:14 12224 1 Sedoso-Wide 5656 25 410 409.5 399.2 399.25 16-Jun 13:45 12670 1 Sedoso-Wide 4475 25 410 411.2 399.2 4016 16-Jun 14:08 12673 1 Sedoso-Wide 4474 25 410 410 399.2 4017 16-Jun 14:30 12675 1 Sedoso-Wide 4474 25 410 410.6 401 4018 16-Jun 15:14 12672 1 Sedoso-Wide 4474 25 410 411.3 399.2 4019 16-Jun 15:37 12674 1 Sedoso-Wide 4474 25 410 410.1 399.2 401

10 16-Jun 16:00 12671 1 Sedoso-Wide 4474 25 410 409.9 399.2 40111 16-Jun 16:22 12676 1 Sedoso-Wide 4474 25 410 409 401 40112 26-Jun 9:12 13109 1 Sedoso-Wide 4474 25 410 410.2 399.2 399.213 26-Jun 9:34 13104 1 Sedoso-Wide 4474 25 410 411 397.4 397.414 26-Jun 9:50 13110 1 Sedoso-Wide 4474 25 410 410.4 397.4 399.215 26-Jun 10:19 13111 1 Sedoso-Wide 4474 25 410 409.3 399.2 399.216 26-Jun 10:40 13062 1 Sedoso-Wide 4474 25 410 409.5 399.2 399.217 26-Jun 11:03 13060 1 Sedoso-Wide 4474 25 410 409.4 397.4 397.418 26-Jun 11:25 13061 1 Sedoso-Wide 4474 25 410 410 395.6 395.619 26-Jun 11:48 13063 1 Sedoso-Wide 4474 25 410 410.8 397.4 397.420 30-Jun 8:13 2113074 1 Sedoso Wide 4474 25 410 410.1 399.2 399.221 30-Jun 8:35 2113357 1 Sedoso Wide 4474 25 410 409.9 399.2 399.222 30-Jun 8:58 2113084 1 Sedoso Wide 4474 25 410 410.1 399.2 399.223 30-Jun 9:21 2113068 1 Sedoso Wide 4474 25 410 409.9 399.2 399.224 30-Jun 9:43 2113085 1 Sedoso Wide 4474 25 410 410.8 399.2 399.225 30-Jun 10:05 2113358 1 Sedoso Wide 4474 25 410 410 399.2 399.226 30-Jun 10:28 2113408 1 Sedoso Wide 4474 25 410 409 397.4 399.2

FABRIC TEMPERATURE DATA FOR SEDOSO-WIDE (volume . 27% total fabric)

Graphical representation of fabric temp variation of various lots from the mean fabric temperature - Sedoso wide

TENTER-2

12336

12344

12352

12224

12670

12673

12675

12672

12674

12671

12676

13109

13104

13110

13111

13062

13060

13061

13063211

211211

211211

211211

394.3

395.8

397.3

398.8

400.3

401.8

403.3 Sedoso “Dye-Side” Fabric Temp

ACTUAL TEMP

AVG TEMP

Tem

pLOT

1233

6

1235

2

1267

0

1267

5

1267

4

1267

6

1310

4

1311

1

1306

0

1306

3

2113

357

2113

068

2113

358

394.5

396.1

397.7

399.3

400.9

402.5

Sedoso “T-4 Side” Fabric Temp

ACTUAL TEMP

AVG TEMP

LOT

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&ĂďƌŝĐ/Ŷ

ANALYSIS

TENTER-2

• The variation between Fabric Temp and the mean Fabric temperature for Sedoso is within 3 standard deviation for 96% of its lots.

• This suggests that the variation in fabric temperature for Sedoso in Zone 6 is under control ( Repeatable fabric temp ).

• The average fabric temperature value (398.8 *F) compared to the average zone temperature (409.9* F) indicates that Tenter-2 oven heating is 97.7 % efficiency.

CONCLUSION

• Since high accuracy is achieved for fabric heating at the three equipment, the next step could be to “increase the fabric speed at the equipment” or “reducing the zone temperature to increase energy saving.”

• The best option is to increase the fabric speed at the equipment by 10% of its current values. In the future, use the new values as benchmark, to perform experiments and further optimize the fabric speed without compromising with the quality and hence achieve higher overall productivity.

TENTER-4 DATA

TENTER-4S.No. Date Time Lot Ornt Style Name Style

No. Fabric Temperature ( Degree F) Zone - temperature ( Degree F) Speed-30 ypm 1 2 3 S C S Z-1 Z-2 Z-3 Z-4 Z-5 Z-6

1 5-Jun 8:35 84799 2Legacy II Heatset 4357 355 356 364 348 355 354 360.2 360.4 360.4 359.1 360.3 359

2 6-Jun 9:01 84251 1Legacy II Heatset 4357 353 355 363 347 354 353 359.7 359.5 360.3 360 359.8 360.2

3 7-Jun 10:19 11756 1Legacy II Heatset 4357 352 355 363 347 354 353 360 360 359 360 359.7 359.4

417-Jun 10:19 12155 1

Legacy II Heatset 4357 348 354 360 347 354 353 360.4 360.1 360.5 360.4 360.1 360.2

517-Jun 10:44 12156 1


617-Jun 15:08 12153 1

Legacy II Heatset 4357 350 353 362 347 354 352 358 342 360.2 359.9 360.3 358.5

717-Jun

3:31 PM 12157 1


817-Jun

3:56 PM 12154 1


918-Jun

2:25 PM90939 2

Legacy-II Heatset 4357 350 355 369 342 351 347 359.6 359.7 359.7 360.3 360.7 348.5

1018-Jun

2:43 PM90938 2

Legacy-II Heatset 4357 350 355 369 347 355 353 361 360.2 360.6 360.2 360.2 361.7

1118-Jun

3:08 PM84287 2

Legacy-II Heatset 4357 351 355 369 347 355 353 360.4 360.3 360.3 360 359.9 360.9

12 9-Jul 4:00 90954 2Legacy-II Heatset 4357 348 354 366 351 356 354 360.5 360.1 359.5 359.7 359.6 361.2

13 15-Jul 8:55 13604 1Legacy-II Heatset 4357 348 353 365 350 355 354 354 359.5 360 359.6 359.9 360.9

14 15-Jul 9:17 90956 1Legacy-II Heatset 4357 347 352 361 348 354 353 353 359.6 359.7 359.5 359.7 361.1

LEGACY-II ( 40,000 yards per week week )

TENTER-4

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6341

343.91

346.82

349.73

352.64

355.55

358.46Z-3 Fabric Temp

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6350.8

351.89

352.98

354.07

355.16

356.25

357.34

Z-4 Fabric Temp

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6354

357.56

361.12

364.68

368.24

371.8

375.36 Z-5 Fabric Temp

LEGACY-II

Graphical representation of fabric temp variation of various lots from the mean fabric temperature – Legacy II

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6341.1

343.1

345.1

347.1

349.1

351.1

353.1 Z-6 Fabric Temp (Side-1)

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6350.8

351.93

353.06

354.19

355.32

356.45

357.58 Z-6 Fabric Temp (Center)

8479

9

8425

1

1175

6

1215

5

1215

6

1215

3

1215

7

1215

4

9093

9

9093

8

8428

7

9095

4

1360

4

9095

6347.4

349.1

350.8

352.5

354.2

355.9


TENTER-4LEGACY-II

Graphical representation of fabric temp variation of various lots from the mean fabric Temperature – Legacy II

TENTER-4ANALYSIS

• The variation between Fabric Temp and the mean Fabric temperature for Legacy-II is within 3 standard deviation for 96% of its lots.

• The average fabric temperature value at Zone-6 (351.2 *F) compared to the average zone temperature (359.08* F) indicates that Tenter-4 oven runs at 97.8 % efficiency.

• Even though the efficiency of Fabric heating at Zone-6 at Tenter-4 is higher as compared to Tenter-2, but the Tenter-2 is equipped with 2 additional heat zones which aid in further heat setting the fabric, and hence, provide an overall increased heating efficiency.

CONCLUSION

• Look out for methods and undergoing new projects to achieve the desired fabric temperature at the previous zones to get better fabric output.

RANGE-6 DATA

RANGE-6

S.No. Date Time Lot

Orienta

tion Style NameStyle No. Speed Fabric Temperature ( Degree F) Zone - temperature ( Degree F) ( 360 )

SCS 2 3 4 SCS SCS Z-1 Z-2 Z-3 Z-4 Z-5 Z-6

1 9-Jun 10:20 11745 1 Hudson 8353 30 261 272 258 304 306 312 366 367 349 319 344 348 399

401.5+AAZ104:AZ14

0 400.8 401.1 399.2 4012 9-Jun 11:16 12115 1 Hudson 8353 30 266 280 263 307 308 315 365 368 355 276 312 345 401 399.7 401.2 398.6 399.5 399.33 10-Jun 13:55 12123 1 Hudson 8358 30 265 280 264 308 308 323 366 364 359 266 310 349 399 400.2 402.4 400.6 399.3 398.64 10-Jun 14:48 12122 1 Hudson 8358 30 268 279 265 307 309 324 370 369 359 276 308 348 401.5 399.5 400.1 400.1 400.1 401.35 11-Jun 14:14 1215 1 Hudson 8358 25 270 282 268 310 310 324 374 370 356 303 321 341 399.3 400.2 399.5 399 400.4 399.26 18-Jun 11:29 12511 1 Hudson 8358 25 265 275 261 305 309 322 376 374 362 303 335 351 400.6 401.9 401.3 401.3 400.4 400.87 20-Jun 13:59 12526 1 Hudson 8358 25 263 274 260 305 309 322 373 370 360 287 321 348 402 401 399 400.8 400.2 398.38 21-Jun 14:27 12525 1 Hudson 8358 25 265 276 262 306 309 322 368 367 352 288 321 347 400 402 399.5 400 397.4 401.79 22-Jun 14:58 12527 1 Hudson 8358 25 269 282 267 308 309 323 376 372 365 250 283 346 399.7 399.9 399.7 399.5 400.2 400.1

10 23-Jun 15:22 12523 1 Hudson 8358 25 267 282 257 308 309 322 369 364 352 252 290 345 400 401.2 400.2 399.7 398.8 399.511 24-Jun 13:08 12933 1 Hudson 8358 25 265 275 262 306 310 324 370 367 351 295 325 347 399.3 401.3 401.3 401.3 398.1 399.212 24-Jun 13:36 112923 1 Hudson 8358 25 266 279 263 306 310 325 371 370 357 276 306 345 401.7 400.2 398.9 401 399 398.813 24-Jun 14:03 112922 1 Hudson 8358 25 265 276 262 306 309 325 372 371 361 272 302 347 399.2 399.7 400.1 400.6 399.9 401.214 25-Jun 9:08 12934 1 Hudson 8358 25 267 279 263 306 310 323 373 370 354 306 325 346 400.3 400.6 400.1 400.3 399.2 399.915 25-Jun 9:36 12519 1 Hudson 8358 25 266 282 260 307 309 322 370 367 360 278 314 346 400.6 400.3 399.6 400.8 399.4 40016 25-Jun 10:05 12520 1 Hudson 8358 25 268 280 266 307 310 323 366 363 345 303 330 344 401.7 398.4 399 399 397.7 397.517 25-Jun 10:32 12534 1 Hudson 8358 25 266 278 262 306 310 324 368 367 363 299 323 345 401.9 400 399.5 399.5 400.1 400.218 25-Jun 10:52 12533 1 Hudson 8358 25 268 279 265 306 310 324 374 367 359 293 323 347 402 399.7 400.1 400.6 399.7 399.9

19 25-Jun 11:28 12924 1 Hudson 8358 25 267 277 263 305 309 322 373 370 360 306 332 348 400.8 400.8 400.8 400.4 400.8 399.220 20-Jun 13:59 12526 1 Hudson 8358 25 263 274 260 305 309 322 373 370 360 287 321 348 402 401 399 400.8 400.2 398.321 21-Jun 14:27 12525 1 Hudson 8358 25 265 276 262 306 309 322 368 367 352 288 321 347 400 402 399.5 400 397.4 401.722 22-Jun 14:58 12527 1 Hudson 8358 25 269 282 267 308 309 323 376 372 365 250 283 346 399.7 399.9 399.7 399.5 400.2 400.123 23-Jun 15:22 12523 1 Hudson 8358 25 267 282 257 308 309 322 369 364 352 252 290 345 400 401.2 400.2 399.7 398.8 399.524 24-Jun 13:08 12933 1 Hudson 8358 25 265 275 262 306 310 324 370 367 351 295 325 347 399.3 401.3 401.3 401.3 398.1 399.225 24-Jun 13:36 112923 1 Hudson 8358 25 266 279 263 306 310 325 371 370 357 276 306 345 401.7 400.2 398.9 401 399 398.826 24-Jun 14:03 112922 1 Hudson 8358 25 265 276 262 306 309 325 372 371 361 272 302 347 399.2 399.7 400.1 400.6 399.9 401.227 25-Jun 9:08 12934 1 Hudson 8358 25 265 276 262 305 310 323 370 367 360 299 331 337 399.9 400.7 399.8 400.4 399.42 399.628 25-Jun 9:36 12519 1 Hudson 8358 25 266 275 263 306 309 324 368 366 361 303 327 338 401.2 399.2 399.9 399.2 399.3 399.829 25-Jun 10:05 12520 1 Hudson 8358 25 268 280 266 307 310 323 366 363 345 303 330 344 401.7 398.4 399 399 397.7 397.530 25-Jun 10:32 12534 1 Hudson 8358 25 266 278 262 306 310 324 368 367 363 299 323 345 401.9 400 399.5 399.5 400.1 400.231 25-Jun 10:52 12533 1 Hudson 8358 25 268 279 265 306 310 324 374 367 359 293 323 347 402 399.7 400.1 400.6 399.7 399.9

32 25-Jun 11:28 12924 1 Hudson 8358 25 267 277 263 305 309 322 373 370 360 306 332 348 400.8 400.8 400.8 400.4 400.8 399.233 27-Jun 13:13 12943 1 Hudson 8358 25 264 275 260 304 310 324 375 371 361 335 351 342 401.8 400.8 400.1 400.1 400.4 399.534 1-Jul 9:48 1332 1 Hudson 8385 25 265 275 260 304 309 320 374 371 366 302 314 340 401.5 400..3 399.9 399.8 399.3 399.735 1-Jul 10:14 13302 1 Hudson 8385 25 265 275 261 305 308 315 372 371 359 290 318 343 400.3 400.4 400.1 399.7 399.32 40036 1-Jul 11:07 13326 1 Hudson 8358 25 265 275 261 305 308 320 375 370 359 295 325 344 399.8 400.1 400.8 400.4 399.2 399.637 1-Jul 11:32 13303 1 Hudson 8358 25 265 275 261 305 309 324 375 370 359 306 331 347 399.4 400.4 399.6 400.8 399.1 399.9

RANGE-6 HUDSON

Graphical representation of fabric temp variation of various lots from the mean fabric temperature – Hudson

252.7

256.8

260.9

265

269.1

273.2


259.3

265.1

270.9

276.7

282.5

288.3

294.1 Z-1 Fabric Temp (Center)

248.2

253

257.8

262.6

267.4

272.2

Z-1 Fabric Temp (Side-2)

RANGE-6 HUDSON


299.14

301.59

304.04

306.49

308.94

311.39


288.16

295.56

302.96

310.36

317.76

325.16


1174

5

1212

312

15

1252

6

1252

7

1293

3

1129

22

1251

9

1253

4

1292

4

1252

5

1252

3

1129

23

1293

4

1252

0

1253

3

1294

3

1330

2

1330

3294.35

304.15

313.95

323.75

333.55

343.35


RANGE-6 HUDSON


1174

5

1212

312

15

1252

6

1252

7

1293

3

1129

22

1251

9

1253

4

1292

4

1252

5

1252

3

1129

23

1293

4

1252

0

1253

3

1294

3

1330

2

1330

3339.74

349.63

359.52

369.41

379.3

389.19

399.08


351.93

357.14

362.35

367.56

372.77

377.98

383.19

Z-5 Fabric Temp (Center)

337.84

344.63

351.42

358.21

365

371.79

378.58Z-5 Fabric Temp (Side-2)

RANGE-6 HUDSON


223.48

246.42

269.36

292.3

315.24

338.18


269.4

286

302.6

319.2

335.8

352.4

369Z-6 Fabric Temp (Center)

1174

5

1212

312

15

1252

6

1252

7

1293

3

1129

22

1251

9

1253

4

1292

4

1252

5

1252

3

1129

23

1293

4

1252

0

1253

3

1294

3

1330

2

1330

3316.95

325.95

334.95

343.95

352.95

361.95


CONCLUSION

• Right side is hotter in zone 5 than left side.

• Left side is hotter in zone 6 than right side.

• Conclusion: The plenum in the cooling zone is not installed properly. This forces more ambient air into the left side of the dryer which cools the web.

• The change in the fabric temperature pattern as the fabric moves from zone 5 to zone 6 opens scope for a new project.

PROJECT-2

TITLE

“Modifying and upgrading Tenter-2 to include Inspection Capabilities” (Time and Activity study for scray tray capacity)

VISION

• Modern day textile industries are in a quest to optimize production processes by reducing waste regarding time and money to benefit the company in the long run.

• The project was completed with the vision to incorporate Six Sigma and LEAN at SAGE Automotive Interiors.

OBJECTIVE

The objective was to modify and upgrade “Tenter-2” with inspection capabilities, with the intention to grade and ship the fabric directly from the equipment. This would completely eliminate the secondary inspection phase at the inspection area of the Gayley plant.

CURRENT SITUATION• At the Sage Gayley plant, fabric from the

dye machine goes directly to tenter-2 for drying or heat setting. At the back-end of this tenter, the fabric is in-lined by two graders.

• In-lining simply refers to the grader

examining the fabric for defects, inputting the defect position on the lot through the BARCO system, and sending it off to the inspection area, where a portion of the fabric has to be graded again.

• It is clear that, the process is inefficient in itself since the same fabric is being graded more than once. A significant cost is involved with grading the fabric at the inspection area rather than on the Tenter.

CURRENT SITUATION

Fig. Associate in-lining fabric at Tenter-2 Fig. Associate inspecting fabric at the Inspection area

Tenter-2 Inspection area

JUSTIFICATION

COST OF INSPECTION SEDOSO

1) Total running cost (Labor, supplies)= $0.151/ yrd

2) In-lining cost ( 85 % ) : $ 0.019/ yrd Off-lining cost ( 15% ) : $ 0.059/ yrd

In-lining cost = 0.85*(0.019)= $0.01615Off-lining cost = 015*(0.059)= $0.00885Total= $0.025

Expected profit = $ 0.151/yrd – $ 0.025/yrd = $0.126/yrd

Yards per week: 75,300

Profit per week = 0.126* 75,300 = $ 9487.8 Profit in a year = $ 9487.8* 50 = $ 474,390

TOTAL SAVINGS PER WEEK: $12,000 + $700 + $400 = $ 13,100TOTAL SAVINGS PER YEAR: 50* $13,100 = $ 655,000

METHOD

• Inspecting the fabric for defects on the Tenter will require the ability to stop and reverse the fabric at the end of the tenter while the fabric is still running continuously through the heaters.

• The best way to achieve this goal is by either installing an accumulator or a scray tray between the in-lining platform and the oven, to accumulate the fabric, while the associate stops the fabric for inspection/grading.

• Since a large volume of fabric like the Headliners and Sedoso runs on Tenter-2 each day, it is important to be precise while designing the scray to the optimum capacity and minimize space.

METHOD

• If the scray tray gets overloaded with fabric due to excessive grading time by the associate, the machine would eventually have to shut down in order to get rid of the excess fabric.

• To achieve high levels of accuracy in dimensioning the scray tray, it was necessary to replicate the operations/ activities of a grader in the inspection area exactly for Tenter-2.

• As a part of this project, a Time & Activity study was conducted to understand all the possible activities performed with its duration to inspection the fabric.

METHOD

• The Time & Activity study required carefully observing and understanding the way the fabric is graded, all the responsibilities & activities of a grader, along with the duration of these activities.

• This study helped us to understand approximately how long it takes to grade each fabric lot and convert these numbers, to estimate the capacity of the scray tray, for in-line grading.

*

BENCHMARKING

In order to get ideas to re-design the Tenter , I visited Milliken Enterprise with Mr. Steven Frank, Gayley assistant plant manager, to benchmark their process.

Fig. Layout of Tenter-1 at the Enterprise

DATA & ASSUMPTIONS

• The report is based on careful examination and observation of 15 fabric lots consisting of fabrics like Taffeta , Aura and Prism.

• 7 of the observations provided useful information for analyzing the inspection process.

• The lots were taken completely randomly to ensure accuracy.

• The duration of the project was 7 days.

• Total fabric yards under observation were appx. 5000 yards.

• Inspection-speed and Tenter-speed are the same. i.e. 25 ypm.

• The speed of reversing the fabric is 10 ypm.

OBSERVATIONS STOPPING

• 53 STOPS IN 4833 YARDS 1 STOP EVERY 91.18 YARDS

• TIME BETWEEN 2 CONSECUTIVE STOPS DURATION/ SPEED

= 91.18 yards/25ypm = 3.64 minutes

• DURATION OF EACH STOP TOTAL DURATION OF STOPS / NO. OF STOPS =18.79 minutes/53 =21.27 seconds (0.41 minutes)

• NO. OF STOPS IN AN HOUR 60 minutes/ (3.64 + 0.41) minutes =14.8 times stopped in an hour

OBSERVATIONS

• TOTAL TIME TENTER IS STOPPED IN AN HOUR DURATION * NO. OF RELEVANT STOPS

= 21.27 sec * 14.28 = 303.73 sec (5.06 min)/ hr

• FABRIC CAPACITY OF THE “SCRAY TRAY” DUE TO STOPPING THE TENTER

STOPPED TIME * FABRIC SPEED

= 5.06 min * 25 ypm = 126.55 yards/ hr (excludes reversing)

OBSERVATIONSREVERSING

• 1.00 Reverse 371.76 yards

• 4.03 Reverse 1500 yards ( or an hour )

• Each Reverse Duration 6.30 Sec

• Total Time taken for Reversing activities 4.03 Reverse * 6.30Sec = 25 seconds per hour (0.41mins)

• Assuming that the Fabric Reverse Speed is 10 yards/min

• Fabric collected at the Scray Tray due to reversing-

(Reverse speed * for reverse activity) + (Tenter speed * Time for reverse activity)

= (10 ypm * 0.41 min per hr) + ( 25 ypm * 0.41 min per hr) = 14.35 yards ( per hr)

CALCULATIONS

TOTAL FABRIC CAPACITY FOR THE SCARY TRAY

Fabric accumulated due to stopping the tenter + fabric accumulated due to reversing the fabric

(126.55 + 14.35 ) yards/hr = 140.9 yards/ hr

Capacity for a 10 hour long shift 140.9 yards/ hr * 10 = 1409 yards per shift of 10 hrs

NOT POSSIBLE

• After careful examination of all the activities of an associate in the Inspection area, it can be concluded that for a shift of 10 hours, the tenter will require an accumulation of 1409 yards of fabric.

• Almost ten thousand yards of fabric run at the Tenter per shift, meaning an accumulation of 1400 yards would cause a 14% reduction in efficiency

• Its not desired to have scray tray with around 1400 yards storage capacity, due to space requirements and additional delay time of approximately an hour. It is advisable to increase the speed of the fabric at the inspection from 25 ypm to 35 ypm in order to reduce fabric accumulation and speed up the process.

OBSERVATION

CALCULATIONS/ CONCLUSION

TOTAL FABRIC CAPACITY FOR THE SCRAY TRAY

• Fabric accumulated due to stopping the Tenter + fabric accumulated due to reversing the fabric

(126.55 + 14.35 ) yards/hr = 140.9 yards/ hr

• Total No. of stops in an hour (Stops + Reverses) = 14.8 + 4.03 = 18.83 per hr

• Accumulation per stop = Total Fabric accumulated per hr / Total stops per hr

= 140.9/ 18.83 (hour) = 7.48 yards (per stop)

• Since the Inspection speed increases from 35 ypm from 25 ypm as soon as the tray is accumulated with fabric, the required capacity of the scray tray is

= 7.48 yards/ 10 ypm = 0.748 mins ( capacity required) = 0.748 mins* 25 ypm = 18.70 yards ( PERFECT WORLD)

REQUIRED NUMBER

CURRENT PROGRESS

Mr. Don West, PE, Menzel Corp. is providing us with the equipment layout design, engineering drawings and the project quotes. I am currently involved in assisting him with all the necessary work and information connected to this project.

Proposed design for Tenter: 2 webs of 65” max width, handle independently along with accumulation. Marking the rolls followed by, doffing them to the carrier.

REFERANCES

1) DOUG MORRIS- PPI

2) STEVEN FRANK- Assistant Plant Manager

3) ROBERT REECE- Plant manager

4) MELLISA MELONY- IE Manager

5) MICHELLE DAVIS- Inspection Associate

THANK YOU

Documents

Final presentation