Effect of Glass Fibers on the Mechanical Properties of Plain Concrete

/in /by

Effect of Glass Fibers on the Mechanical Properties of Plain Concrete

The effect of Glass fibers on the mechanical properties of plain concrete

Capstone Design Project I: Literature Review and planning Project II.

Capstone Design Project II: Practical Part of the project. Carry out the experiment part of the project and write up the final part of the report.

Objective:

The main objective of this investigation is to determine the effect of combined glass fibers on the engineering properties of plain concrete such as; compressive strength, tensile splitting strength, flexural strength (modulus of rupture), static modulus of elasticity and water absorption. The results of the effect of the GLASS fibers on the engineering properties of concrete will be compared with same properties obtained from sound, control, samples, i.e samples without fibers.

 

Experimental Program

Details of test Specimens 

The following tests should be carried out to study the latter:

  1. compressive strength on 150x150x150 mm2 cubes [11]
  2. Indirect tensile splitting on 100×200 mm2 cylinders [12]
  3. flexural strength, Modulus of Rupture , MoR, on 100x100x500 mm3 prisms [13]
  4. static modulus of elasticity on 150×300 mm2 cylinders [14]
  5. water absorption on 150x150x150 mm3 cubes [15]

3– Concrete mixes and material properties:

Four mixes should be used to study the effect of the glass fibers and steel fibers on the engineering properties of concrete, mixes 1, 2, 3 and 4 contain 0kg/m3, 10 kg/m3, 15 kg/m3 and 20 kg/m3 of glass fibres respectively, table 1b. Mix 1, 0 kg/m3, was the control mix and the manufacturer.

 

Ingredients Source Unit Weight
OP Cement UCC kg/m3 400
Water MUN m3 0.20
20mm aggregate RAK kg/m3 700
10mm aggregate RAK kg/m3 330
5mm aggregate RAK kg/m3 515
Sand – F RAK kg/m3 295
Glass Fibers % (Mixes 1, 2, 3 and 4) RAK kg/m3 0, 10, 15, 20

Table 1b: Glass Fibers mix proportions for mixes 1 (Control), 2, 3 and 4.

4 – Production of the specimens:

The samples should be cast in steel moulds. The samples must be vibrated externally using a table vibrator. After trowelling the concrete surface smooth, the beams must be stored under polythene sheets. All the specimens must be unmoulded after one day and then cured for 28 days in water tank at 20oC and 100% relative humidity. The tests should be carried out within 1 hour of removal of the samples from the conditioning tanks.

5 – Apparatus and test procedure:

Use the 3000kN controlled compression machine to test all the samples. The rate of loading of 0.3N/(mm2.s) must be applied.

 

6 – Test results and discussion

Use the following table to tabulate the results.

 

 

Properties of Concrete

  

Glass Fiber

  

Combined Glass Fiber and Steel Fiber
Mix 1 – Control (0kg/m3) Mix 2 (10kg/m3) Mix 3 (15kg/m3) Mix 4 (20kg/m3) Mix 1 – Control (0kg/m3) Mix 2 (0.91kg/m3) Mix 3 (1.82kg/m3) Mix 4 (2.73kg/m3)
Cube Compressive Strength (N/mm2)                
Cylinder Compressive Strength (N/mm2)                
Indirect Tensile Test (N/mm2)                
Modulus of Rupture (N/mm2)  

 

  

 

  

 

  

 

        
Modulus of Elasticity (N/mm2)  

 

  

 

  

 

  

 

        
Water Absorption (g)       

 

  

 

  

 

  

 

        
 

Slump (mm)

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

 

Table 2 – The effect of Glass and steel fiber on the mechanical properties of concrete

Properties of Organic Compounds

/in /by

Properties of Organic Compounds

Demonstrate comprehensive understanding of the properties of organic compounds.

AS91391 2 CH3.5X20
QUESTION ONE
The structures of 3 molecules A, B and C extracted from plants are shown below.
A
HC CH2
O
CH CH2 CH C
CH2 CH3
CH3
OH
C:
CH3 C CH2 C C CH CH3
CH3
CH3
O OH
B:
CH2 CH2 CH CH2 CH C
CH3 CH3
C O CH3
O
CH3
(a) Two of these molecules are constitutional isomers. Identify these molecules and give
their molecular formula.
(i) Molecules ______________ Molecular formula: _______________________
(ii) Explain why they are constitutional isomers.
(b) Each of the three molecules has enantiomers (optical isomers).
(i) Circle the chiral carbon on each of the structures above (the carbon atom responsible
for the optical isomerism).
(ii) Draw the structural relationship between a pair of enantiomers using molecule A as
an example.
AS91391 3 CH3.5X20
(iii) Describe a measurement that could be made to distinguish between a pair of optical
isomers.
(c) Explain how each of the solutions, acidified potassium permanganate, K2Cr2O7/H+(aq),
and BenedicW¶V VRlXWiRn, could be used to distinguish between molecules A and C. In
your answer, you should
x describe expected observations
x give a reason for the different reactions linked to the functional groups in the
molecules. (You are not expected to write structures for the reaction products)
x draw structures for any organic products .
K2Cr2O7/H+(aq)
BenedicW¶V VRlXWiRn
AS91391 4 CH3.5X20
(d) Molecule B can be produced from reactions of Molecule D (below) in a two -step
process.
Complete the table below to document the functional groups taking part in each reaction
step, the reagents needed for each reaction and the type of reaction occurring.
Functional
group
Reagents Type of
reaction
D
HC CH2
O
CH CH2 CH C
CH3 CH3
CH3
Ļ
Intermediate X
Ļ
CH2 CH2 CH CH2 CH C
CH3 CH3
C O CH3
O
CH3
AS91391 5 CH3.5X20
QUESTION TWO
(a) Complete the table below by giving the IUPAC systematic name or the structural
formula for each compound.
Compound Structural formula IUPAC systematic name
A
B 3-chlorobutanamide
C
D 4-methylpentan-2-one
E
AS91391 6 CH3.5X20
(b) (i) Complete the following reaction scheme for molecule A by writing the appropriate
products in the boxes provided.
MnO4
±
/ H+ Ag+
/NH3
(ii) Compare and contrast the two reactions. In your answer you should include:
x the type of reaction that occurs
x a description of the changes observed when the reaction is carried out
x reasons for the difference in the products of the two reactions
AS91391 7 CH3.5X20
(c) (i) Molecule C can undergo a reaction to produce a molecule with the same
molecular formula at the final step. Complete the following reaction scheme with
the formula of the most likely products at each step.
HBr KOH(alc)
(ii) In EACH of the steps for the reaction in (i), there are two possible products.
Give a reason for the two different products and explain why the product you
have drawn is the one most likely to be formed.
Step 1:
Step 2:
AS91391 8 CH3.5X20
QUESTION THREE
(a) (i) Polyhydroxybutryrate (PHB) is a plastic used in food packaging. It is made from
renewable resources and is completely biodegradable. A portion of the structure of
this polymer with two repeating units is shown here:

In the box below, draw a monomer which could be reacted to form this polymer.
(ii) A different type of nylon polymer can be formed from two monomers:
ClOC(CH2)2COCl and H2N(CH2)6 NH2
In the box below, draw a single repeating unit of the resulting polymer chain and
give the formula of the other product.
+
(b) The nylon polymer chain can be broken down in the presence of acid or base.
Compare and contrast the reactions of this polymer with both dilute acid and base
solutions. In your answer, you should include:
x the name of the type of reaction occurring
x structural formulae of the products formed from both acidic and basic reactions
x reagents and conditions required.
AS91391 9 CH3.5X20
Question 3c continues on the next page
AS91391 10 CH3.5X20
(c) Complete the reaction scheme below to show the structural formulae of compounds B, D
and E and the missing reagents and conditions required at steps 1 and 2
(ii) Both molecules C and D above can be used for further reactions with alcohols in the
production of esters. Explain which would be the preferred option
Step 1
B
Step 2
SOCl2(Ɛ) D
E
CH3CHCH2NH C
CH3 O
CH2CH2CH2CH CH CH CH3
CH3

Energy system integration of offshore energy: exploring synergies between oil and gas and renewables sectors

/in /by

Energy system integration of offshore energy: exploring synergies between oil and gas and renewables sectors

The offshore wind and Oil & Gas sectors are historically largely separate. This project seeks to exploit synergies between the two in order to reduce the costs associated with O&G abandonment. Specific objectives are to:

• Identify hotspots where the two sectors, have the strongest synergies, e.g. hub locations
• Assess the potential to exploit existing O&G infrastructure, e.g. for O&M, CCS, geothermal energy and/or hydrogen
• Analyze how the planned, staged abandonment could optimally be aligned with offshore wind developments
• Assess the potential for cost reductions achievable through the above insights

The project will explore specific scenarios, for example:

a) Offshore hydrogen production (at O&G facility) + O&G as electricity hub for offshore wind – conversion of pipeline to hydrogen to send hydrogen to shore.
b) Offshore CCS + O&G as electricity hub for offshore wind – conversion of pipeline for CO2 transport + transmission line in parallel – hydrogen onshore with district heating.
c) Offshore hydrogen production/storage/fuel cell + O&G as electricity hub for offshore wind/transmission line to shore
The method is energy systems analysis, which takes real-world data on the offshore energy system to create an accurate model. Building on existing work in this area (e.g. offshore wind), existing datasets and models should be extended to include offshore O&G assets and abandonment schedules.

You can do calculations in Excel (no need for software)

Lab Report Motion on an Incline

/in /by

Lab Report Motion on an Incline

Use information attached

3 sources

4 pages

We consider an oil-well in the Gulf of Mexico the deepest oil rig with a depth of 2450 meters

/in /by

We consider an oil-well in the Gulf of Mexico the deepest oil rig with a depth of 2450 meters

We consider an oil-well in the Gulf of Mexico, the deepest oil rig with a depth of 2450 meters. The oil is pumped from this depth to a floating spar platform (see image1). In the oil reservoir, the temperature of the oil is around 60˚C. From this reservoir, crude oil is pumped towards the oil-platform. In this assignment, we assume that the pipeline goes straight up to this platform (in reality this is not the case). The oil is pumped via a cylindrical pipeline with an outer diameter of 42 cm and a wall thickness of 1 cm. This platform is said to produce approximately 600 m3/hr oil.

Part I

The goal is to obtain all the information on the flow conditions in this pipeline. Consider steady state conditions.

1a. First try to perform some hand calculations: Assume that ocean water has a constant temperature of 12˚C and that there are no radial temperature differences in the oil stream. You are asked to find a temperature profile (final expression of the oil temperature as a function of the ocean depth, and other parameters). Additional data is given below. Plot the resulting temperature profile as a function of the ocean depth.

1b. One value in the additional data is not correct. From other parameters given in this assignment, the correct value for this wrong parameter can be calculated. Which parameter is this? Calculate the new value and plot the new temperature profile.

2. Derive a pressure profile over the length of the pipeline. The pipe wall may be assumed to be smooth. What should be the pressure after the pump at the bottom of the ocean to pump oil to this platform? Plot the pressure inside the oil pipeline as a function of the ocean depth. The oil should be delivered to the platform at 1 bar.

Additional data:

ρoil= 900 kg/m3
ηoil = 50 mPa.s
λsteel = 14.3 W/(m.K)
λoil = 0.15 W/m.K
hinner = 1000 W/m2.K
Pr = 667 (-)
houter = 100 W/(m2.K)
Cp,oil= 2.0 KJ/(kg.K)

Part II

In reality, the water temperature is not constant, but it varies significantly over the ocean depth (see figure 1). Ocean temperature data is given in the provided matlab file. In this case, a numerical method is required to find a temperature profile over the pipeline. Use the data to approach a realistic temperature profile by using matlab. For this problem, use equations obtained in Part I. Plot the temperature as a function of ocean depth.

Compare temperature profiles of part 1 with part 2 and answer the following questions:

What is a crucial assumption in the pressure drop calculation? Use keyword: viscosity.
What possible measures would you consider to prevent heat loss of oil to the ocean water? How would you see this back in the calculations? Use keyword: Heat resistance

 

Use of Battery as Energy Storage in Renewable Energy Applications

/in /by

Use of Battery as Energy Storage in Renewable Energy Applications

One of the significant drawbacks of renewable energy is that renewable sources of energy such as solar and wind are intermittent with different degrees of intermittency. That means they only generate power while the sun is shining or while the wind is blowing. One of the most promising methods to overcome the intermittent energy supplies of energy is to use a battery to enable renewable energy generation to be stored until required. Different batteries types have different characteristics, such as energy density, battery voltage, efficiency and lifetime.
Write a research paper which discuss, the use of battery as energy storage in renewable energy applications the outline of the paper.
Outline: includes
• Abstract
• Introduction
• Literature review ( include )
 Importance of battery storage in renewable energy
 Application of using battery as energy storage in renewable energy
 Challenges of using battery for renewable energy
 How battery is integrated with renewable energy
 Types of battery use in renewable energy application for energy storage & the advantages of each type:
 The important parameters and factors for designing battery for renewable energy application
 Working principle of batteries used in renewable energy application
 the Important parameters for battery performance
 the Factors impacting the life of batteries in renewable energy application
 The different approaches used to predict the lifetime of batteries
• Discussion
• Conclusion
Additional Instructions 

  • Harvard Reference Style
  • 30-40 Sources (books, credible websites, peer-reviewed journals)
  • 30-35 pages (excluding abstrat, cover page, table of content, appendices, diadrams, reference page, tables)
  • Include diagrams/charts/tables etc

Physics Lab Report Measurements

/in /by

Physics Lab Report Measurements

TITLE:
• Date:
• Experimentalist:
• Apparatuses:
1 Ruler and Samples
• Prepare a stick ruler which you can measure lengths in centimeters (cm). If you just have rulers with inches,
you can use it as well, but the centimeter stick is perferred. A ruler for thirty centimeter (about a foot) would
be fine.
• How long is the finest tick of the ruler?
[Unit: ]
• For this experiment, four samples of round shape are needed. Try to find four round things with perfect
circles in its crosssection, which are not too big, but different sizes. Something like coins, bottles, can, will
work.
• When the samples are perpared, put labels on samples, A, B, C, and D.
• Describe each sample briefly. Take a picture of samples with the ruler you have and attach it below.
Figure 1: Samples and Ruler
PHYS 2111 Experiment B. Measuring Lengths – Online 2
2 Sample A
2.1 Measuring the Diameter of Sample A:
• Measure diameters of the samples by using the device chosen six times. Make sure to follow the rule to get
the one more number guessed, after the finest tick. Write down measurements in Table 1.
Diameter Di Di − D¯ (Di − D¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PDi Sum P(Di − D¯)
2
Average D¯ =
PDi
N
σD =
q
(Di−D¯)
2
N−1
Table 1: Measurement of the Diameters of the Sample, A.
• Add all measurements to get the sum, and obtain the average of your measurements of the longer length in
Table 1.
• Calculate the standard deviation for the statistical uncertaiinty of this measurement in Tabel 1. Write the
result below;
DA = D¯ ± σD = ± [Unit : ]
2.2 Circumference of Sample A
• By the rolling the sample over lines in Figure 2 and using a ruler, the circumference of sample A in Table 2.
Before you start rolling, put a mark on each sample to know where it starts. Understand the method very
well first and try to reduce uncertainty of this measurement.
Circumference Ci Ci − C¯ (Ci − C¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PCi Sum P(Ci − C¯)
2
Average C¯ =
PCi
N
σC =
q
(Ci−C¯)
2
N−1
Table 2: Measurement of Circumference of Sample A
PHYS 2111 Experiment B. Measuring Lengths – Online 3
Circumference #1: C1 = mm
Circumference #2: C2 = mm
Circumference #3: C3 = mm
Circumference #4: C4 = mm
Circumference #5: C5 = mm
Circumference #6: C6 = mm
Figure 2: Measuring Circumferences of Sample A
PHYS 2111 Experiment B. Measuring Lengths – Online 4
• Calculate the average of the circumference in Table 2.
• Calculate the standard deviation of this measurement for the statistical uncertainty in Table 2.
Circumference Measured; CA = C¯ ± σC = ± [Unit : ]
3 Sample B
3.1 Measuring the Diameter of Sample B:
• By using the same method, measure the diameter of sample B in Table 3.
• Obtain the average and statistaical uncertainty of the measurement in the same table. Write the result below;
DB = D¯ ± σD = ± [Unit : ]
Diameter Di Di − D¯ (Di − D¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PDi Sum P(Di − D¯)
2
Average D¯ =
PDi
N
σD =
q
(Di−D¯)
2
N−1
Table 3: Measurement of the Diameters of the Sample, B.
3.2 Circumference of Sample B
• By using the same method, measure the diameter of sample B in Figure 3, and write the the resulting
circumference measurements in Table 4.
• Obtain the average and statistical uncertainty of the circumference measurementsin Table 4.
Circumference Measured; CB = C¯ ± ∆C = ± [Unit : ]
4 Sample C
4.1 Measuring the Diameter of Sample C:
• By using the same method, measure the diameter of sample C in Table 5.
• Obtain the average and statistaical uncertainty of the measurement in the same table. Write the result below;
DC = D¯ ± σD = ± [Unit : ]
PHYS 2111 Experiment B. Measuring Lengths – Online 5
Circumference #1: C1 = mm
Circumference #2: C2 = mm
Circumference #3: C3 = mm
Circumference #4: C4 = mm
Circumference #5: C5 = mm
Circumference #6: C6 = mm
Figure 3: Measuring Circumferences of Sample B
PHYS 2111 Experiment B. Measuring Lengths – Online 6
Circumference Ci Ci − C¯ (Ci − C¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PCi Sum P(Ci − C¯)
2
Average C¯ =
PCi
N
σC =
q
(Ci−C¯)
2
N−1
Table 4: Measurement of Circumference of Sample B
Diameter Di Di − D¯ (Di − D¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PDi Sum P(Di − D¯)
2
Average D¯ =
PDi
N
σD =
q
(Di−D¯)
2
N−1
Table 5: Measurement of the Diameters of the Sample, C.
PHYS 2111 Experiment B. Measuring Lengths – Online 7
4.2 Circumference of Sample C
• By using the same method, measure the diameter of sample C in Figure 4, and write the the resulting
circumference measurements in Table 6.
Circumference #1: C1 = mm
Circumference #2: C2 = mm
Circumference #3: C3 = mm
Circumference #4: C4 = mm
Circumference #5: C5 = mm
Circumference #6: C6 = mm
Figure 4: Measuring Circumferences of Sample C
• Obtain the average and statistical uncertainty of the circumference measurementsin Table 6.
Circumference Measured; CC = C¯ ± ∆C = ± [Unit : ]
PHYS 2111 Experiment B. Measuring Lengths – Online 8
Circumference Ci Ci − C¯ (Ci − C¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PCi Sum P(Ci − C¯)
2
Average C¯ =
PCi
N
σC =
q
(Ci−C¯)
2
N−1
Table 6: Measurement of Circumference of Sample C
5 Sample D
5.1 Measuring the Diameter of Sample D:
• By using the same method, measure the diameter of sample B in Table 7.
• Obtain the average and statistaical uncertainty of the measurement in the same table. Write the result below;
DD = D¯ ± σD = ± [Unit : ]
Diameter Di Di − D¯ (Di − D¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PDi Sum P(Di − D¯)
2
Average D¯ =
PDi
N
σD =
q
(Di−D¯)
2
N−1
Table 7: Measurement of the Diameters of the Sample, D.
5.2 Circumference of Sample D
• By using the same method, measure the diameter of sample D in Figure 5, and write the the resulting
circumference measurements in Table 8.
• Obtain the average and statistical uncertainty of the circumference measurementsin Table 8.
Circumference Measured; CD = C¯ ± ∆C = ± [Unit : ]
PHYS 2111 Experiment B. Measuring Lengths – Online 9
Circumference #1: C1 = mm
Circumference #2: C2 = mm
Circumference #3: C3 = mm
Circumference #4: C4 = mm
Circumference #5: C5 = mm
Circumference #6: C6 = mm
Figure 5: Measuring Circumferences of Sample D
PHYS 2111 Experiment B. Measuring Lengths – Online 10
Circumference Ci Ci − C¯ (Ci − C¯)
2
[Unit: ] [Unit: ] [Unit: ]
1
2
3
4
5
6
Sum PCi Sum P(Ci − C¯)
2
Average C¯ =
PCi
N
σC =
q
(Ci−C¯)
2
N−1
Table 8: Measurement of Circumference of Sample D
6 Discussion
• Summarize the measurement of the diameter and circumference of four samples in Table 9.
Samples Diameter, D [Unit: ] Circumference, C [Unit: ]
A ± ±
B ± ±
C ± ±
D ± ±
Table 9: Summary of Measurements of the Shortest Length
• How are the precision (or statistical uncertainty) of circumference measurements are compared? Are they
close to each other? Which sample has the best precision? Which one the worst? Try to explain.
• What is a major source of the uncertainty? Discuss how you can reduce the uncertainty.

Design the hydraulic system for a box pushing machine

/in /by

Design the hydraulic system for a box pushing machine.

Fluid Power Technology

Design the hydraulic system for a box pushing machine. Your responsibility is to provide the design for
the hydraulic system only, your design will dictate the rest of the machine design.
The force required to push the box and overcome friction is 9,500 Lbs. The required design should be
able to push one box every 15 seconds. The box will be loaded by an operator and the box will be
pushed/moved 24 inches (by your hydraulic system) onto a conveyor for further processing.
Provide a complete design of the items listed in the grading rubric in printed format (no electronic
copies). Handwritten calculations are preferred (neat and organized).

Fluid Power Technology Design the hydraulic system for a box pushing machine

/in /by

Fluid Power Technology Design the hydraulic system for a box pushing machine

Design the hydraulic system for a box pushing machine. Your responsibility is to provide the design for
the hydraulic system only, your design will dictate the rest of the machine design.
The force required to push the box and overcome friction is 9,500 Lbs. The required design should be
able to push one box every 15 seconds. The box will be loaded by an operator and the box will be
pushed/moved 24 inches (by your hydraulic system) onto a conveyor for further processing.
Provide a complete design of the items listed in the grading rubric in printed format (no electronic
copies). Handwritten calculations are preferred (neat and organized).

12 Steps of Kaizen

/in /by

12 Steps of Kaizen

We have a case study related to manufacturing where an issue was creating waste and they created a team to solve the issue using a Kaizen tool called 12 steps kaizen and they solve the issue successfully. the case study need to explain the issue that happened (which is attached), then explaine the 12 steps Kaizen tool. and finally merage the case study with the tool using the case study as an example of the tool application

Introduction:

One of the main challenges that you can face as a production line engineer/manager of running a production line is facing an unexpected issue during the production. It effects the productivity, waste and most importantly a direct cause of cost losses. This paper will start with a review a case that has happened an international manufacturing company that is considered the market leader in its business, using one of the Kaizen methodology tools a team was created to find a solution for a new cause of short stops. Sue to the success of eliminating the issue permanently, this case study was chosen to be an example of a propose way of problem solving that we belief can be a guide to solve any issue faced on a production line. In summery this paper will include a review of the case, followed by explanation of the tool used by the team. And finally, a purpose guide to future use of the tool.

Add Background of the Company 

Background of problem solving

Background of the issue

Tetra Pak is the world’s leading food processing and packaging solutions company working to provide safe food. It is a Swedish company that produce several types of Packaging solutions to all the liquid products such as milk, Juice and even Homos and honey to the solid cheese. The company has several locations in different countries either as a factory that produces carton packs or as a customer service office.

The case that we are about to study was on one of the carton factories that produces the food and liquid packs. When it comes to the packs it varies on shape, size and design printed on the pack as per the costumer requirement. Tetra Pak factories focuses on three main objects: ensure the safety of the employees working on the site, full costumer satisfaction and the high quality of product. That high quality ensures the protection of the food and liquids inside the packs for a year without the need to add any additives.

The case occurs on one of the main production lines of the factory, which is the printing line, the first line on the factory. The purpose of the line is to print the required designs as per the costumer order. Tetra Pak ureses a Flexo printing machine which is one of the industrial printing methods that has the capability of printing more than a million packs per hour depends on the sizes.

Flexo Printing …

Case story..

On the second quarter of 2018 the printing process started to have a repeated stop due to a defect Known as smearing. Smearing is a defect that happened due to un-dry ink which causes a bad appearance of the printed design*(add a picture). Which contributed to an accumulative loss on the plan capacity and the productivity of the machine. At the time they could not figure out the source of the defect, so a team was lunched to analyses the issue and propose the solutions to eliminate the defect using a Kaizen tool called 12 step Kaizen.

12 Step Kaizen Tool:

It is a tool used to study an anomaly and close it with a solutions and standers that will help on resolving the anomaly.

  1. Identify the losses:

The first step focuses on identifying the losses caused by the anomaly that we are studying.

  1. Select theme and justify
  2. Understand the process equipment
  3. Grasp the actual situation
  4. Establish objectives
  5. Update the master plan
  6. Cause analyses
  7. Propose actions
  8. Implement the actions
  9. Check the results
  10. Standardization
  11. Future Plans

Case study

  1. Identify the losses:

As per the factory strategy and must happens, one of the main KPI’s on the printing process is Printing efficiency. So, the team started with the main loss of printing line efficiency. and deployed the losses to identify the anomalies that caused then to not achieve the target. The first deployment losses showed that the rank of the efficiency losses is set up time, speed losses (running with slow speed), short stops, break down and other small losses. The anomaly that we are studying is categorized under the second main losses which is the speed losses. Deploying the speed loss shows us that searing is the second main loss. Hint, the Ramp up/down loss is a technological loss that comes with the printing machine. However, having the smearing loss in the second rank is not normal and we need to analyze it and come up with actions that will allow us to reduce smearing loss and restoring the Printing EE.

  • Should we explain more what is the set-up losses, and which KPI is normal and which one is not

Why we used the tool ( on conclusion )

Always why and how.

  1. Select theme and justify

In summery smearing is a speed loss anomaly that is causing printing efficiency losses which is a loss that can be transferred as factory capacity losses and cost losses. But as the team is a floor team that focuses on reducing the process losses only, they did not include the factory losses in their scope. Having that specified the team has decided to set an initial target of 50% reduction on smearing losses.

The team has set the focus to be fixing the smearing defect, which can will be followed under the printing EE (equipment efficiency) with an initial target to reduce the speed losses due to smearing by 50%. They started with reviewing what is concept of smearing and what is the exact defect that they are focusing on to avoid destruction of the other defects on their analyses.

What is Smearing?

It is the ink that smear out in a vertical direction from a part of the printed design.

  1. Understand the process equipment

*print unit explanation*

Explain the print unit with a reference to the ink smearing defect

Then next step explains the impact of its condition on the defect, also we can add the actual situation of the equipment’s

What do we need to include on the study:

  • Print unit
  • Cooling system
  • Drying system
  • ITC system
  • Ink

So we need to explain the printing on Print unit including the ITC, then the chill roller system and drying and finally the ink it self.

Printing Unit:

The printing unit is one of the main parts of the printing machine and it is responsible of printing one color as per the required design. The number of colors varies from one design to others however in each unit only one color is printed so every printing machine is equipped with more than one printing unit as per there costumer requirement.

  1. Grasp the actual situation

This step is required to review the condition of the element on step 3, and in case we find any abnormality we should add it to this step as a focus area.

(a) Drying system:

On the drying system the team has found 2 anomalies. One is the cleaning status of the drying system which was affecting the flow on the air on the system. Second is an anomaly found on the mechanism of the hot air flow system.

(b) Ink temperature

There was no anomaly found on the ink temperature as the ink temperature was controlled by an automation system. Add to it that the actual temperature was monitored through a quality system and in case of high or low temperature on any print unit the system will alarm * SPC system explanation*

(c)  Main burner

The filter of the main burner required a periodic change which in case missed would affect the control of the air flow which will affect the air temperature control.

(d) Ink drying system

*scratch on paper due to the drying system small gaps*

(e) Ink component

The ink used on the Flexo printing is a water-based ink and it is in simple explanation a mixture of base ink and varnish. The team reviewed the based-on Tetra Pak standard and there were no anomaly detected except the varnish behavior which based on the experience of team was not clear and it was recently changed, so the a trail was planned to try the old and new varnish to test the behavior.

5. Establish objectives

The objective is stated on step 2 and confirmed on this step after reviewing the actual situation on the machine. We are focusing on reducing the speed losses due to the smearing by at least 50%.

6. Update the master plan

Based on the findings on step 3 and 4 the team decided to validate the 50% target. And the master plan was updated to cover the coming steps.

  • Should we explain the master plan on details
  1. Cause analyses

Each anomaly detected on step 4 was analyzed deeply using the 4M-5Y tool known as fishbone analyses where you need to ask why question 5 times for each root cause.

*go in detail on the 4M-5Y*

* explain the fishbone tool*

  1. Propose actions

*explaine the CML steps*

* list the proposed actions*

  1. Implement the actions
  2. Check the results

Reviewing the result starting form June to end of the year after implementing the actions there were a 50% reduction on the speed losses, which was 2.4% on the printing efficiency. Which was enough to achieve the target. And when it comes to the smearing defect due to the root causes found the printing process did not a single stop.

 

  1. Standardization

*list the standard added to the system*

  1. Future Plans

Recommendation

Conclusion