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Applicability of Process Control Techniques inPET Strapping Production Process
Banu al
Banu Tuba Turgut
!le" #en$ar
Prof% &r% S%'"it ()tay *rat
+ar"ara ,ni$ersity-
*aculty of Engineering-
&epart"ent of .ndustrial Engineering
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Content
Overview Literature Summary Process Control Techniques Applied Studies and Findings
PET Strapping Production Process ata Collection and Preparation
Findings Conclusions and !ecommendations
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($er$ie/
The concept o# applica$ility o# ProcessControl Techniques %PCTs& to PET%Polyethylene terephthalate& strappingproduction process is presented $y using 'istograms Control charts Process capa$ility
#or #our main CT(s %$rea)ing strength* width*thic)ness* and total weight&
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SPC 0Statistical Process Control1
SPC is a well,esta$lished procedure in which data iscollected* organi-ed* analy-ed and interpreted so thata process can $e maintained at its present level o#quality or improved to a higher level o# quality.
SPC involves using statistical techniques to identi#ysource o# variation to improve per#ormance andquality simultaneously.
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Process control #ocuses on reducing the processvaria$ility to achieve the potential $ene#its coming alongwith process improvements
The aim o# process control is to )eep )ey processoperating parameters within narrow intervals and tostreamline the system $y minimi-ing the occurrence o#quality related pro$lems.
There are many ways to implement process control. PCTsgive the advantages o# monitoring the production
processes and maintaining proper #eed$ac) controlad0ustment.
Process Control
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Typical Process Control Techniques
2ey monitoring and investigating tools are given $elow3
'istograms Control Charts
Chec) Sheets Pareto Charts Cause and E##ect iagrams e#ect Concentration iagrams
Scatter iagrams
4n this study* mainly histograms and control charts are used.
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2istogra" 0continued1
Trans#orming data is the remedy o# dealing with thispro$lem.
8y this way* data are converted into trans#ormed metric so
that they have 6ormal istri$ution appearance.
There are use#ul graphical and analytical approaches #ortrans#orming the data.
4n this study log9* 9" and 1:9 tran#ormations were used.
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Control Charts Control charts are tools used to determine whether a manu#acturing
or $usiness process is in a state o# statistical control or not.
These charts consist o# a centre line %CL& which is the sample grandmean %average o# averages& and upper and lower control limits %
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Control Charts
4# a control chart indicates that the process is currently under control*
then it can $e used with con#idence to predict the #uture per#ormanceo# the process.
4# the chart indicates that the process $eing monitored is not incontrol* the pattern it reveals can help to determine the source o#variation to $e eliminated in order to $ring the process $ac) into
control.
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Control Charts 0continued1
3hy ,se Control Charts4 ?onitor process variation over time i##erentiate $etween assigna$le and common cause
variation
Assess e##ectiveness o# changes Communicate process per#ormance ?onitor process mean and varia$ility o# the process
together @
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Control Charts 0continued1
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Process Capability 0PC1
PC deals with the uni#ormity o# the process.
Daria$ility o# CT(s in the process is a measure o# theuni#ormity o# the output.
PC study #requently "easures#unctional parameters orCT(s on the product.
PC does not "easurethe process itsel#.
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5iterature Su""ary 6
Author- 7ear 7ear Sector Type of Control
Chart
8igel P% 9rigg- :eannette &aly and+ar;orie Ste/art
6
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5iterature Su""ary
Author- 7ear 7ear Sector Type of Control
Chart
:ianGin @oger :iao H Petri T% 2elo 8ylon *iberProduction
C,S,+- +5?C,S,+
Eleni +% S"etia- &e"etrios E%orona)isb- Spyridon % 9olfinopoulosa
I 3ater toGicity E3+A- C,S,+
ang- 5ee- Seong- 2a/)ins I Clinical Che"istryCJ 0Coefficient of
Jariation1
Jahid A"ir!adeh- +ashaallah +ashinchi-Abbas Parcha"i
?Bar- s
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Applied Studies and *indings
PET Strapping ProcessesPET Strapping $ecomes more an more
popular day $y day $ecause o# the advantagesversus steel hoop. As compared to steel hoops*
PET strapping tapes meanwhile o##er a range o#considera$le $ene#its3
The sta$ility o# PET tapes is compara$le to that steel hoops ue to its higher elasticity* the PET tape does not damage
the edges o# the goods pac)ed. The ris) o# in0ury in considera$ly lower than that steel
hoops Less e9pensive than steel hoops.
17
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Applied Studies and *indings
*ir"Ms Profile 4mplementation is done in Polipa)
Plastic Pac)aging San. Ltd ti which
has $een esta$lished in 1=;5* andstarted to produce PP strapping* since">>+ Company started to produce PETstrapping.
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Applied Studies and *indings Cont%
Selected product to analy-e is 1"mm>.7>mm Pet Strapping that is produce$y using twin,screw technology that is a
computer $ased control and dataacquisition system. 8y using this technology all process
parameters are controlled andmonitored via '?4 %'uman:?achine4nter#ace& so#tware
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Applied Studies and *indings Cont%
Process *lo/ of PETProduction process o#
the 1"mm Pet strapping can $ede#ine as The material #la)esare melted in e9truder* then#iltered and shape in die intoseveral straps emerging side $y
side.
A#ter $rie# cooling in thewater $ath* the straps undergosecondary processing in theproduction line namely several
annealing and streching stagesto provide them the requiredtensile strength. Producedstraps winding $y usingwrappings.
">
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Applied Studies and *indings Cont%
For PET Strapping production process* / main CT(s asthe product varia$les3
$rea)ing strength* width* thic)ness* total weight %gram:mt&
are analysed separately in order to identi#y the status o#the o$tained data whether they are in statistical control ornot.
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&ata Collection and Preparation
">= o$servations >1.>.">>= G 1".";.">>= ata
Strength ma9,min daily idth ma9,min daily Thic)ness ma9,min daily
Total weight %Hram:mt& daily
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&ata EGa"ination
'istograms Assesing 6ormality, Trans#ormations Control Charts
Process Capa$ility
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2istogra" of t hic)ness "in
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Transfor"ations
1/x x2 5og0G1
$rea)ingIstrengthImin Very Narrow Very Narrow
$rea)ingIstrengthIma9 Very Narrow Very Narrow
widthImin Continuity - Continuity - Continuity -
widthIma9 Continuity - Continuity - Continuity -
thic)nessImin Continuity - Continuity - Continuity -
thic)nessIma9 Veri Narrow Narrow Very Narrow
totalIweight %gram:mt& Right Skewe Narrow
http://var/www/apps/conversion/tmp/scratch_3/Histograms-1%200ver%20x.dochttp://var/www/apps/conversion/tmp/scratch_3/Histograms-x2.dochttp://var/www/apps/conversion/tmp/scratch_3/Histograms-log.dochttp://var/www/apps/conversion/tmp/scratch_3/Histograms-log.dochttp://var/www/apps/conversion/tmp/scratch_3/Histograms-x2.dochttp://var/www/apps/conversion/tmp/scratch_3/Histograms-1%200ver%20x.doc8/12/2019 11-C3-Applicability of Process Control Techniques in PET Strapping Production Process-Calis_Firat_Senvar_Turgut
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Applied Studies and *indings Cont%J At the begining of the study- the control charts are prepared by using +initab
soft/are- /hich are gi$en belo/%
+1
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
J A#ter graphing control charts* outliers aredetermined and related data are eliminatedand control charts are drawn with modi#ieddata.
J For the 8rea)ing Strength data* three timeselimination is used #or Thic)ness and idthdata* two times elimination is done and#inally #or Total eight %Hram:?t& data onlyone elimination is implemented
J 6ew control charts are as #ollow3
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
J Last control charts are analy-ed $y using Kone !uleswhich areG One or more points outside o# the control limitsG Two o# three consecutive points outside the two sigma
warning limits $ut still inside the control limitsG Four o# #ive consecutive points $eyond the one sigma limitsG A run o# eight consecutive points on one side o# the
centerlineG Si9 points in a row steadily increasing or decreasingG Fi#teen points in a row in -one C%$oth a$ove and $elow the
centerline&
G Fourteen points in a row alternating up and downG Eight points in a row on $oth sides o# the centerline with nonin -one C
G An unusual or non random pattern in the dataG One or more points near a warning or control limit
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Applied Studies and *indings Cont%
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Process Capability 0PC1
PC deals with the uni#ormity o# the process.
Daria$ility o# CT(s in the process is a measure o# theuni#ormity o# the output.
PC study #requently "easures#unctional parameters orCT(s on the product.
PC does not "easurethe process itsel#.
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9eneral @eco""endations for Processes
For an e9isting process* the Cp is a$ove the recommended minimum%1.++&
For a new process* the Cp is a$ove the recommended minimum%1.>&
For an e9isting critical process %sa#ety* strength&* the Cp is a$ove therecommended minimum %1.>&
For a new critical process %sa#ety* strength&* the Cp is a$ove the
recommended minimum %1.57&
@eference Jalues
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Conclusions and@eco""endations
Apart #rom histograms and control charts* other PCTs can$e applied to control the process and improve productuni#ormity.
4n this study log9* 9" and 1:9 tran#ormations were used. 4tis reali-ed that assumption o# normal distri$ution is valid.So original data is used without trans#ormation.
A#ter monitoring the process* causes o# out,o#,controlsignals can $e determined and eliminated so thatimprovement can $e attained #or overall processper#ormance.
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Conclusions and@eco""endations
4mportant signals #or each parameters areo$served as For Total weight %Hram,?t& "* +* = and 1>* For 8rea)ing Strength 1* + and 1>* For Thic)ness 1* + and 1>* For idth data + and 1>.
?ost o# the out,o#,control signals are detected#or the third and tenth rules.
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Conclusions and@eco""endations
For the #irm* a pac)age program can $e permanently used to
monitor the process and
-one rule + and rule 1> may $e investigated in detail.
4n #act* monitoring only the #our CT(s o# a product isnot seen su##icient to de#ine and improve a process.
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Conclusions and@eco""endations
Controlling manu#acturing processes during operationis also suggested in order to satis#y customer
requirements.
The $ene#its derived #rom SPC in the areas o# reducedinternal and e9ternal #ailures should o##set any
additional costs incurred #rom sample collection* testingand data analysis.
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Than)s #or yourattention...