Beruflich Dokumente
Kultur Dokumente
OF
PAKISTAN LIMITED
INTERNSHIP PROGRAM REPORT
CONDUCTING IN COMPOUNDING DEPARTMENT
FOR
THE GENERAL TYRE AND RUBBER COMPANY OF PAKISTAN
DURATION
st
From 1 JULY 2015 to 14th JULY, 2015
Submitted To:
Submitted By
Internee:
ACKNOWLEDGMENT
First of All, I would like to thank Almighty ALLAH, the most Gracious and most Merciful, who
educated Men by Pen.
By the Grace of ALLAH, who gave me the strength and will to overcome the surfaced during the
completion of my Internship and Internship Report.
In this report all basic and most necessary topics are clearly mentioned and made easy to
understand about the Tyre Manufacturing Process and Operations as well as Tyre Engineering,
Tyre Technology, Tyre components and Nomenclature of Tyre.
I would specially like to thankful to Mr. S. KHUSRO IQBAL (Head of Human Resource
Department), who were very cooperative and gave me the precious ISLAMIC book SAHI E
BUKHARI.
I am very thankful from the core of heart to honorable Mr. Moiz Sarwar (Manager of
Compounding Department) in The General Tyre and Rubber Company of Pakistan for
providing me the opportunity for internship training program.
I wish to express my deep gratefulness to Mr. Aziz Ur Rehman, Mr. Muhammad Khalid, Mr.
Ayub, Mr. Kaleem, Mr. Usman, and Mr. Faraz Muhammad Abbasi, for this consideration and
supervision. It was a memorable time in The General Tyre and Rubber Company of Pakistan
due to his kind concern.
I also thankful to staff members of The General Tyre and Rubber Company of Pakistan for the
valuable information provided by them in their respective fields, for the great encouragement and
cooperation, because of which I have successfully completed my internship training.
ZEESHAN ZAHID
POURPOSE OF INTERNSHIP
In GENERAL TYRE & RUBBER COMPANY OF PAKISTAN,
I had visited many different sections and areas according to the schedule
provided by Compounding Department.
These visits were very helpful. All the personals, I referred were very cooperative.
The main purpose of this internship is that know about the manufacturing
process of Tyre in the GENERAL TYRE and also working principle, quality control,
environment, quality policies, quality assurance and much more.
This internship is very useful for me for my upcoming educational and
professional life.
INDEX
S.NO
CONTENTS
PAGE NO
1.
2.
TYRE
3.
TYPES OF TYRE
4.
TYRE NOMENCLUATRE
5.
6.
7.
MIXING
8.
MILLING
9.
EXTRUDER
10.
CALENDERING
10
11.
10
12.
11
13.
11
14.
STEELASTIC AREA
12
15.
TUBE DEPARTMENT
12
16.
TYRE CURING
13
17.
FINAL FINISH
14
18.
14
19.
15
20.
QUALITY CONTROL
16
21.
17
22.
FIND/OBSERVED HAZARDROUS
18
23.
SUGGESTIONS
19
1.
1.1.
2.
TYRE
2.1.
The Body Ply is the calendared sheet of rubber and reinforcement (fabric).
It gives the structural strength to the tyre.
The fabric cords are highly flexible but relatively inelastic.
The textile materials used are cotton in early years now replaced by Rayon, Nylon,
and Polyester.
2.1.4. BEADS
Bead is the part of tyre which come contact with the rim.
Beads are bands of high tensile-strength steel wire, encased with rubber compound.
Beads wire is coated with special alloys of Brass.
Coatings protect the steel from corrosion, rusting and pitting.
Copper in the alloy and sulphur in the rubber cross-link to produce copper sulphide,
which improves bonding of the bead to the rubber.
Beads are inflexible and inelastic, and provide the mechanical strength to fit the tyre
to the wheel.
Beads rubber includes additives to maximize strength and toughness.
2.1.5. FILLER
Belts are calendared sheets consisting of a layer of rubber, a layer of closely spaced
steel cords, and a second layer of rubber.
Belts give the tyre strength and dent resistance while allowing it to remain flexible.
The steel cords are oriented radially in radial tire construction, and at opposing
angles in bias tire construction.
2.1.7. TREAD
Tread is a thick extruded profile that comes directly in contact with the road.
Tread compounds include additives to impart wear resistance and traction in
addition to environmental resistance and protect the inside tube of tyre from friction.
Hard tread compounds have long wear characteristics but poor traction, while in soft
tread compounds have good traction but poor wear characteristics.
3.
TYPES OF TYRE
There are two types of tyres:
1. Bias Tyre
2. Radial Tyre
3.1.
BIAS TYRE
3.2.
RADIAL TYRE
4.
TYRE NOMENCLUATURE
Nomenclature of tyre means marking on the tyre or traceability of the tyre.
The General Tyre making Bias/Radial tyres and their nomenclature are as follows:
4.1.
BIAS TYRE
For the nomenclature of bias tyre, taking the motor cycle tyre. In motor cycle tyre two
types of tyre used:
1. Front
2. Rear
4.1.1 FRONT
The G.T.R motor cycles front tyre/product name 2.25-17 F Hyper sonic.
2.25 - Section width measured in Inches.
17 - Rim diameter in Inches
F
- Shows Front tyre
HS - G.T.R Design name
4.1.2. REAR
The G.T.R motor cycles rear tyre/product name 2.50-17 R Black Cobra.
2.50 - Section width measured in Inches
17 - Rim diameter in Inches
R
- Shows Rear tyre
BC - G.T.R Design name
4.2
RADIAL TYRE
Two types of vehicle radial tyre making in G.T.R:
1. Passenger Tyre
2. Light Truck Tyre
5.
6.
7.
HF-270
It is also a Banbury mixer.
It is widely used for the finish mixing.
HF is the company name while 270 is volume of this mixer.
It is also a PLC based mixer.
KN-01
It is a Kneader mixer.
Mostly used to make the Master Batch.
The batch size for this machine is 80 kg only.
It is a manually based machine & Two KN-01 machines are available in G.T.R.
8.
MILING
9.
EXTRUDING
Extruding is a very important operation.
It converts the thick and heavy rubber sheets into thin rubber sheets.
It is often referred to as a Tuber, because it creates tube like rubber sheets.
It consists of a screw, barrel, head and die.
A core or spider is used to form the hollow inside of tubing.
By this operation, many of the tyre components such as large, flat section of tyre are
made like Tread, Inner Liner, Side wall etc.
There are two types of extruder:
1. Dual Extruder (Hot Feed Extruder)
2. Triplex Extruder (Cold Feed Extruder).
IN THE GENERAL TYRE BOTH TYPES OF EXTRUDER ARE USING:
DUAL EXTRUDER
It is also called Hot Feed Extruder.
It is only used to form Bias tyre components making like Tread and Side Wall for
Passengers, Truck and Tractor tyres.
It has four mills and two large screws. Mills name are follows:
1. Break down Mill
2. Feed Mill
3. Hopper
4. Screws and Die
Finish is transported to break down mill and it makes the slits into strips.
By the conveyor belt it carried to the feed mill then hopper mill.
Then the coming compound forward to screws and here screws push the material in
the direction of the die here the line speed is maintain in FPM (Foot per Minute).
Die have the cavity of the size of either tread or side wall to be extruded.
If required, Cushion gum is applied after the extrusion of the die.
The extruded component is sent to the cooling purpose.
This extruder has spray water system for cooling.
After cooling, its goes to the cutting machines, there it can cut into different sizes.
The drawback of this extruder is:
It required valuable worker for milling.
Water is more required for cooling purpose.
9.1.
The rubber sheet comes out from Banbury mixer is not that perfect, so In this
operation the shaping of rubber takes place.
Milling machines shape the rubber into flat, long strips by forcing and some heating.
For this operation, two roll mils rotating in different directions at different speeds.
The 1st mil is called Dump Mill and the 2 nd mill called Shelter Mill.
After the milling operation this will cold by the fans and then sent it to different
section for different working.
9.2.
TRIPLEX EXTRUDER
It is also called Cold Feed Extruder.
It is more efficient extruder as compared to Dual Extruder.
It is only used to form Radial tyre components making like Tread and Side Wall.
It has three screws of different sizes of diameter.
1st Screw diameter is 50 mm.
2nd Screw diameter is 90 mm.
3rd Screw diameter is 120 mm.
These screws are sealed in the housing and having separately feed area.
In this extruder, small pins are fitted to blend the rubber properly.
In this extruder, different dies can be mounted at the same time.
If required, Cushion gum can be applied separately.
After extrusion, the material forward for cutting (Because It is cold feed extruder and
here is no requirement for mill to warm up the feed) where, it can cut at the specific
angle mostly cut at 280 degree.
It has one cutter (Fair wood/Barnat Shah) for cutting purpose.
The advantages of triplex extruder:
No need mill workers.
Cost efficient and high productive.
10.
CALENDERING
The calendering is the operation which continues to shape rubber.
This machine consists of one or more rolls (often it have four rolls).
In this operation the rubber sheets are forced by rolls for shaping.
The main functions of calendering are:
To prepare compounded rubber as a uniform sheet of definite thickness and
width.
To place a thin coat of rubber on a fabric (Coating).
To force rubber into the interstices of fabric by friction.
IN THE GENERAL TYRE 4-ROLLS CALENDER IS USING FOR CALENDERING PURPOSE
10.1
FOUR-ROLLS CALENDER
It is set of large diameter rolls that squeeze the rubber compound into a thin sheet.
It produces an upper and lower rubber sheet with a layer of fabric in between rubber
sheet.
Calender used is to produce the Body Plies and Belts.
For Calendering many types of fabrics can be used like nylon, polyester and rayon.
11.
assembling machine.
The components of a tyre include Beads, Chafer, Plies, Side Walls, Chipper and
Treads.
After the components are assembled, the tyre is often referred to as a Green Tyre
and also called Uncured Tyre.
In General Tyre:
For the making of Beads, two different machines are using:
BD-2 > It making one bead at a time.
BD-3 > It making three beads at a time.
For the making of Stock Preparation, five different machines are using:
FC-2 to FC-4
FS-1 to FS-2
For the making of Band, Five machines are using:
BB-1 to BB-5 (BB Means Band Building)
12.
These machines consist of two rollers, which press multiple piles together by the
pneumatic pressure.
Band is the set of plies.
Plies are cut according to the circumferential of size of the tyre.
These plies are build up at opposite angles forming the criss cross pattern.
13.
14.
The main function of brass coated steel cords is in a temperature and humidity
controlled environment.
If it is not used so corrosion due to moisture may cause the steel belt to lose adhesion
with rubber.
15.
TUBE DEPARTMENT
In General tyre, this department making:
1. Tubes
2. Bladder
3. Flaps
15.1 TUBES
15.2. BLADDER
The bladder is the flexible rubber which used in the curing press machine.
It is attached to the inside of the mold.
It is filled with steam or hot water when the tyre is cured.
It can done 200 cycles of curing.
Before using the bladder, determine the dimensions and geometry for the job.
15.3. FLAPS
16.
TYRE CURING
Design Parameters of Dome type curing machine based on Steam, Hot water & Cold
Water:
200 psi steam in bladder, Orifice opens.
200 psi steam in bladder, Orifice closed.
Apply steam in dome, 100 psi.
Mold temperature 155 to 158 0C.
Non-circulating hot water in bladder at 280 to 300 psi.
Drain dome steam.
Circulating cold water in bladder at 280 psi.
Full blow down.
Apply vacuum in bladder.
Open mold & remove tyre.
17.
FINAL FINISH
18.
Tyres that are qualified from all the tests are sent to Finish Good Ware House for the
shipment to the dealers or OEMs.
After the full filling the all tests then tyre is packed.
The storage and handling of tyres is done manually or by cranes which can handle
the bunch of tyres.
The art of the handling the goods in the ware house is the great job.
Accommodating more and more goods in a proper manner in a small area requires
skills of handling.
Easy withdrawal of goods at the time of shipment is made possible.
The delivery of tyres from F.G.W.H is done by the invoice which comes from the sales
department.
MATERIAL &
LABOR
REPORTING
DEMAND
PLANNING
DAILY
SCHEDULE
CAPACITY &
REQUIREMENT
PLANNING
PROCESS
PRIORITY
Quality control means check out the quality of product before the sale.
In General tyre,
Quality control department beings with the delivery of raw materials.
In G.T.R, the chemists do random sampling or testing in the testing lab.
In the Black carbon as raw material, check the iodine number by the titration
with sodium thio sulphate.
In Master Batch testing, check the viscosity of the master compound.
For the checking of viscosity two type of viscometers are using:
1. Moni Viscometer
2. Brookfield Viscometer
The finish compound checked by different testing equipments.
If the result is found OK so finish compound release & shifted to concerned
area, and if is found NO so then compound hold at holding area.
After curing, physically checked the dispersion of chemicals by the strong
machines.
Physically checking in static and dynamic conditions like:
1. Curing check
2. Tensile strength
3. Breaking strength
4. Hardness
5. Modulus
6. Adhesion between plies
7. Plunger testing
8. Uniformality
9. 9. X-Ray testing
10. Reliability
o High speed test > Maximum speed with constant load.
o Endurance test > Constant load with maximum speed.
After this all checking the material, compound or tyre passed to final inspection
for physically check with hands and eyes.
In General tyre,
Quality Assurance Department ensures that ISO Standards are followed and is
responsible for its certification.
Its main purpose is preventing the claims from customers.
In case of receiving such claims on quality of provided products and services,
this department starts searching the reasons about that claim.
If a tyre on examination is found to be having some manufacturing faults then
the G.T.R Company will either repair it free of cost or may be change.
It is also responsible for taking market surveys to check, If the product is
meeting its requirement or not.
The G.T.R quality policy SOLAGAN is given below:
We are a Company of dedicated people who enjoy working as a team and with our
customers in an enterprise committed to quality.
We will continually strive to bring improvements in our products, services &
quality management system to meet or exceed our customer needs and
expectations.
We will work within the framework of legal and regulatory requirements.
FIND/OBSERVED HAZARDROUS
I observed the following Hazards during the internship training program in General
Tyre:
In the mixing area, the filling of Black Carbon in the mixer is dangerous for mixer
operator because there is poor ventilation system and the Black Carbon is
Carcinogenic and danger for operator health.
The workers who are working in the field are not working according to given safety
parameters.
The house keeping is also very important but in some areas there is no proper
housekeeping system.
Workers should not allow eating harmful things like pan, tobacco and other types of
food etc but they not only eat those things also spit over there.
Mill operators are generally concerned with safety hazards associated with the open
operation of the turning rolls due to this, mill operators are exposed to heat as well
as noise.
Some operators do not put the used apparatus on their right place and also dont
wear safety protective equipments.
SUGESSTIONS
I would like to suggest the following points:
Above hazards should be considered very seriously.
A protective mask should be given to the workers and the students to protect them for
the dangerous gasses and poisons smell.
A student guide should be available who guide the students about the given plan and
also help them to visit the plant.
Pick and drop facility should be given to male students also.
Seminars should be arranged for workers to guide them about safety measures.