REPORT ON

ENHANCING THE PRODUCTIVITY OF DUST CAPS

AND TO REDUCE THE OPERATOR FATIGUE BY
USING LOADING PALLET.

PROJECT MEMBERS

R.KARTHICK (212212114043)

D.ARAVINDAN (212212114008)

DATE : 28.3.2016
ABSTRACT:

Typically in Rubber Industries, the operators load the raw

materials into the mould cavity by hand in turn to generate
a new product.

Hence, the operator has to load the jobs consistently in

the high temperature area (200 deg celsius) and it takes
about one minute.

Therefore to cut down the production cycle time and to

improve safety to the operator we proposed a LOADING
PALLET which directs the above factors resulting in
production increase.
INTRODUCTION:

K. R.Industries is one of the leading Manufacturer

specializing in all types of Rubber moulded and metal
bonded products. They operate scientifically with the
direction of activities controlled by over 20 years of
experience moving towards High Productivity and
Organizational Stability.

They use all types of Elastomers depending on the

needs of our customers.

They manufacture Rubber moulded components,

Metal Bonded Components, Gaskets, ‘O’ Rings and
Rubber Sheets made from Silicone, Fluoroelastomers,
Chloroprene, NBR, EPDM, SBR and Natural Rubber.
Their products find application in Automobile, Home
appliances, Industrial applications and Sports
Accessories.
 Their Products have been acknowledged and
accepted by the customers (Some of the best Brands of
the world) across the globe.

BRIEF DESCRIPTION ON PALLET :

 Pallets – An efficient and safe way of material
handling system.

 Pallets are an integral part of any basic materials

handling and storage system common to a wide
range of stores and warehouses.

 A pallet (sometimes called a skid) is a flat transport

structure that supports goods in a stable fashion while
being lifted by a forklift, pallet jack, or other jacking
device.

 A pallet is the foundation of a unit load design, which

can be as simple as placing the goods on a pallet, a
securing them with straps or stretch-wrapped plastic
film or as exotic as a ULD mini container.
Types Of Pallets :

• Loading pallets

• Export pallets Boards

• Angles and a variety of components-Specialty

product- Single-decked pallet (2 way)- Reversible
pallet,Double-decked pallet (2 way)Double bridge
pallet (4 way).
Types Of Pallets contd..
METHODOLOGY:

PROBLEM FINALREVIEW AND

IDENTIFICATION REPORT

QUANTITY
DESIGN
ANALYSIS

MATERIAL TIMESTUDY AND

SELECTION PROCESS PLANNING

MANUFACTURING MECHANICAL
and ASSEMBLY ANALYSIS
DESCRIPTION ON LOADING PALLET:

Loading pallet is a kind of material handling equipment

which facilitate in arranging the raw materials for rubber
products into the mould cavity of molding machine.

The components of loading pallets are

 Top plate
 Sliding plate
 Pin
 Main support
 Sliding guide
 stopper
 bolt and nuts.
WORKING PROCEDURE OF LOADING PALLET:

 The raw materials were kept on the sliding plate of

loading pallet. Then it is brought to the moulding zone
and it is fixed with the help of pins such that the whole
set up won’t be shaken while loading into the cavity.

 Following this, a slight drag to the sliding plate leads

to load all the raw materials simultaneously into the
cavity.

 Finally, it is taken away from the molding region and

activating on the (Directional control valve) DCV.
MATERIALS USED:

S.No PART NAME MATERIAL NAME

1 Top plate Bakelite(Hylam)

2 Sliding plate Bakelite(Hylam)

3 Pin Cast Nylon

4 Main support Aluminium

5 Sliding guide Aluminium

6 Stopper BaKelite(Hylam)

7 Bolt and nut High Carbon Steel

ADVANTAGES OF LOADING PALLET:

 Increase in Productivity.
 Reduce the operator’s fatigue.
 Improvement in safety.

DISADVANTAGES OF LOADING PALLET:

 Design is so complicated.
 Time consumed in manufacturing is high.
 High skill is needed in assembly.
DESIGN OF LOADING PALLET:

STOPPER
TOP PLATE

PIN

SLIDING PLATE

MAIN
SUPPORT
MATERIALS SELECTION:

Based on the application , we require high heat resistant

material with less weight and non brittle. Some of the
materials are

• BESTHERMO SERIES

• MS SERIES

• KALHON –L

• PHENOTHERM INSULATION
MATERIAL

• HYLAM SHEET
 MATERIAL PROPERTIES:

TEST ITEMS UNIT BESTHERMO- PHENOTHERM KALHON-L

F
Degree
HEAT 300 250 300
celsius
RESISTANCE

FLEXURAL MPA 189 159 464

STRENGTH

COMPRESSIVE MPA 406 319 584

STRENGTH 148 113 365
J/cm
IZOD IMPACT 3.7 4.8 6.6
STRENGTH
-
SPECIFIC 2.0 1.8 2.0
GRAVITY
W/mK
THERMAL .24 .21 .23
CONDUCTIVITY

ARC SEC 320 250 180

RESISTANCE
BAKELITE (HYLAM) PROPERTIES:

PARAMETERS VALUE UNIT

DENSITY 900 Kg/m3

-
SPECIFIC GRAVITY 0.9

TEMPERATURE Deg celsius

250

MPa
MECHANICAL 99
STRENGTH

Based on the availability and low cost , we selected a

Hylam Sheet for the project.
MANUFATURING OPERATIONS:

S.NO. PART NAME MAJOR

OPERATIONS

1 TOP PLATE BAND SAWING

2 SLIDING PLATE BAND SAWING

3 PINS TAPER TURNING

4 MAIN SUPPORT CUTTING and

DRILLING

5 SLIDING GUIDE CUTTING and

DRILLING
AFTER MANUFACTURING:
MOULDING CAVITIES:
TIME STUDY ANALYSIS:

WITHOUT LOADING PALLET

TIME CAPTURED in seconds

S.NO. PROCESS TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 4

Cutting the
1 raw material 70 72 72 69
to approx.
size of
40*40mm

Weighing and
2 Arranging on 80 81 80 77
the basket.

Loading into
3 the mould 65 64 65 69
cavity by
hand.

Development
4 of DUST 225 220 230 230
CAP
product
TOTAL
PRODUCTION 430 437 447 437
CYCLE TIME (7min (7min (7min (7min
10sec) 17sec) 27sec) 17sec)
 WITH LOADING PALLET

TIME CAPTURED in seconds

S.NO. PROCESS TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 4

1 Cutting the
raw material 70 72 72 69
to approx.
size of
40*40mm

2 Weighing and
Arranging on 80 81 80 77
the basket.

3 Loading by
PALLET 14 13 16 14

4 Development
of DUST 225 222 221 226
CAP
product

TOTAL 389 388 389 386

PRODUCTION (6min (6min (6min (6min
CYCLE TIME 39sec) 38sec) 39sec) 36sec)
CHART ANALYSIS:

CHART ANALYSIS

250

200
TIME TAKEN in sec

150

100 WITHOUT PALLET

50 WITH PALLET

0
PROCESS PROCESS PROCESS PROCESS
1 2 3 4
PROCESS

PROCESS 1 PROCESS 2 PROCESS 3 PROCESS 4

WITHOUT
PALLET 70 80 65 220

WITH 70 79 16 219
PALLET
LINE CHART ANALYSIS:

LINE CHART ANALYSIS

500

450

400
TIME TAKEN IN sec

350

300

250

200

150

100

50

0
PROCESS PROCESS PROCESS PROCESS
1 2 3 4
WITHOUT PALLET 70 150 215 435
WITH PALLET 70 149 161 380
PROCESS PLANNING ON LOADING BY HAND:

Cutting the raw material to the Switching on the

approx. size of 40*40mm Hydraulic unit.

Loading the material into

Weighing and arranging the the cavity 12
material in the basket
Loading the material into
Setting up the temperature
the cavity 11
and turning on.
Loading the material into

Loading the material into the cavity 10

the cavity 1
Loading the material into
Loading the material into
the cavity 9
the cavity 2

Loading the material into Loading the material into the

the cavity 3 cavity 8

Loading the material into the Loading the material into the
cavity 4 cavity 7

Loading the material into the Loading the material into the
cavity 5. cavity 6
PROCESS PLANNING ON LOADING PALLET:

Cutting the raw material to the

approx. size of 40*40mm

Weighing and arranging the material

in the LOADING PALLET

Setting up the temperature and turning

on.

Loading all the raw materials into

the mould cavity simultaenously
by LOADING PALLET.

Switching on hydraulic unit.

TOTAL NUMBER OF PRODUCTS per annum :

WITHOUT WITH LOADING

S.NO PARAMETERS LOADING PALLET
PALLET

1 Number of trials per hour 8 9

2 Number of products 12 12
produced per trial

3 Total hours for a shift 10 10

(PER DAY)

4 TOTAL NUMBER OF
PRODUCTS PER DAY 960 1080

TOTAL NUMBER OF 288,000 324,000

5 PRODUCTS PER
ANNUM(300 DAYS)
QUANTITY ANALYSIS:

1200

1000

800

600

400

200

0
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Hour Hour Hour Hour Hour Hour Hour Hour Hour Hour

WITHOUT
PALLET
QUANTITY ANALYSIS CONTD..

WITHOUT DIFFERENCE IN
PALLET WITH PALLET PRODUCTS

1st Hour 96 108 12

2nd Hour 192 216 24
3rd Hour 288 324 36
4th Hour 384 432 48
5th Hour 480 540 60
6th Hour 576 648 72
7th Hour 672 756 84
8th Hour 768 864 96
9th Hour 864 972 108
10th Hour 960 1080 120
 COMPARISON ANALYSIS

330000
PRODUCTS PRODUCED PER DAY

320000

310000

WITHOUT
300000
PALLET
290000
WITH PALLET
280000

270000

WITHOUT WITH PALLET

PALLET
PRODUCTS
PRODUCED PER 288000 324000
ANNUM
COST ESTIMATION:

SL.NO DESCRIPTION QUANTITY RATE PER TOTAL COST

UNIT

1 HYLAM SHEET 1 PLATE RS 450/kg INR 900

(600 * 600) 5MM
THICKNESS

2 HYLAM SHEET 1 PLATE RS 450/kg INR 900

(600 * 600) 3MM
THICKNESS

3 ALUMINIUM L- 3500MM RS 250/kg INR 150

ANGLE 1.5MM LENGTH

4 ALUMINIUM L- 1000MM RS 250/kg INR 150

ANGLE 3MM LENGTH

5 CAST NYLON 300MM RS 600/kg INR 300

LENGTH

6 NUT &BOLT M3 50 UNITS - INR 300

7 MACHINING COST INR 2000

TOTAL COST INR 4700

REFERENCES:

● Coyle, J.J., et al., 1992, Management of Business

Logistics, 5th ed., West.

● Apple, J.M., 1972, Material Handling System Design,

New York: Ronald.

● MHI, 2000, The Ten Principles of Material Handling,

Charlotte,NC: Material Handling Institute