Conveyor Belt design for bottling plant of Coca Cola

Conveyor Belt Design

Conveyor Belt Design Ashay Mehta, Kartik Menda and Vivek Pattni Tech Tech Report 3 !nstr"ctors #avdeep Malhotra and Dr$ M$%$ &re'al Monday, ("ly 3, )*

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%"++ary #e' Prod"cts are designed designed and developed y 'orking e--iciently in a tea+$ The a"thors selected the pro.ect o- /Conveyor Belt Design0 in PT prod"ction line at Kandhari Beverages Pvt$ 2td, a -ranchise o- Coca Cola !ndia 2td KBP24$ The pro.ect selected y the a"thors 'as in5line 'ith the o.ective o- the organi6ation$ The 'riters 'orked in tea+ and each represented a partic"lar -"nctional area and 'as responsile -or delivering the pro.ect activities on ti+e$ Pro.ect report on conveyor elt design 'as divided into +a.or sections na+ely introd"ction, disc"ssion, concl"sion and reco++endations$ Disc"ssion o- the pro.ect report -ollo'ed the syste+atic prod"ct develop+ent process that the 'riters estalished and -ollo'ed it rigoro"sly$ The activities 'ere divided into -o"r +ilestones and the individ"al +ilestone consisted o- activities pertaining to all the three -"nctional areas, na+ely Pro.ect Manage+ent, Design and Develop+ent and Man"-act"ring$ Milestone one co+prised o- the -"nda+ental and gro"nd'ork st"dy that strengthened the -o"ndation o- the pro.ect$ Ma.or activities like pro.ect approval, reverse engineering, and 7"ality 8"nction Deploy+ent 78D4 -or the ne' prod"ct 'ere a part o- this +ilestone$ 78D 'as divided into t'o phases to -ollo' the -lo' o- activities and incorporate the voice o- c"sto+er in the -inal prod"ct$ D"ring the stint, the tea+ +e+ers visited the co+pany -or st"dying the -"nctions and design o- the +etal link$ Milestone t'o 'as critical and intense, as scr"p"lo"s engineering kn o'ledge 'as re9"ired -or prod"ct designing$ :ith the increase in the n"+er o- activities it 'as necessary to +anage the data and ens"re that all the pro.ect tea+ +e+ers 'ere 'orking to'ards the sa+e goals$ Blend o- engineering a nd +anage+ent activities helped to "ild "p relevant skills 'ithin the tea+ +e+ers$ Pro.ect +anage+ent practices +ade it convenient -or the a"thors to achieve the engineering goals easily$ The activities like 'ork reakdo'n str"ct"re, ench+arking st"dy, 78D phase ), concept creation, CAD +odeling and CA analysis 'ere the key aspects o- this +ilestone$ Milestone three 'as dedicated -ore+ost -or +old design and to reach to the concl"sion o- the pro.ect$ The a"thors intended to design a CAD +odel o- the +old that 'o"ld help the readers to vis"ali6e and "nderstand the +old design para+eters$ The tea+ +e+ers visited Central !nstit"te -or Plastic ngineering and Technology to learn ao"t the +old design para+eters$ 7"ality +anage+ent plan, design calc"lations and +old CAD develop+ent 'ere the +a.or activities$ Milestone -o"r 'as only +eant -or disc"ssing the learning o"tco+es -ro+ the pro.ect and 'as +eant to thank each other -or their intense involve+ent in the pro.ect$ !t 'as concl"ded that P;M co"ld e "sed -or the conveyor elt application as it -"l-illed the c"sto+er re9"ire+ents$ :hen co+pared to +etal conveyor elt, the P ;M elt 'o"ld e cost e--ective, res"lting in several "siness "siness ene-its$ The a"thors also reco++ended "sing the +entioned engineering ."sti-ication and calc"lations -or c"sto+i6ed conveyor elt design< this report 'as e=cl"sively prepared -or KBP2$


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Ackno'ledge+ent :e -irstly thank Mr$ Mr$ #avdeep Malhotra, o"r +entor +entor -or the pro.ect$ :itho"t :itho"t his "no"nd dedication and ti+e a-ter ti+e g"idance, this pro.ect 'o"ld not have een possile to co+plete$ >e p"shed "s hard 'hen 'e 'ere st"ck, and picked "s "p 'hen 'e 'ere do'n and o"t$ :e are grate-"l to Dr$ M$ %$ &re'al !nstit"te Director, Canadian !nstit"te -or !nternational %t"dies4 -or sharing his i++ense kno'ledge that helped "s to overco+e +a.or di--ic"lties -aced d"ring the pro.ect$ :e also like to o--er o"r regards to Mr$ &"r+ohinder %ingh College Ad+inistrative Ad+inistrative Depart+ent4 -or providing "s a link to Kandhari Beverages Pvt$ 2td$, and helping "s o"t to sec"re a pro.ect 'ith the+$ :e 'ill like like to thank Mr$ Mr$ %$ %$ &re'al Director Director Tech44 Tech44 o- Kandhari Beverages Pvt$ 2td -or providing "s the opport"nity to carry o "t a pro.ect in their plant$ :e are also grate-"l to Mr$ Vinod Vinod %har+a %tore !n charge4, Mr$ Ra.esh %har+a Asst$ %tore ;--icer4, Mr$ #arendra %ingh lectrical !n charge4, Mr$ Bagh %ingh Maintenance Manager4, Mr$ Charan.eet %ingh Plant Manager4, Manag er4, Mr$ B$ P$ Bharad'a. Asst$ 7"ality Manager4, Mr$ &"rse'ak %ingh %yste+ Manager4, Mr$ (ag+ohan %ingh %enior Che+ist4, Mr$ T$ T$ C$ M"n.al Manager 2a4, Mr$ Ka+al %har+a P"rchase Manager4, Mr$ Ashish %ethi PT !n charge4 and Mr$ &$ K$ (oshi D& !n charge4, e+ployees oKandhari Beverages Pvt$ 2td$, -or assisting "s on any 9"eries that 'e p"t -or'ard to the+ and taking o"t so+e val"ale ti+e to g"ide "s to an appropriate sol"tion$ :e also thank Rink", a peon, 'ho provided "s aerated drinks 'henever 'e desired$ :e e=press gratit"de gratit"de to Mr$ R$ M$ Mishra and Mr$ Mr$ %$ %har+a, -ac"lty at C!PT Central !nstit"te -or Plastic ngineering and Technology4$ Technology4$ They enlightened "s ao"t vario"s aspects o- +old designing and +an"-act"ring in the t'o5day visit that 'e paid to the+$ This proved to e enor+o"sly help-"l in +aking o- an i+proved design o- the +old$ ("ly 3, )* Ashay Mehta Kartik Menda Vivek Pattni


Tale Tale o- Contents Page %"++ary

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Tale o- Contents

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2ist o- !ll"strations

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!ntrod"ction

11

Backgro"nd

11

P"rpose

13

%cope

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Prod"ct Design and Develop+ent Milestone 1

1* 1

1$1$1  Pro.ect Tea+ Declared

1

1$1$)  Approval -ro+ Kandhari Beverages Pvt$ 2td

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1$1$3  Pro.ect Concept Doc"+ent

)1

1$1$?  Prod"ct Develop+ent Deliverales

)3

1$1$  !denti-y Re9"ire+ents -or Mentor

)?

1$)$1  Vol"+e sti+ates Availale

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1$)$)  7"ality 8"nction Deploy+ent  Phase 1

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Milestone )

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)$1$1  Pro.ect Monitoring and Control

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)$1$)  Pro.ect Charter Prepared

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)$1$3  Change Re9"est Plan

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)$1$?  Pro.ect %cope %tate+ent &enerated

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)$1$  Pro.ect Planning

?

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)$1$  :ork Breakdo'n %tr"ct"re Availale

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)$)$1  Bench+arking %t"dy Co+pleted

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)$)$)  7"ality 8"nction Deploy+ent  Phase )

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)$)$3  Design Calc"lations



)$)$ )$)$? ?  M"lt M"ltip iple le The The+e +e Con Conce cept ptss Base Based d on 8"n 8"nct ctio iona nall Re9" Re9"ir ire+ e+en ents ts

3

)$)$  CAD Modeling

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)$)$  D58MA -or the %elected Concept

*1

)$)$*  CA Analysis

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)$)$@  %a-ety

**

)$)$  Maintainaility

*@

)$)$1  Concerned Resol"tions

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)$)$11  Prod"ct Design 8ree6e

@

)$)$1)  Dra'ing Release

@1

)$)$13  Mold Design %trategy

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)$)$1?  Cons"ltant !denti-ied -or Mold Design

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)$3$1  Man"-act"ring Process %elected

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)$3$) )$3$)  !den !dentiti-ica icatio tion n o- 8aci 8acili litie tiess Re9"i Re9"ired red to Man" Man"-ac -act"r t"ree the the Prod"ct Prod"ct

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)$3$3  Preli+inary Process Planning %heets Ready

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Milestone 3

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3$1$1  Pro.ect Monitoring and Control

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3$1$ 3$1$) )  7"al 7"alit ity y Man Manag age+ e+en entt Pla Plan n in in Accor ccorda danc ncee to to DeDe-in ined ed 7"al 7"alit ity y

@@

3$)$1  7"ality Check Para+eters De-ined

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3$)$)  ngineering B;M Availale

1

3$)$3  Mold %t"dy at the Cons"ltantEs 2ocation

)

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3$)$?  Mold Math Data Availale

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3$)$  Mold CAD Develop+ent

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3$)$  Mold Dra'ing Release

@

3$)$*  Mold 5B;M Availale

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3$)$@  Mold Details

1

3$3$1  Costing

11

3$)$)  8inal Prod"ct %peci-ications stalished

13

Milestone ?

1

?$1$1  2essons 2earnt Archived

1

Concl"sion

1

Reco++endations

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&lossary

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Re-erences

11 Appendices

A$ Pro.ect Tea+ Tea+ Declaration B$ Pro.ect Kick5o-- Meeting Agenda C$ Pro.ect Concept Doc"+ent D$ Prod"ct Develop+ent Process Deliverales $ Mentor Agree+ent 8or+ 8$ Conveyor Conveyor Path 2ayo"t 2a yo"t &$ Partial 78D  1 >$ Pro.ect %tat"s Report !$ Pro.ect Charter ($ Change Re9"est Plan

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K$ :ork Breakdo'n %tr"ct"re 2$ &antt Chart M$ #et'ork Diagra+ #$ Co++"nication Plan ;$ Revised Pro.ect %cope %tate+ent P$ D58MA  Conveyor 2ink 7$ Design 8ree6e Meeting R$ Co+ponent Dra'ingF @@ %$ Co+ponent Dra'ingF @? T$ Process Control Chart G$ 8inal Pro.ect %tat"s Report V$ 7"ality Manage+ent Plan :$ Mold Dra'ing #oF 11 H$ Mold Dra'ing #oF 1) I$ Mold Dra'ing #oF 1? J$ Mold Dra'ing #oF 1

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2ist o- !ll"strations Page 8ig"re 1F Block Diagra+ o- Conveyor %yste+

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8ig"re )F Co+plete 78D

1@

8ig"re 3F >o"se o- 7"ality conveyor Path

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8ig"re ?F Conveyor Path

3

8ig"re F Degree o- 8reedo+ o- Move+ent in I5a=is

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8ig"re $ 8orce d"e to conveyor elt only

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8ig"re *F 8orce 'ith the ottles on the conveyor elt

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8ig"re @F 8orce d"e to acc"+"lated load

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8ig"re F Traction -orce d"e to gravity at the inclinations

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Tale 1F %peed o- conveyor elt at di--erent ele+entary sections

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Tale )F lectric +otor speci-ications

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Tale 3F Traction -orce -or all the ele+entary sections

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Tale ?F 8orces -or all the three conditions -or all the nine sections

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Tale F Bend -actor val"es

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Tale F Design, per-or+ance and cost targets

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Tale *F 2ist o- poly+er properties

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Tale @F Material %election

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8ig"re 1F Bench+arking 8eat"res

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Tale F Bench+arking Res"lts

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8ig"re 11F The+e Concept 1

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8ig"re 1)F The+e Concept )

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8ig"re 1?F The+e Concept ?

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8ig"re 1F Concept 1

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8ig"re 1F Concept )

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8ig"re 1*F Concept ) Asse+ly

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8ig"re 1@F Concept 3

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8ig"re 1F Concept 3 Asse+ly

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8ig"re )F Concept ?

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8ig"re )1F Concept ? Asse+ly a4

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8ig"re ))F Concept ? Asse+ly 4

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8ig"re )3F Pin -or concept ?

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8ig"re )?F %napshot o- Analysis on P;M

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Tale 1F ngineering Dra'ing Release

@1

Tale 11F Processing properties o- P;M >o+opoly+er

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Tale 1)F Bill o- Material o- Conveyor link

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8ig"re )F Mold Top Plate

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8ig"re )F Mold Botto+ Plate

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8ig"re )*F %plit Core

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8ig"re )@F Mold Asse+ly =ploded Vie' 1

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8ig"re )F Mold Asse+ly =ploded Vie' )

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Tale 13F ngineering Dra'ing Release -or Mold

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Tale 1?F Bill o- Material o- Mold

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8ig"re 3F :eight Co+parison

1*

8ig"re 31F 2i-e Co+parison

1*

8ig"re 3)F Cost Co+parison

1*

1

Note: 8ollo'ing sy+ols "sed in the pro.ect report$

 5 De-inition provided in glossary$ Gp arro'F I5a=is, right arro'5 H5a=is and -or'ard arro'5 J5a=is ;n the e=tre+e right o- every s"heading a n"+er in the -or+ o- H$A is 'ritten, 'here H denotes the +ilestone n"+er and A denotes the -"nctional area as sho'n elo'F A 1 ) 3

Functional Area Pro.ect Manage+ent Design and Develop+ent Man"-act"ring


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!ntrod"ction Backgro"nd The pro.ect o- +aterial conversion o- conveyor elt -ro+ stainless steel to P;M Polyo=y+ethelene4 'as "ndertaken and co+pleted at Kandhari Beverages Pvt$ 2td, #aip"r, P"n.a, 'hich is a -ranchise o- Coca Cola !ndia Pvt$ 2td$ The conveyor elt is driven y other +echanical apparat"s and electric +otor attached to it$ These other +echanical apparat"s associated 'ith the conveyor elt are +ainly ind"ction +otors, gear +echanis+ 'ith the ind"ction +otor and nylon gears$ The inp"t sha-t o- the gear +echanis+ is attached 'ith the +otor is "sed to ad."st the speed o- the conveyor elt in accordance 'ith the -iller speed$  The ind"ction +otors single or three phase4 are controlled y the V8Ds Variale 8re9"ency Drive4 that are controlled y Progra++ale 2ogic Controllers P2Cs4$ A nylon gear is attached to the o"tp"t sha-t o- the gearo= and the teeth o- the nylon gear +eshes 'ith the otto+ s"r-ace o- the link and th"s drives the conveyor elt$ The integration o- the gearo= 'ith the nylon gear and the ind"ction +otor is as sho'n in the -ollo'ing -ig"reF Conveyor Belt

Conveyor Belt

&ear Bo=

#ylon &ear #ylon &ear

;"tp"t sha-t &ear Teeth

Motor

!nd"ction Motor Side View Front View

8ig"re 1F Block Diagra+ o- Conveyor %yste+


1)

The processing o- the aerated drinks is done 'ithin a -"lly a"to+ated syste+ and controlled environ+ent$ There are t'o prod"ction -acilities in the plant, na+ely R&B Recycled &lass Bottle4 line and PT Polyethylene Terephthalate4 ottle line$ The transportation o- these ottles -ro+ one process to another is done on the conveyor elt$ Conveyor elt is the +a.or +echanical apparat"s "sed in the plant and its "se is contin"o"s and rigoro"s, hence it is a critical part o- oth the prod"ction lines$ There-ore, any da+age to the conveyor elt and its related co+ponents s"ch as +otors, gears and links 'o"ld stop the prod"ction line and res"lt in severe losses$ The conveyor elt "sed at the plant 'as an asse+ly o- stainless steel links .oined together 'ith the help o- a stainless steel cylindrical pin$ %tandard ten -eet strips o- links "sed to "ild the conv eyor elt -or oth the prod"ction lines 'ere i+ported -ro+ &er+any and the average li-e othis stainless steel conveyor elt is   * years$ The stainless steel conveyor  elt had een in "se since )1 and hence, a replace+ent o- the conveyor elt 'as d"e$ There-ore, this pro.ect 'as "ndertaken y the a"thors to select a s"itale +aterial to replace the stainless steel conveyor elt "sed -or the PT ottle prod"ction line$ Traditionally, stainless steel has een "sed as the standard +aterial -or the +an"-act"ring o- the links -or the ind"strial conveyor elts$ The density o- stainless steel is very high and the s"r-ace o- the links has to e s+ooth to -"l-ill the design and per-or+ance re9"ire+ent -or 'hich, -inishing operations s"ch as honing and lapping are per-or+ed a-ter the initial processing$ This res"lts in an increase in the +an"-act"ring cost o- the stainless steel links$ To s"rvive in the co+petitive +arket, the ind"strial de+and is to red"ce 'eight and cost o- the prod"ct 'itho"t degrading the 9"ality o- the prod"ct$ This enco"raged the a"thors to take "p the pro.ect to -ind a s"itale +aterial that is lighter and cheaper than stainless steel "t has several e ne-its -or the sa+e application$


13

Plastics have een in "se in the +an"-act"ring ind"stry since 13s and their develop+ent and "tili6ation has -lo"rished re+arkaly over the last -e' years$ Plastic prod"cts have several ene-its over +etals in ter+s o- 'eight, asse+ly, aesthetics, -le=iility and cost$ There-ore, the a"thorsE e--ort 'as to convert +etal conveyor elt to plastic conveyor elt +ade -ro+ P;M Polyo=y+ethelene4, an engineering plastic$

P"rpose The o.ective o- the pro.ect 'as to replace the +aterial o- the conveyor elt o- PT prod"ction line -ro+ stainless steel to P;M Polyo=y+ethelene4, engineering plastic that is lighter and cheaper than stainless steel and has several ene-its -or the sa+e application$ The conversion o- the +aterial helped to red"ce the r"nning costs o- the ottling plant like service and +aintenance o- the conveyor elt and +echanical co+ponents s"ch as ind"ction +otors, earings and gears that are integrated 'ith it$ This alteration res"lted in the -ollo'ing advantagesF •

The service and +aintenance costs o- the P;M conveyor elt 'ere red"ced$ ;n stainless steel conveyor elt, l"rication 'as "sed to +ake the s"r-ace s+oother so that the PT ottles 'o"ld slide on the s"r-ace as per re9"ire+ents$ The "se ol"rication 'as eli+inated -or the P;M conveyor elt eca"se the s"r-ace o- the links +ade -ro+ P;M 'as s+ooth that -acilitated the ottles to slide 'itho"t -alling do'n$

•

The earings o- the ind"ction +otors contin"o"sly "ndergo -atig"e load d"e to the 'eight o- the PT ottles and the conveyor elt$ The alteration o- the +aterial


1?

-ro+ stainless steel to P;M helped in red"cing the 'eight o- the conveyor elt and th"s res"lted in red"ction o- the 'orking stress e=perienced y the earings$ This increased the li-e o- the +otors, as there 'as less 'ear and tear o- the parts d"e to decrease in the 'orking stress$ •

As the conveyor elts 'ere i+ported -ro+ &er+any, the cost o- logistics and c"sto+ d"ty 'as also added to the -inal cost o- the prod"ct$ Also, the lead5ti+e -or the prod"ct 'as aro"nd 3 days, and as a res"lt, a certain level o- inventory 'as +aintained$ !n the case o- P;M conveyor elts, the ottling plant had the advantage o- +an"-act"ring the conveyor elt links in5ho"se y investing on a >and !n.ection Molding Machine$ >ence, the ordering and carrying costs o- the conveyor elt 'ere red"ced$ The in5ho"se +an"-act"ring o- the P;M conveyor elt links also helped in the c"rtail+ent o- the hidden costs associated 'ith the inventory$


1

%cope The pro.ect o- altering the +aterial o- the conveyor elt -ro+ stainless steel to P;M 'as considered only -or PT prod"ction line$ !t 'as concl"ded y the 'riters that the pro.ect 'o"ld not e -easile and -"nctional in the R&B prod"ction line eca"se the pieces o- roken glass o- the ottle 'o"ld da+age the P;M conveyor elt$ >ence, the +aterial change -or the conveyor elt "sed in R&B prod"ction line 'as e=cl"ded -ro+ the scope$ D"ring the pro.ect, certain ass"+ptions 'ere +ade 'hile per-or+ing engineering analysis, collecting the data and calc"lating the -inal cost o- the P;M conveyor elt, average li-e and the -inal cost o- the +old$ The ass"+ptions +ade y the 'riters are as stated elo'F •

The engineering analysis o- the conveyor elt link 'o"ld e done on Pro5 Mechanica so-t'are

•

The data provided y Kandhari Beverages Pvt$ 2td 'as regarded as correct$

•

The +ilestones o- the pro.ect 'o"ld e acco+plished as per the planned sched"le$

•

The nat"ral -re9"ency o- the conveyor elt 'o"ld not a--ect the per-or+ance othe conveyor elt$

•

The proposed design is not patented$

•

The coe--icient o- -riction et'een the g"ide rail and the ottle is negligile$

•

The cost o- +an"-act"ring the +old is Rs$ ,,

•

The di+ensional acc"racy o- the o- the conveyor elt link and the co+ponents othe +old 'o"ld e 'itho"t tolerance$


1

The pro.ect also had several constraints -aced y the a"thors 'hich are as listed elo'F •

The prod"ct co"ld not e -aricated d"e to li+itation in the "dget allocated -or the pro.ect

•

The testing co"ld not e per-or+ed "nder act"al conditions d"e to li+itation in reso"rces$

•

The validation o- the prod"ct 'as not done y per-or+ing physical tests, as so+e o- the testing e9"ip+ents 'ere not availale$

•

The +old 'as not developed eca"se o- the restriction in ti+e and cost assigned to the pro.ect$

•

#oise created y the conveyor elt +otion 'as not +eas"red as the instr"+ents -or +eas"ring noise 'as not availale


1*

Prod"ct Design and Develop+ent The 9"ality tool, 7"ality 8"nction Deploy+ent 78D4 'as " sed y the a"thors to -ind o"t the e=pectations o- the c"sto+er and "se the+ to drive the Prod"ct Develop+ent Process$ !t enaled the 'riters to concentrate on the c"sto+er re9"ire+ents d"ring the design phase, therey red"cing the i+ple+entation ti+e$ The incorporation o- 78D in the pro.ect helped to achieve the desired 9"ality that con-ir+ed to c"sto+erEs re9"ire+ents$ 8ollo'ing steps 'ere per-or+ed in creating the co+plete the ho"se o- 9"alityF •

Co+petitive in-or+ation 'as "sed to -oc"s on c"sto+er re9"ire+ents, and reso"rces 'ere prioriti6ed according to the str"ct"red in-or+ation ac9"ired -ro+ the c"sto+er$

•

%i+"ltaneo"sly 'ork 'as started on the design o- the prod"ct y the a"thors that avoided -"t"re red"ndancies and helped in recogni6ing -"t"re application opport"nities to avoid post introd"ction di--ic"lties$

•

A cross5-"nctional tea+ 'as created 'hich -acilitated in decision5+aking aility othe pro.ect tea+ and look -or discovering vario"s opport"nities in i+proving the 9"ality o- the prod"ct$

•

The 'hole process 'as then doc"+ented in a syste+atic +anner to create dataase -or -"t"re pro.ects$ !t 'o"ld also help in the contin"o"s i+prove+ent o- the prod"ct$

8ig"re )F Co+plete 78D


1

MilestoneF 1 1$1$1  Pro.ect Tea+ Declared

1$1

The activity 'ith 'hich the pro.ect 'as started 'as the declaration o- the pro.ect tea+$ The pro.ect tea+ 'as -or+ed co+prising o- three +e+ers, 'ho have a diverse e=perience and skills$ The tea+ +e+ers have also 'orked in n"+ero"s +"ltinational and estee+ed organi6ations s"ch as &eneral Motors and Rena"lt$ The details o- each +e+er incl"ding contact in-or+ation and vocational e=periences are +entioned in the Appendi= A$


1$1$) 5 Approval -ro+ Kandhari Beverages Pvt$ 2td$

)

1$1

8or selecting the pro.ect, the a"thors re9"ested -or an approval -ro+ Kandhari Beverages Pvt$ 2td, a -ranchise o- Coca Cola !ndia Pvt$ 2td to carry o"t a live pro.ect at their location and 'ere allo'ed to st"dy the processing and 'orking o- the PT and R&B prod"ction plant$ !t 'as oserved that oth the plants 'ere co+pletely a"to+ated and the conveyor elt 'as the only +echanical co+ponent that 'as "sed incessantly to prod"ce the everages$ >ence, it 'as in-erred that the conveyor elt 'as the +ost critical +echanical co+ponent and an enhance+ent in the cost and 9"ality o- the conveyor elt 'o"ld res"lt in s"stantial ene-its to the organi6ation$ >ence, this pro.ect 'as identi-ied y the tea+ +e+ers to change the +aterial o- the stainless steel conveyor elt to poly+er at Kandhari Beverages Pvt$ 2td$ A pro.ect kick5o-- +eeting 'as organi6ed to have -or+al introd"ctions o- the pro.ect tea+ +e+ers 'ith the co+pany e=ec"tives and disc"ssion on the pro.ect 'as done -or otaining an approval$ The copy o- the agenda o- the +eeting is +entioned in Appendi= B$


1$1$3 5 Pro.ect Concept Doc"+ent

)1

1$1

To start 'ith the pro.ect a Pro.ect Concept Doc"+ent PCD4 'as -or+ed y the a"thors to s"+it to the revie' co++ittee in 'hich an overvie' o- the pro.ect 'as provided along 'ith the signat"res o- the revie' co++ittee$ The co+plete pro.ect concept doc"+ent -or the pro.ect is provided in the Appendi= C$ The concept doc"+ent 'as divided into three sections that covered -ine points o- the pro.ect as +entioned elo'F %ection ;ne: Co+pleted y the re9"estor •

B"siness ("sti-icationF This section provided in-or+ation ao"t the p"rpose o- the pro.ect and 'hat "siness iss"es or prole+s 'ill e solved$

•

Pro.ect DescriptionF The pro.ect description stated the o.ective o- the pro.ect and gave rie- in-or+ation ao"t the o"tco+es o- the pro.ect "pon its co+pletion$

•

Pro.ect CostsF A high5level esti+ate o- the pro.ect costs 'as listed in this section stating the li+ited "dget a+o"nt allotted -or di--erent areas$

•

Ti+e 8ra+eF The pro.ect 'as divided into -ive +a.or phases na+ely initiation, planning, e=ec"tion, +onitoring and control and closing$ >ence, a starting date and the end date esti+ate 'as provided -or each phase$

%ection T'o: Co+pleted y the pro.ect +anager •

Planning sti+atesF This section gave rie- in-or+ation ao"t the +a.or activities o- the pro.ect and the ti+ing -or each to e co+pleted$

•

B"siness Areas !+pactedF !n this section, concise in-or+ation is stated ao"t the "siness "nits i+pacted y this pro.ect$


))

%ection threeF Co+pleted y the Revie' Co++ittee •

%election co++ittee revie'F This section 'as provided -or verdict o- the selection co++ittee and related co++ents on the pro.ect$

•

%ignat"res o- the revie' co++itteeF The signat"res o- the revie' co++ittee at the end a"thenticated the veri-ication o- the pro.ect concept doc"+ent$


1$1$? 5 Prod"ct Develop+ent Deliverales

)3

1$1

8or every ne' develop+ent o- the prod"ct, there is a syste+atic process, 'hich is kno'n as #e' Prod"ct Develop+ent Process #PD4$ The activities o- this process di--er -ro+ prod"ct to prod"ct and are "ni9"e -or each prod"ct$ The a"thors developed the ne' prod"ct develop+ent process -or the design o- the poly+er conveyor elt$ This process incl"ded the activities o- the pro.ect, 'hich 'ere distri"ted a+ong three +ilestones$ The develop+ent o- this process 'as necessary at the initial stage so as to acco+plish the pro.ect in a syste+atic +anner$ !t also helped the tea+ +e+ers to eco+e a'are o- their roles and responsiilities at vario"s stages o- the pro.ect$ A high level deliverales o- the prod"ct develop+ent process 'ere +entioned 'ith respect to the +ilestones and the -"nctional areas, i$e$ Pro.ect Manage+ent, Design and Develop+ent and Man"-act"ring$ The list is +entioned in Appendi= D$ !t 'as necessary -or the pro.ect tea+ to acco+plish all the activities o- the previo"s +ilestone to start 'ith the activities o- the ne=t +ilestone$ The activities 'ithin the +ilestone +ight e per-or+ed in parallel depending on the availaility othe reso"rces$


1$1$ 5 !denti-y Re9"ire+ents -or Mentor

)?

1$1

A +entor is a pro.ect stakeholder 'ho has pro-icient skills and kno'ledge that is speci-ic to the s".ect o- the pro.ect and th"s provides assistance to the pro.ect tea+ -or solving prole+s 'ith respect to the s".ect o- the pro.ect$ The tea+ +e+ers needed a +entor and -ollo'ing 'ere the criteria -or the selection o- the +entorF •

The +entor sho"ld have an e=e+plary kno'ledge ao"t plastic +aterial properties eca"se the end prod"ct o- the pro.ect 'o"ld e +an"-act"red -ro+ P;M, an engineering plastic$

•

>eL%he sho"ld e an e=pert in the -ield o- +old design and develop+ent eca"se it is the part o- the scope o- the pro.ect$

•

The +entor sho"ld e pro-icient in +an"-act"ring processes and para+eters to e considered -or plastics$ The +entor 'as selected on the asis o- the aove criteria and an agree+ent -or+

'as signed 'ith the +entor, 'hich is in the Appendi= $


1$)$1 5 Vol"+e sti+ates Availale

)

1$)

To st"dy the -easiility o- prod"cing the links and analy6e "siness gains -ro+ it, the vol"+e esti+ation has to e de-ined$ The n"+er o- conveyor elt links re9"ired to satis-y the o"tco+es o- the pro.ect, 'as o tained y +eas"ring the total length othe conveyor elt theoretically as 'ell as practically$ Theoretically, the di+ensions othe stainless steel conveyor elt s"ch as the length, 'idth and thickness 'ere +eas"red and noted do'n$ The a"thors +ade a plant layo"t o- the conveyor elt incl"ding the n"+er o- +otors and their locations thro"gho"t the length o- the conveyor elt$ The plant layo"t can e re-erred -ro+ the Appendi= 8. 1$)$1$1 5 Theoretical Val"e The theoretical val"e -or the n"+er o- links 'as deter+ined in the -ollo'ing +annerF •

Total 2ength o- the conveyor elt  *3 inch

•

2ength o- the conveyor elt link  1$ inch

•

>ence, no o- links re9"ired  Total length o- the conveyor elt  *3 2ength o- the conveyor elt link 1$  ?@*$ ≈

5000

1$)$1$) 5 Practical Val"e Practically, n"+ers o- links 'ere co"nted -or 3 -eet$ This val"e 'as "sed to esti+ate the vol"+e o- the links needed in -ollo'ing +annerF •

8or 3 -t  3 inch, no o- links  )?

•

There-ore, -or *3 inch, no$ o- links  *3)?


)

3  ?@*1 ≈ 5000 The aove val"es gave a ro"gh esti+ate o- the prod"ction vol"+e and 'o"ld e "sed to calc"late the -inal cost o- the conveyor elt$


1$)$)  7"ality 8"nction Deploy+ent 5 Phase1

)*

1$)

The ho"se o- 9"ality, 'hich is the principal tool o- 78D, 'as applied to translate the voice o- the c"sto+er into design re9"ire+ents that +eet speci-ic target val"es$ The -ra+e 'ork o- the ho"se is as sho'n in the -ig"re elo'F

!nter5relationship et'een technical descriptors

Technical descriptors Voice o- the organi6ation4 e e + r i o " t 9 s e " C R r e o e + c o i t o s " V 3 C

Relationship et'een Re9"ire+ents and descriptions

Prioriti6ed technical descriptors

P r i R o e r i 9 t " i 6 i r e e d + C e " n s t t s o +

8ig"re 3F >o"se o- 7"ality

The Process o- generating the ho"se o- 9"ality 'as divided into t'o phases na+ely phase 1 and phase ) according to the activities per-or+ed re-er Appendi= D4$ !n the -irst phase, the shaded sections in the -ig"re ) 'ere co+pleted and the partial 78D as created y the a"thors incl"ding the activities that -acilitated in co+pleting these sections is sho'n in Appendi= &$ The list o- these activities are disc"ssed in detail as -ollo'ingF


)@

1$)$)$1 5 C"sto+er Re9"ire+ents &enerated 8or the develop+ent o- any prod"ct, it is essential to -irst de-ine the c"sto+er re9"ire+ents that are converted into design speci-ications y Design a nd Develop+ent tea+$ The tea+ is responsile -or designing the prod"ct in accordance 'ith the c"sto+er re9"ire+ents$ To -"l-ill c"sto+er re9"ire+ents, 9"ality o- the prod"ct sho"ld neither e less nor +ore eca"se less 9"ality res"lts in ad prod"cts and e=cess 9"ality is a 'aste in prod"cts as it adds e=tra cost to the prod"ct$ >ence, the activity o- ac9"iring c"sto+er re9"ire+ents assisted the a"thors in in-erring the characteristics o- the poly+er conveyor elt as desired y the c"sto+er are +entioned elo'F •

The average li-e o- the poly+er conveyor elt sho"ld e et'een eight to ten years, considering the -act that the average li-e o- the stainless steel conveyor elt is seven years$

•

The -inal landed cost o- the conveyor elt sho"ld e less than the cost o- the stainless steel conveyor elt, i$e$ Rs$ @L 1 -t

•

The 'eight o- the elt sho"ld e less than the +etal conveyor elt -or red"cing the +aterial handling prole+s$

•

The poly+er elt sho"ld e ale to 'ithstand the 'eight o- co+pletely -illed )5litre PT ottle and sho"ld e ale to r"n -or eight to ten years 'itho"t reakdo'n$

•

The +aterial o- the poly+er conveyor elt sho"ld not react 'ith the che+icals "sed in the plant "nder prevalent environ+ental conditions$


)

1$)$)$) 5 Conversion o- C"sto+er Re9"ire+ents into Technical %peci-ications 8or +aking any +odi-ications in the e=isting design, it 'as i+portant to per-or+ reverse engineering and st"dy the design para+eters that had to e considered in order to -"l-ill the c"sto+er re9"ire+ents$ These -"nctional para+eters eca+e inp"t -or the design and develop+ent tea+ to create +"ltiple the+e concepts -or the poly+er links$ >ence, the tea+ did reverse engineering othe stainless steel links and the -ollo'ing in-erences 'ere +ade accordinglyF •

2engthF As disc"ssed in the ackgro"nd, a nylon gear is attached to the o"tp"t sha-t o- the gearo=$ Re-er 8ig"re 14$ A oss 'as provided on the otto+ s"r-ace o- every links so as to +esh 'ith the teeth o- the nylon gear$ >ence, the length 'as the distance et'een t'o s"se9"ent osses, 'hich 'as according to the pitch o- the nylon gear$

•

:idth  According to the design proced"re, the 'idth o- the link sho"ld e three to -o"r ti+es the 'idth o- the oss provided at the center on the otto+ s"r-ace$ This proportion is -or the staility o- the conveyor elt to avoid the elt -ro+ co+ing o"t o- the path at the end d"e to its inertia$ The a"thors in the R&B plant o- the co+pany oserved this pheno+enon 'here the 'idth othe link 'as 1 ++$

•

8latness 5 The +ain -"nction o- the conveyor elt is to transport ottles -ro+ one place to another 'hile di--erent operations are carried on it$ There-ore, the s"r-ace has to e -lat to carry the ottles 'itho"t their -alling do'n d"e to the


3

.erks ca"sed d"ring the stopLstart o- the conveyor elt$ 8latness is also essential -or sliding the ottles -ro+ one conveyor elt to another$

•

A=es +ove+ent 5 !t 'as oserved that the path o- the conveyor elt 'as not straight and 'as in the shape o- an ellipse, 'hen vie'ed -ro+ the side$ The top vie' o- the layo"t, as +entioned in Appendi= D, sho's that the path took le-t and right t"rn at di--erent locations$ Th"s, it 'as re9"ired -or the poly+er conveyor elt to +ove in all the three a=es o- +otion as sho'n in the -ig"re elo'F

Direction o- the -lo' o ottles on conveyor elt

I J H

Bend Angle Top View

8ig"re ?F Conveyor Path

Bend Radi"s


•

31

Bend angle  As sho'n in the aove -ig"re, the conveyor elt took le-t and right t"rns at several locations at a certain ang le$ The angle at every t"rn on the path'ay 'as oserved y the a"thors to e  degrees Re-er Appendi= 84

•

Bend radi"s  Bend radi"s is the s+allest t"rn that can e +ade y the conveyor elt at the t"rn$ The t"rning radi"s 'as calc"lated y the a"thors as sho'n elo'F 2L)πR4  θL34 :here, 2  arc length  ?E?0 R  t"rning radi"s N θ 

T"rning angle  ° ⇒ )inchL)πr4

•

 L34

⇒ r

 ) = ?4L) π

⇒ r

= )E0

Degree o- -reedo+ o- +ove+ent o- the link in I and J5a=es  8or the s+ooth +ove+ent o- the conveyor elt at the hori6ontal and vertical end, the distance o- ?$? ++ et'een the rear edge and the -ront edge o- the link in the asse+ly 'as +aintained$ The +a=i+"+ end angle is  degree and hence, the relative ang"lar +ove+ent o- the link had to e deter+ined -or the sa+e angle$

•

Conveyor elt .ointF 8or the asse+ly o- the links, considering the degree o-reedo+ in +ove+ent as disc"ssed in the aove section, the type o- conveyor elt .oint 'as identi-ied$ !t 'as concl"ded that the cylindrical pin insert 'o"ld


3)

-"l-ill the design -"nctionality and the c"sto+er re9"ire+ents as e=plained in the -ig"re sho'n elo'F

Position A Ma=i+"+ degree o-reedo+

2ink

Pin

Position B

8ig"re F Degree o- -reedo+ o- +ove+ent in I5a=is

1$)$)$3 5 Technical Math Data Calc"lations 5 1 !n order to co+pare the +"ltiple the+e concepts, it 'as necessary to carry o"t engineering analysis on all the concepts$ As sho'n in the Conveyor Path layo"t Re-er Appendi= 84, the path o- the conveyor elt 'as divided into  ele+entary sections$ The +a=i+"+ traction -orce 'as calc"lated -or each ele+entary


33

section to esti+ate the drive "nit capacity and the +a=i+"+ tension o- conveyor elt -or the -ollo'ing conditionsF

Conditions -or traction -orce 1$ Traction -orce 'itho"t any ottles on the conveyor elt$ The +ove+ent o- the conveyor elt is in the direction o- the -orce 84 applied on it$ The -orce d"e to the 'eight o- the conveyor elt acts in the do'n'ard direction$ 8or this condition, only the 'eight o- the link 'as considered -or the length 2 and the coe--icient o- -iction et'een the conveyor link and otto+ strip as sho'n in the -ig"re sho'n elo'F

8ig"re F 8orce d"e to conveyor elt only

)$ Traction -orce 'ith ideal 9"antity o- ottles !n this condition, the traction -orce 'as calc"lated con sidering the 'eight o- the elt and the ottle -or a partic"lar length 2$ The direction o-


3?

the traction -orce and the -orce d"e to load o- the conveyor elt carrying ottles is as sho'n in the -ollo'ing -ig"reF

8ig"re *F 8orce 'ith the ottles on the conveyor elt

3$ Traction -orce 'ith acc"+"lated ottles %o+eti+es, the ottles get acc"+"lated in one section o- the conveyor elt and hence the load is increased$ The coe--icient o- -riction et'een the conveyor link and the ottles 'as taken into acco"nt -or calc"lating the -orce 'ith acc"+"lated load as depicted in the -ollo'ing -ig"reF

8ig"re @F 8orce d"e to acc"+"lated load


3

?$ Traction -orce at the inclination !n case o- an inclination, gravitational -orces are also incl"ded -or the calc"lation o- the traction -orce$ This condition 'as not regarded, as there 'as no inclination provided in the conveyor syste+ "sed in the PT plant$ Re-er Appendi= 84$ The -ollo'ing -ig"re e=plains this conditionF

8ig"re F Traction -orce d"e to gravity at the inclinations

8or+"la "sed The -or+"la "sed -or calc"lating the traction -orce is as +entioned elo'F P=O8=v :here, P  Po'er o- the +otor "sed to drive the conveyor elt :4 O  --iciency o- the +otor 8  Traction -orce #4

9"ation 14


3

v  velocity o- the conveyor elt +Ls4

8orce Calc"lations -or the -irst three conditions 8or deter+ining the traction -orce -or each ele+entary section o- the conveyor path, the po'er and the velocity 'ere deter+ined practically y the a"thors$ The distance traveled y the conveyor elt 'as deter+ined and 'ith the help o- stop'atch, ti+e 'as noted do'n -or the respective distance$ This data 'as collected -or all the nine ele+entary sections as sho'n in the tale elo'F

1

Time (s) 2

3

3.3 2.9 5.2 5.1 5.8 3.8 4.8 6.4 5.6

3.3 2.9 5.2 5.2 5.7 3.8 4.7 6.3 5.5

3.2 2.9 5.2 5.2 5.7 3.9 4.7 6.2 5.6

Elementary Section

1 2 3 4 5 6 7 8 9

Distance Avg time (in) (s)

48 46 40 60 38.5 38.5 47 75 39.5

3.27 2.90 5.20 5.17 5.73 3.83 4.73 6.30 5.57

Speed (in/s)

14.69 15.86 7.69 11.61 6.72 10.04 9.93 11.90 7.10

Tale 1F %peed o- conveyor elt at di--erent ele+entary sections %peci-ication o- the lectric +otor The +otor "sed in the plant at all the ele+entary section 'ere o- the sa+e speci-ications as depicted in the -ollo'ing taleF Specifications

Value

nits

Output Power Max rpm Voltage Ampere re!ue"#$ '(()#)e"#$

1.1 1400 415 2.45 50 77

KW rpm V A %& *


3*

Tale )F lectric +otor speci-ications

Traction -orce calc"lation at ele+entary section 1 8ro+ the aove data, the val"es o- velocity and the po'er 'ere "sed in the e9"ation 1, to calc"late the traction -orce$ The calc"lations are sho'n elo'F &iven 8ro+ Tale 1  Tale )4, P  11 : O  $** v  1?$ inLsec  $3* +Ls 8 N There-ore, 8  P = O4Lv  11 = $**4L$3*  ))$?1 #

%i+ilarly, the traction -orce -or the re+aining @ ele+entary sections 'ere calc"lated and ta"lated as sho'n elo'F

1

Time (s) 2

3

3.3 2.9 5.2 5.1 5.8 3.8 4.8 6.4 5.6

3.3 2.9 5.2 5.2 5.7 3.8 4.7 6.3 5.5

3.2 2.9 5.2 5.2 5.7 3.9 4.7 6.2 5.6

!otor "ocation

1 2 3 4 5 6 7 8 9

Avg Distance Distance time (in) (m) (s)

48 46 40 60 38.5 38.5 47 75 39.5

1.2192 1.1684 1.016 1.524 0.9779 0.9779 1.1938 1.905 1.0033

3.27 2.90 5.20 5.17 5.73 3.83 4.73 6.30 5.57

Speed Speed (in/s) (m/s)

Traction force (#)

14.69 15.86 7.69 11.61 6.72 10.04 9.93 11.90 7.10

2+269.41 2+102.28 4+335.04 2+871.50 4+965.88 3+320.21 3+358.30 2+801.10 4+699.46

Tale 3F Traction -orce -or all the ele+entary sections

0.37 0.40 0.20 0.29 0.17 0.26 0.25 0.30 0.18


3@

The conveyor path 'as divided into nine ele+entary sections that 'ere driven y separate electrical +otors allocated -or these sections respectively$ To calc"late the load d"e to the 'eight o- the conveyor elt, the 'eight o- the individ"al link 'as ass"+ed to e )) g+$ The vol"+e othe part -or the calc"lation 'as considered to e sa+e as that o- stainless steel link$ The poly+ers like P;M, PC and PA 'ere reco++ended -or the application and hence the +aterial 'ith the highest density, i$e$ P;M 'as chosen -or calc"lating the -orces$ The a"thors, -or the aove5+entioned -irst three conditions, calc"lated the tensile -orce on the conveyor elt -or the respective section$ The calc"lation -or the -irst ele+entary section is as sho'n elo'F Condition 1 Tension $it%out &ottles '1  '* + l ("c + "&) ,r - . 0%ere '1  total te",)o" -/ '*  eleme"tar$ te",)o" -/ l  le"gt o( te eleme"tar$ #o"e$or -m/ "c  loa ue to #a)" we)gt -m/ "&  loa ue to #ompletel$ ()lle ottle, -m/ ,r  #oe(()#)e"t o( (r)#t)o" etwee" te l)" a" ,tr)p .  e" (a#tor

&ivenF '1  -/ '*  0 -/ l  2.01 -m/ "c  6.84 -m/ "&  0 -m/ ,r  0.1 .  1


There-ore, 81  Q  )$1 $@? 4 = $1S 1  1.37 N

Condition ) 8or+"la "sedF Tension $it%out accumulation ($it% &ottles) '1  '* + l ("c + "&) ,r - . 0%ere '1  total te",)o" -/ '*  eleme"tar$ te",)o" -/ l  le"gt o( te eleme"tar$ #o"e$or -m/ "c  loa ue to #a)" we)gt -m/ "&  loa ue to #ompletel$ ()lle ottle, -m/ ,r  #oe(()#)e"t o( (r)#t)o" etwee" te l)" a" ,tr)p .  e" (a#tor

&ivenF iven '1  -/ '*  0 -/ l  2.01 -m/ "c  6.84 -m/ "&  222 -m/ ,r  0.1 .  1

There-ore, 81  Q  )$1 $@?  )))4 = $1S 1  45.92 N

3


?

Condition 3 Tension $it% accumulation '1  '* + l ("c + "&) ,r + l 4 "a 4 , & - . 0%ere '1  total te",)o" -/ '*  eleme"tar$ te",)o" -/ l  le"gt o( te eleme"tar$ #o"e$or -m/ "c  loa ue to #a)" we)gt -m/ "&  loa ue to #ompletel$ ()lle ottle, -m/ ,r  #oe(()#)e"t o( (r)#t)o" etwee" te l)" a" ,tr)p .  e" (a#tor "a  a##umulate loa -/ ,&  #oe(()#)e"t o( (r)#t)o" etwee" l)" a" ottle,

&ivenF '1  -/ '*  0 -/ l  2.01 -m/ "c  6.84 -m/ "&  222 -m/ ,r  0.1 .  1 "a  318 -/ ,&  0.2

There-ore, 81  Q  )$1$@?  )))4 = $1  )$1 = 31@ = $)S  192.0 N


?1

%i+ilarly, the -orces 'ere calc"lated -or the re+aining eight ele+entary sections -or the -irst three conditions$ These calc"lations 'ere ta"lated and the res"lts are as sho'n in the tale elo'F

Elementary Section

1 2 3 4 5 6 7 8 9

5onveyor "engt% 6end 'actor 'orce 'orce (5ondition1) (m) (.) (5ondition2)

2.01 9.45 5.46 6.15 3.96 3.35 2.39 12.12 6.96

1.0 1.0 1.6 1.0 1.0 1.0 1.6 1.6 1.0

1.37 6.46 5.98 4.20 2.71 2.29 2.61 13.26 4.76

45.92 216.23 199.95 140.66 90.68 76.73 87.42 443.61 159.26

'orce (5ondition3)

7o$er 8e9uired (0)

192.80 907.88 839.54 590.61 380.72 322.15 367.06 1862.62 668.71

93.45 475.04 213.03 226.24 84.33 106.72 120.22 731.45 156.52

Tale ?F 8orces -or all the three conditions -or all the nine sections

.  &end factor at turn for t%e follo$ing degree 3*: ;<: =*: >*:

1.2 1.3 1.4 1.6 httpFLL'''$-le=5linea"to+ation$co+L8ilesL%tandard)Conveyor)%yste+s$pd- 4

Tale F Bend -actor val"es >ence, the opti+"+ po'er re9"ired -or each ele+entary section 'as calc"lated and the res"lts are as sho'n in the aove tale$


?)

1$)$)$? 5 Design, Per-or+ance and Cost Targets Based on the c"sto+er re9"ire+ents, prod"ct design re9"ire+ents and technical +ath data calc"lations disc"ssed aove, targets 'ere set in ter+s o- the design, per-or+ance and cost o- the poly+er conveyor elt$ The targets are listed in the -ollo'ing taleF Sr? #o

1 2 3 4 5 6 7 8 9 10 11 12

7arameters

Moeme"t )"  )re#t)o" Moeme"t )"  )re#t)o" Max)mum :ra#t)o" or#e Max. :emperature V ra$,
Type

Target

e,)g" e,)g" e,)g" Per(orma"#e Per(orma"#e Per(orma"#e Per(orma"#e Per(orma"#e Per(orma"#e ;o,t Per(orma"#e Per(orma"#e

or 90 egree e" a"gle or 90 egree e" a"gle 5000  60 egree ;el#)u, =tro"g Ver$ low =tro"g =tro"g =tro"g ?e,, ta" <,.700010 (t ?e,, ta" 50 gm 'x#elle"t

Tale F Design, per-or+ance and cost targets

1$)$)$ 5 Properties o- Relevant Materials %elected


?3

Properties s"ch as +echanical, ther+al, electrical, environ+ental, che+ical and +iscellaneo"s properties 'ere considered 'hile designing the poly+er conveyor elt link$ The type o- properties considered -or the poly+ers is as sho'n in the tale elo'F

Tale *F 2ist o- poly+er properties

1$)$)$ 5 Material %election


??

;n the asis o- technical +ath data calc"lation, c"sto+er re9"ire+ents and prod"ct design speci-ications, +aterial -or the conveyor elt 'as selected$ The relevant properties 'ere selected -ro+ Tale *$ The data -or the respective property -or each +aterial 'as collected$ The tale 'as divided into si= col"+ns na+elyF PropertyF This col"+n contained a list o- selected properties that 'ere relevant -or the speci-ic application o- the prod"ct$ MaterialF Three +aterials 'ere considered -or the -"nction Val"eF The val"es 'ere -o"nd o"t -or each +aterial -ro+ vario"s so"rces like ooks and !nternet RatingF The rating -ro+ the scale o- 1  1 1  very poor, 1  e=cellent4 'as assigned to the +aterials on the asis o- its per-or+ance -or the speci-ic application o- conveyor elt link$ M"ltiplying 8actorF The +"ltiplying -actor -acilitated the a"thors 'ith the scoring o- the +aterial -or a partic"lar property$ The +"ltiplying -actor 'as allocated val"es o- 1,) and 3 on the asis o- the priority o- the property, 'here 1 +eant least i+portant, ) +eant +oderate and 3 +eant the +ost i+portant$ Total %coreF Total score 'as otained y +"ltiplying the rating val"e 'ith the +"ltiplying -actor -or the respective +aterial$ The addition o- the total score -or all the properties o- a partic"lar +aterial 'as done to otain the -inal score or per-or+ance o- the +aterial$ This val"e -or all the three +aterials 'as co+pared and the +aterial 'ith the highest score 'as selected -or the application$ The +aterial selection tale is sho'n elo'F


5%emical 7roperties A#), @ )lute Alal), Aromat)# $ro#aro", Brea,e, a" O)l, Keto"e,

!aterial PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P;

Values Poor Poora)r Boo Booa)r Poor BooPoor Boo Boo Poor Boo Boo Booa)r Boo Booa)r Poor

8ating 4 6 8 6 4 5 8 8 8 8 9 7 8 7 4

PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P;

3.6 3.7 2.9 25 20 1567 10D13 10D15 10D15 1012  1016 10D14  10D16 10D15 10D17

7 8 5 8 7 9 6 8 8 7 8 8

PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM

5 15 to 20 10 to 15 0.20.3 0.2  0.35 0.31 M82 M94 M70 30250 75  130

3 8 6 8 9 6 7 10 6 7 8

!'@ 2 3 1 3 2

?

Total Score 8 12 16 18 12 15 8 8 8 24 27 21 16 14 8

Electrical 7roperties

)ele#tr)# #o",ta"t C1M%& )ele#tr)# ,tre"gt -V mm 1/ =ur(a#e
1 1 3 3

7 8 5 8 7 9 18 24 24 21 24 24

!ec%anical 7roperties

Ara,)e re,),ta"#e  A=:M 1044 -mg1000 #$#le,/ ;oe(()#)e"t o( (r)#t)o" %ar"e,, 
E&o )mpa#t ,tre"gt -F m1/

Po),,o"G, rat)o :e",)le moulu, - BPa /

3 3 3

3 P;

6085

5

PA6 POM P; PA6 POM

0.39 0.35 0.37 2.63.0 2.9  3.1

6 9 7 7 9

3 3

9 24 18 24 27 18 21 30 18 21 24 15 18 27 21 21 27


:e",)le ,tre"gt - MPa / lexural Moulu, -BPa/ lexural =tre"gt -MPa/ =ear =tre"gt -MPA6/

P; PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P;

2.32.4 78 70 5575 2.3 2.83 2.3 85 95.6 90 59 60.3 63

5 9 8 7 6 9 6 5 8 6 7 8 9

PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P; PA6 POM P;

1130 1420 1200 %H %H V0V2 Poor Poor a)r I8 0.6  0.9 0.35 2.7 0.25 0.1 18.5 14.2 6

5 9 6 7 7 8 5 6 7 3 7 9 2 8 9 4 7 9

PA6 POM P; PA6 POM

95 122 6670 200 170

7 6 8 8 7

3 3 2 3

?

15 27 24 21 18 27 18 10 16 12 21 24 27

7%ysical 7roperties 3

e",)t$ -g #m / lamma)l)t$ ltra)olet Water a,orpt)o"  e!u)l)r)um -*/ Water a,orpt)o"  oer 24 our, -*/ 'lo"gat)o" at )el -*/

3 3 2 3 3 3

15 27 18 21 21 24 10 12 14 9 21 27 6 24 27 12 21 27

T%ermal 7roperties

;oe(()#)e"t o( termal expa",)o" -x106 K1/ %eate(le#t)o" temperature  0.45MPa -;/ %eate(le#t)o" temperature  1.8MPa -;/ =pe#)()# eat -F K 1 g1/ :ermal #o"u#t))t$ C23; -W m1 K1/

2

2 P;

140

5

PA6 POM P; PA6 POM P; PA6 POM

80 135 128138 1700 1500 J1200 0.240.28 0.22  0.24

5 8 7 5 7 8 5 7

2 2 3

14 12 16 16 14 10 10 16 14 10 14 16 15 21


P;

0.190.22

8

?*

24

Tale @F Material %election The -inal scores o- all the three +aterials 'ere adde d and -ollo'ing are the res"ltsF •

PA  ?3

•

PC  )*

•

P;M  @

>ence, the +aterial o- the poly+er conveyor link 'as P;M

MilestoneF )

)$1$1 5 Pro.ect Monitoring and Control

)$1

Pro.ect Monitoring and Control Activity 'as per-or+ed -or all the +ilestones to veri-y or con-ir+ the stat"s o- all the previo"s activities$ >ence, it assisted the pro.ect


?@

+anager to analy6e the deviations o- the act"al pro.ect activities -ro+ the planned activities in ter+s o- ti+e, cost and 9"ality$ !t also helped to assess the pro.ect risks that +ay e enco"ntered in near -"t"re and keep the pro.ect tea+ "pdated on the progress o- the pro.ect$ A checklist 'as prepared to +onitor the progress o- the pro.ect that is sho'n in the Appendi= >$ This checklist is the list o- activities, -"nctional areas, responsile person -or the activities, sched"led co+pletion da tes and the act"al co+pletion dates -or every activity 'ith the stat"s o- the activity$ The stat"s o- the activities 'as denoted y three colorsF red, yello' and green$ The signi-icance o- each color is as e=plained elo'F •

Red  The activities that 'ere "nder risk and had no ack"p plan 'ere +arked y red color$ !t also indicated that the pro.ect 'o"ld e delayed i- these activities 'ere neglected$

•

Iello'  Iello' color signi-ied that the activity is inco+plete "t had a ack"p plan ready to co+pensate the deviation -ro+ the sched"led plan$ This activity 'as o- lo' risk as the ack"p plan 'as availale, "t it co"ld not e neglected$

•

&reen  &reen colored activities denoted that the activities 'ere co+pleted and doc"+ented$

)$1$) 5 Pro.ect charter prepared

)$1

A pro.ect charter 'as created that provided a +ore detailed description than pro.ect concept doc"+ent o- n"+ero"s aspects o- the pro.ect s"ch as strategic plan, roles and responsiilities and the o.ective o- the p ro.ect$ The +a.or p"rpose o- the


?

pro.ect charter 'as to ackno'ledge the eginning o- the pro.ect y the assign+ent oroles and responsiilities to every tea+ +e+er and co++itting reso"rces to the pro.ect$ The co+plete charter is depicted in the Appendi= ! and -ollo'ing are the vital contents o- the pro.ect charterF •

Pro.ect overvie'  This section incl"ded the p"rpose o- the pro.ect and also e=plained the reason -or "ndertaking the pro.ect$

•

Pro.ect o.ectives  Pro.ect o.ectives incl"ded the -actors that assisted in deciding i- the pro.ect 'as s"ccess-"l$

•

B"siness ."sti-ication 5 This section provided in-or+ation ao"t the p"rpose o- the pro.ect and 'hat "siness iss"es or prole+s 'o"ld e solved$

•

Reso"rce and cost esti+ates 5 A high5level esti+ate o- the h"+an and -inancial reso"rces re9"ired -or the pro.ect 'as +entioned in this section$

•

Roles and responsiilities  !n this section, a detailed chart is presented sho'ing the roles and responsiilities assigned to every tea+ +e+er$

•

%ignat"res  This section contained the signat"res o- key stakeholders s"ch as pro.ect +anager, pro.ect sponsor and the c"sto+er$ The +ain p"rpose o- the sign5 o-- 'as to ass"re that the key stakeholders "nderstood p"rpose and the o.ective o- the pro.ect$

)$1$3 5 Change Re9"est Plan

)$1

The changes +ade to the scope, "dget and sched"le d"ring the co"rse o- the pro.ect 'ere re9"ested to the revie' co++ittee in the -or+at o- Change Re9"est$




Plan$ Re-er Appendi= (4 Doc"+enting the changes assisted the pro.ect tea+ in "nderstanding the ca"ses, d"e to 'hich change occ"rred and 'hen the change 'as sched"led$ There 'ere pri+arily three 9"estions that 'ere e=a+ined -or each o- the changesF 14 :hy is the change neededN )4 :hat 'ill e the i+pact on the pro.ect or prod"ct o- the pro.ect i- the change is not i+ple+entedN 34 Are there alternatives to the changeN The ans'ers to these 9"estions 'ere doc"+ented in the Change Re9"est 8or+ every ti+e a change 'as re9"ired$ 8ollo'ing ele+ents 'ere incl"ded in the change re9"est -or+F %ection ;neF Co+pleted y the re9"estor •

Description o- Change Re9"est  The detailed description o- the change re9"ired in the scope o- the pro.ect$

•

B"siness ("sti-ication -or Change  A thoro"gh description o- ho' the change 'o"ld ene-it the organi6ation 'as +entioned in this section

•

!+pacts o- #ot Making the Change  The conse9"ences that the pro.ect +ight -ace i- the change is not +ade 'ere speci-ied "nder this section$

%ection T'oF Co+pleted y the Pro.ect Manager •

!+pacts o- the Change  !n this section, the i+pacts that the change 'o"ld have on the pro.ect sched"le, "dget and 9"ality o- the prod"ct 'ere descried in detail$

•

Reco++endation to the Change Control Board  This section incl"ded the opinion o- pro.ect +anager to approve or deny the change along 'ith the ."sti-ication$


1

%ection ThreeF Co+pleted y the Change Control Board •

Reco++endations and date o- revie'  !n this section, a disc"ssion concerning the i+pact o- the change on the goals o- the pro.ect and 'hether the change sho"ld e considered a ne' pro.ect or an e=tension o- the e=isting pro.ect 'ere +entioned along 'ith the date o- the revie'$

•

%ignat"re 5 This section contained the signat"res o- key stakeholders s"ch as pro.ect +anager, pro.ect sponsor and the c"sto+er$ c"sto+er$

)$1$?  Pro.ect %cope %tate+ent &enerated

)$ 1

The pro.ect scope state+ent -or+ed y the pro.ect +anage+ent tea+ contained a co+prehensive list o- the goals and o.ectives o- the pro.ect and other planning


)

esti+ates s"ch as ti+e and cost esti+ates$ The p"rpose o- the scope state+ent 'as to -or+ a strong ase -or all the decisions o- the pro.ect$ This 'as done y listing goals and o.ectives, deliverales, re9"ire+ents, ass"+ptions and constraints$ A revised revised pro.ect scope state+ent 'as +ade incorporating the change$ The revised pro.ect scope state+ent as +ade y the tea+ is +entioned in the Appendi= ;. 8ollo'ing are the ele+ents that 'ere incl"ded in the pro.ect scope state+entF •

Pro.ect ;vervie'F !n these section, the -inal prod"ct 'as descried and the reasons that inspired the a"thors to "ndertake the p ro.ect along 'ith the p"rpose o- the pro.ect$

•

Pro.ect &oals and ;.ectivesF This section incl"ded the goals and o.ectives that 'ere descried "sing %MART and -or+"la$ These goals and o.ectives 'ere "sed to +eas"re the s"ccess o- the pro.ect "pon its co+pletion

•

Co+prehensive list o- pro.ect deliveralesF These incl"ded the activities that +"st e co+pleted in order to satis-y the goals o- the pro.ect$ The activities activities had +eas"rale o"tco+es and critical s"ccess -actors 'ere also +entioned$

•

Co+prehensive list o- pro.ect re9"ire+entsF The list o- pro.ect re9"ire+ents incl"ded the individ"al tasks that had to e acco+plished in order to consider c onsider the deliverale co+plete$

•

=cl"sions -ro+ scopeF Certain deliverales or re9"ire+ents 'ere not part o- the pro.ect and these activities 'ere listed in this section$ section$

•

Ti+e sti+ateF The planning esti+ates o- the pro.ect p ro.ect s"ch as ti+e esti+ates 'ere +entioned in this section and 'ere "pdated "p dated 'ith the addition or deletion o- any an y activity$


•

3

Roles and responsiilitiesF The contents o- this ele+ent incl"ded the roles and responsiilities o- individ"al pro.ect tea+ +e+ers

•

Ass"+ptionsF A co+prehensive list o- all the ass"+ptions +ade d"ring the pro.ect 'as listed in this section$

•

ConstraintsF All All the constraints -aced y the pro.ect p ro.ect tea+ d"ring the co"rse o- the pro.ect 'ere listed "nder this section$

•

%ignat"resF This section contained the signat"res o- key stakeholders s"ch as pro.ect +anager, pro.ect sponsor and the c"sto+er$ c"sto+er$

)$1$ 5 Pro.ect Planning

)$1


?

The pro.ect planning consisted o- several pro.ect +anage+ent tools s"ch as sched"le, critical path +ethod, change re9"est plan, and co++"nication plan, 'hich are e=plained in detail as elo'F )$1$$1 5 %ched"le )$1$$1$1 5 &antt Chart The pro.ect s"+ission date 'as given to the a"thors and according to it a pro.ect sched"le 'as prepared "sing Microso-t Pro.ect in the -or+ o- &antt chart$ The sched"le -acilitated the 'riter to acco+plish the pro.ect activities as planned$ This helped the tea+ +e+ers to +onitor the progress o- the pro.ect e--ectively$ The &antt chart -or the pro.ect sho'ing the sched"le -or every activity is sho'n in the Appendi= 2. )$1$$1$) 5 Critical Path Method The Critical Path Method CPM4 'as "sed to calc"late the d"ration o- the pro.ect in the -ollo'ing +annerF •

The tasks 'ere -irst listed in the M% Pro.ect 'orksheet, in accordance 'ith the tasks +entioned in the :B%$

•

%o+e activities 'ere independent, 'hile the other activities 'ere dependant, 'hich +eant that the eginning o- certain tasks dependant "pon the co+pletion o- the task previo"s to it$ This dependency -or each task 'as assigned in the 'orksheet$

•

The early start date and early -inish date -or each task 'ere calc"lated$

•

The late start and late -inish date -or each task 'ere also calc"lated$


•



The -loat -or each task 'as calc"lated y s"tracting the early start date -ro+ the late start date$

•

The critical path or net'ork diagra+ -or the pro.ect 'as deter+ined y adding the d"ration o- every activity 'ith 6ero -loat$ The critical path +ethod helped the tea+ +e+ers to deter+ine the critical

activities and acco+plish the pro.ect activities according to the sched"le$ The net'ork diagra+ depicting the critical path is sho'n in the Appendi= M$

)$1$$) 5 Co++"nication Plan The co++"nication plan 'as prepared y the pro.ect +anage+ent tea+ to descrie in detail 'ho got 'hat in-or+ation and 'hen$ !t also doc"+ented ho' to collect, -ile, and archive pro.ect co++"nications and the distri"tion +ethods "sed to in-or+ the stakeholders$ The detailed co++"nication plan -or the pro.ect can e re-erred -ro+ the Appendi= #$


)$1$ 5 :ork Breakdo'n %tr"ct"re Availale



)$1

A :ork Breakdo'n %tr"ct"re :B%4 organi6es the 'ork o- the pro.ect into logical gro"pings si+ilar to a +ilestone chart "t displays the in-or+ation in a tree -or+ or an o"tline -or+$ The pro.ect +anage+ent tea+ created the :B% to divide the pro.ect into +a.or +ilestones$ These +ilestones 'ere -"rther divided into deliverales and each deliverale contained certain activities that had to e acco+plished -or the deliverale to e co+plete$ As the pro.ect had +"ltiple levels 'ith a n"+er o- tasks, the 'ork reakdo'n str"ct"re 'as presented in the o"tline vie'$ A detailed :B% is ill"strated in Appendi= K$


)$)$1 5 Bench+arking %t"dy Co+pleted

*

)$)

The stainless steel and the poly+er conveyor elt links 'ere ench+arked in order to identi-y certain -eat"res that assisted the tea+ to design prod"cts to +eet c"sto+er re9"ire+ents$ !t 'as ti+e and cost e--icient eca"se the process involved adoption rather than p"re i+itation or invention$ Th"s, a 'orking +odel o- an i+proved prod"ct 'as -or+ed in 'hich the planning, testing and prototyping e--orts 'ere red"ced$ The ench+arking o- the stainless steel link 'as per-or+ed y the design tea+ and the -ollo'ing steps 'ere -ollo'edF 14 The ench+ark 'as decidedF The ench+ark design -or the conveyor link 'as decided to e the stainless steel and the poly+er link that 'as in "se at A+ritsar plant$ )4 C"rrent per-or+ance 'as "nderstoodF The -"nctional and operational -eat"res othe ench+arked links 'ere st"died y the a"thors$ 34 The tea+ learned -ro+ the data ac9"iredF The 'riters identi-ied the critical -eat"res o- the respective ench+arked prod"cts i$e$ Prod"ct A  stainless steel link and Prod"ct B  poly+er link$

8ig"re 1F Bench+arking 8eat"res


?4 The -indings 'ere "sed to develop a etter prod"ctF A-ter st"dying the critical -eat"res, the 'riters "sed the res"lt to develop the n e' i+proved design y adapting the -eat"res o- oth the designs along 'ith their ."sti-ications$ The res"lt tale -or the ench+arking process is as sho'n elo'F

Tale F Bench+arking Res"lts

@


)$)$)  7"ality 8"nction Deploy+ent Phase  )



)$)

This activity is the contin"ation o- phase  1 'here co+plete ho"se o- 9"ality 'as developed$ The re+aining sections 'ere co+pleted y the design and develop+ent tea+ and the co+pleted 78D is sho'n in 8ig"re ) Pg  1@4$

)$)$3  Design Calc"lations

)$)

8or creating +"ltiple the+e concepts, the proportions -or the concepts 'ere deter+ined -ro+ the ench+arking st"dy and -orce calc"lations$ The cylindrical pin "sed -or the asse+ly o- t'o conveyor links 'as designed and the thickness o- the poly+er link 'as calc"lated$ )$)$3$1 5 Pin Design The pin "sed -or the asse+ly o- t'o links, 'as designed y the a"thors y calc"lating the pin dia+eter$ The -or+"la "sed -or deter+ining the pin dia+eter is as +entioned elo'F 1  Taum + t 4 Tau a # Ssu SBsn

0%ere #  e,)g" (a#tor Taum mea" ,ear ,tre,, -m 2/ Taua  alter"at)"g ,ear ,tre,, -m 2/ t  ,tre,, #o"#e"trat)o" (a#tor Ssu  ult)mate te",)le ,tre"gt u"er ,ear SBsn  e"ura"#e ,tre"gt )" ,ear u"er a#tual

#o")t)o"




Ssu  *?C< (TS) 0%ere Ssu  ult)mate te",)le ,tre"gt u"er ,ear -m 2/ TS  ult)mate te",)le ,tre"gt -m 2/

SBsn  *?
#o")t)o" -m2/ SBn  e"ura"#e ,tre"gt u"er a#tual #o")t)o", -m2/

SBn  Sn 4 5m 4 5st 4 5r 4 5s 0%ere

=G"  e"ura"#e ,tre"gt u"er a#tual #o")t)o" -m2/ ="  e"ura"#e ,tre"gt -m 2/ ;m  mater)al (a#tor ;,t  t$pe o( ,tre,, (a#tor ;r  rel)a)l)t$ (a#tor ;,  ,)&e (a#tor

'mean

 'ma4 + 'min 2

'alternating

 'ma4  'min 2

The +a=i+"+ -orce and the +ini+"+ -orce acting on the conveyor elt link 'as taken -ro+ Tale ?, in the -ollo'ing +annerF

&ivenF F!a"  ?1@$* l F!in  $31 l

Calc"lationsF


'mean 'alternating Ssu Sn SnB SBsn A d2

1

209.53 209.22 56250 45000 33750 19473.75 0.028938 0.036863

The +aterial selected -or the pin 'as A"stenitic %teel )1 %)1 1L? hard as the strength o- the +aterial is s"itale -or resisting the -orces acting on the pin$ !aterial ield strengt% Tensile strengt% 5r (8elia&ility 'actor) 5m (!aterial 'actor) 5st (Type of Stress 'actor) 5s (SiFe 'actor) # (Design 'actor) t (Stress 5oncentration 'actor)

 Au,te")t)# =teel 201 =20100 14 ar 75000P,) 125000P,) 0.75-or 0.999 rel)a)l)t$/ 1-or wrougt )ro"/ 1-or e")"g =tre,,/ 1-or 0.3 )"#/ 4-or M)l =o#,/ 1-or >")(orm )ameter/

1  Taum + t 4 Taua # Ssu SBsn

A  G + - 1H $%ere AAreaH GTau mH t 4 Tau a # 2 S su SBsn

A  *?*1 + *?*2- ; 2

I d2  *?*2J>3C=2C ;

d2  *?*3=J=3


)

d  *?1> inc%  ;?J2= mm

d 
Th"s, the dia+eter o- the pin 'as kept $ ++ -or increasing the -actor o- sa-ety$

)$)$3$) 5 2ink ThicknessF The thickness o- the part 'as calc"lated y "sing the -or+"la as sho'n elo'F

Stress  'orce / Area

:here, 8orce  8+a= -ro+ Tale 4 %tress  Iield strength o- P;M  *? psi Area  length = thickness, length  1) ++  $?@ + There-ore, Area  8orceL%tress 2ength = thickness  8+a=LIield strength o- P;M 2ength = thickness  ?1@$*L*?  $ There-ore, thickness  $L?@  $11 in  2. !! Th"s, the thickness o- the part 'as kept 3 !! )$)$? 5 M"ltiple The+e Concepts Based on 8"nctional Re9"ire+ents

)$)


3

>and sketches give direction to the design and create a path on 'hich a design can e developed$ They save a lot o- ti+e spent on the co+p"ter thinking o- a ne' concept$ The initial concepts o- the link 'ere hand sketched y the design and develop+ent tea+ ased on the c"sto+er re9"ire+ents and the design para+eters$ The sketches o- +"ltiple the+e concepts are as sho'n elo'F



8ig"re 1)F The+e Concept )

?



8ig"re 1?F The+e Concept ?

)$)$ 5 CAD Modeling

)$)






Co+p"ter Aided Design CAD4 +odeling is the design o- the prod"ct 'ith the help o- CAD so-t'are on co+p"ter$ The CAD +odeling o- the conveyor elt link allo'ed the design and develop+ent tea+ in vie'ing the t'o5di+ensional and three5 di+ensional dra'ings at the sa+e ti+e on the co+p"ter screen$ !t assisted the tea+ in co++"nicating the di+ensions, color and critical -eat"res o- the design concepts e--ectively 'ith the pro.ect tea+$ The so-t'are "sed y the a"thors 'as to develop CAD +odels 'as Pro ngineer :ild-ire 3 and -ollo'ing are the i+ages o- the CAD ModelsF )$)$$1 5 Concept 1F !n this concept, the +ove+ent in I and H  a=es 'as restricted and hence co"ld not -"nction as per the c"sto+er re9"ire+ent$

8ig"re 1F Concept 1

)$)$$) 5 Concept )F !n this concept, the +ove+ent in H5a=is 'as restricted and stress concentration on the .oint +ight lead to its -ail"re


8ig"re 1F Concept )

8ig"re 1*F Concept ) Asse+ly

)$)$$3 5 Concept 3F The pin dia+eter 'as very less and eca"se o- that the pin +ay r"pt"re in shear and res"lt in reakdo'n$ !- the pin dia+eter 'as increased

*


then the thickness i$e$ *  @++, o- the part 'o"ld increase si+"ltaneo"sly creating di--ic"lty in +an"-act"ring$

8ig"re 1@F Concept 3

8ig"re 1F Concept 3 Asse+ly

)$)$$? 5 Concept ?F This concept 'as created considering the res"lts o- the ench+arking activity$ Re-er Tale 4 This concept 'as designed as per the

@




design calc"lation activity y deter+ining pin dia+eter and the part thickness$ These calc"lations 'ere "sed so that the co+ponent 'as ale to 'ithstand the -orces as +entioned in technical +ath data calc"lation 1 -or -"l-illing c"sto+er re9"ire+ents$

8ig"re )F Concept ?

8ig"re )1F Concept ? Asse+ly a4


8ig"re ))F Concept ? Asse+ly 4

8ig"re )3F Pin -or concept ?

)$)$  D58MA -or %elected Concept

)$)

*


*1

The Design 8ail"re Mode and --ect Analysis D58MA4 'as per-or+ed -or the selected concept$ The D8MA done -or the pro.ect is +entioned in Appendi= P$ To cond"ct D58MA o- the selected concepts, the steps listed elo' 'ere -ollo'edF •

8MA #"+er  The 8MA doc"+ent n"+er, 'hich 'as "sed -or tracking 'as entered$

•

%yste+, %"syste+, or Co+ponent #a+e and #"+er  This sections indicated the appropriated level o- analysis and the tea+ +e+ers decided on 'hat constit"ted a syste+, s"syste+ or co+ponent -or certain speci-ic activities$

•

Design Responsiility  The na+e o- the depart+ent responsile -or the activity 'as incl"ded in this section$

•

Prepared By  The na+e, telephone n"+er, and the depart+ent o- the engineer responsile -or preparing the 8MA 'as +entioned$

•

8MA Date  The date on 'hich the original 8MA 'as co+piled and the latest revision date 'as entered$

•

Core Tea+  This col"+n incl"ded the na+es o- the responsile individ"als and depart+ents that had the a"thority to identi-y and per-or+ tasks on the design$

•

!te+L8"nction  The na+e and other pertinent in-or+ation o- the ite+ eing analy6ed 'as listed here$ Also the -"nction o- the prod"ct eing analy6ed to +eet the design intent 'as incl"ded$


•

*)

Potential 8ail"re Mode  ach potential -ail"re +ode associated 'ith the partic"lar prod"ct and its -"nction 'as listed and the ass"+ption 'as +ade that the -ail"re co"ld occ"r "t +ight not necessarily occ"r$ A revie' o- past things that had gone 'rong, concerns, reports and gro"p rainstor+ing 'as done$ Potential -ail"re +odes that co"ld occ"r only "nder certain operating conditions and "nder certain "sage conditions s"ch as only d"ring the prod"ction o- )5liter ottles or  +l ottles 'ere considered$ Also potential -ail"re +odes 'ere descried in physical or technical ter+s, not as a sy+pto+ necessarily noticeale y the c"sto+er$

•

Potential --ects o- 8ail"re $ The potential e--ects o- the -ail"re 'ere descried and the possiility o- the -ail"re +odes i+pacting the sa-ety or non5co+pliance to reg"lations$ The intent o- the section 'as to -orecast the -ail"re e--ects, to the tea+Es level o- kno'ledge$

•

%everity  %everity 'as a related ranking 'ithin the scope o- the individ"al 8MA$

•

Classi-ication  This col"+n 'as "sed to classi-y any special prod"ct characteristics -or co+ponents, s"syste+s, or syste+ that +ight re9"ire additional design or process controls$

•

Potential Ca"sesL Mechanis+ o- 8ail"re very potential ca"se and -ail"re +echanis+ -or each -ail"re +ode 'as listed co+pletely so that re+edial e--orts co"ld e ai+ed at pertinent ca"ses$

•

;cc"rrence # The occ"rrence ranking n"+er 'as a relative rating 'ithin the scope o- the 8MA and did not re-lect the act"al likelihood o- occ"rrence$ The


*3

tea+ agreed on eval"ation criteria and ranking syste+, that 'as consistent, even i- +odi-ied -or individ"al prod"ct analysis$ •

C"rrent Design Controls  The prevention, design validationLveri-ication DV4, or other activities that had een co+pleted or co++itted to ens"red the design ade9"acy -or the -ail"re +ode and ca"seL+echanis+ "nder consideration$ The t'o types o- design controls that 'ere considered are as -ollo'sF a$ Prevention  The ca"seL+echanis+ o- -ail"re o- the -ail"re +ode 'ere prevented -ro+ occ"rring, or the rate o- occ"rrence 'as red"ced$ $ Detection  The ca"seL+echanis+ o- -ail"re o- the -ail"re +ode, either y analytical or physical +ethods, e-ore the dra'ings got released -or prod"ction$

•

Detection  A-ter +aking the detection ranking, the tea+ revie'ed the occ"rrence ranking and ens"red that the occ"rrence ranking 'as still appropriate$ This val"e 'as "sed to rank order the concerns in the design that 'ere 'ithin the scope$ !n order to achieve a lo'er ranking, the planned design control validation and veri-ication activities 'ere i+proved$

•

Risk Priority #"+er RP#4  The risk priority n"+er -or each design 'as calc"lated y the design and develop+ent tea+ y "sing the -ollo'ing -or+"laF RP#  severity ranking4 H ;cc"rrence ranking4 H Detection ranking4

•

Reco++ended Actions  ngineering assess+ent -or preventiveLcorrective actions 'ere -irst directed at high severity activities designated y the tea+$ The intent on reco++ended action 'as to red"ce ranking is the -ollo'ing orderF severity, occ"rrence and detection$ The pri+ary o.ective o- reco++ended actions 'as to red"ce risks and increase c"sto+er satis-action y i+proving the


*?

design$ :hen engineering assess+ent lead to entering U#oneE in this col"+n indicated that no reco++ended actions -or a speci-ic -ail"re +odeLca"seLcontrol co+ination$ •

Responsiility -or the reco++ended actions  The na+e o- the individ"al responsile -or each reco++ended actions and the target co+pletion date 'as +entioned in this section$

•

Actions Taken  A-ter the actions had een i+ple+ented, a rie- description othe act"al action and e--ective date 'as entered$

•

Action Res"lts 5 A-ter the preventiveLcorrective action had een identi-ied, the res"lting severity, occ"rrence, and detection rankings 'ere esti+ated and recorded$ The res"lting RP# 'as esti+ated and recorded and i- no action 'ere taken, the related ranking col"+ns 'ere le-t lank$


)$)$* 5 CA Analysis

*

)$)

Co+p"ter Aided ngineering CA4 assisted the design and develop+ent tea+ to achieve the e=act val"e o- vario"s stresses e=perienced y the conveyor elt links, nylon gear and the earings$ The tea+ constr"ed the stresses and -orces acting on the link, nylon gear and the earings 'ith the help o- Pro ngineering Mechanica so-t'are$ The CA analysis 'as done -or all the +"ltiple the+e co ncepts in order to eval"ate the tensile stress acting on the conv eyor elt link, shear stress e=perienced y the pin, the ad."stale allo'ale stress on the teeth o- nylon gear and the radial stress on the earings$ The l"e color on the co+ponent depicts that it 'as ale to s"stain the +a=i+"+ -orces that 'o"ld e acting "nder act"al conditions$ The part 'as tested y applying earing stress o- 5 " 10$ N%!2 on the osses on oth the sides$ Also the theoretical val"e otained -ro+ the +an"al calc"lations +atched the res"lts o- the analysis$ %everal iterations 'ere per-or+ed y selecting di--erent constraints and the res"lts sho'ed that the part 'as sa-e according to the +an"al calc"lations and properties othe +aterial$ A-ter trying several analytical, the a"thors arrived at this concl"sion that the co+ponent -"l-illed the re9"ire+ent o- s"staining the +a=i+"+ traction -orce$ The res"lt is as sho'n in the i+age on the ne=t pageF


8ig"re )?F %napshot o- Analysis on P;M

*


)$)$@  %a-ety

**

)$)

%a-ety 'as incorporated in the design not only to red"ce the risk "t also the "ncertainty$ !t 'as a +a.or concern and the +ost i+portant o.ective in the design o poly+er conveyor elt$ The a"thors cond"cted a st"dy to create an inherently sa-e design that +ini+i6ed the intrinsic dangers in the process incl"ding the potential ha6ards$ The sa-e design 'as achieved y integrating the -ollo'ing aspects o- the prod"ctF •

Ro"nd dgesF The edges o- the conveyor link 'ere ro"nded to avoid c"ts on the hands o- the 'orkers$ The sharp edges +ight also da+age the parts that are in contact o- the conveyor link as the elt is +oving contin"o"sly$

•

lectrical Cond"ctivityF There is a prod"ction o- static electricity 'hen the plastic is r"ed against another +aterial$ There is al'ays 'ater spilled on the links eca"se o- the condensation -ro+ PT ottles$ >ence, there is al'ays a chance o- the 'orker getting an electrical shock that +ight ca"se severe in."ries$ Th"s, the +aterial 'ith the least electrical cond"ctivity 'as selected$

•

8la++ailityF There 'as al'ays a proaility o- a -ire and hence sa-ety +eas"re that 'as inherent to the design 'as selecting the +aterial that 'as sel-5 e=ting"ishing$ Th"s, the +aterial -or the conveyor elt link 'as selected as P;M, 'hich has the property o- a"to5e=ting"ishing$


)$)$  Maintainaility

*@

)$)

Maintainaility st"dy 'as cond"cted -or all the +"ltiple the+e concepts in order to validate the di--ic"lties -aced d"ring the +aintenance an d reg"lar service$ !t 'as i+portant to select a design that co"ld e repaired, replaced, l"ricated and +aintained y the 'orker at the ottling plant$ >ence, +aintainaility trials 'ere virt"ally st"died on the concept that 'as selected -or CA analysis$ The concept 'as -o"nd to e sa-e and si+ple -or servicing and +aintaining the sa+e$ The res"lts o- the +aintainaility st"dy -or the selected concept are listed elo'F •

8ront &rooveF A -ront groove 'as provided on the otto+ s"r-ace o- the link as disc"ssed in the Tale $ The p"rpose o- providing the groove 'as also to disasse+ly o- the conveyor elt -or reg"lar service and +aintenance$

•

2ight :eightF The 'eight o- the prod"ct 'as red"ced signi-icantly to 1 g+ as co+pared to stainless steel link i$e$ @) g +$ The red"ction in 'eight 'o"ld also red"ce the +aterial handling cost and da+ages s"stantially$


)$)$1 # Concerned Resol"tions

*

)$)

!n case o- any concern, 'ith respect to any o- the para+eters s"ch as -"nctional i+age, c"sto+er re9"ire+ents, -orce calc"lation and sa-ety and +aintainaility st"dy< it 'as necessary -or the a"thors to resolve the concerns at this stage -or otaining the approval o- design -ro+ the stakeholders$ The design and the -"nctional i+age satis-ied the c"sto+er re9"ire+ents and also the +aterial 'as ale to s"stain the -orces applied$ The res"lts o- the CA analysis and +an"al calc"lations ill"strated that the poly+er conveyor link 'as ale to s"stain the +entioned -orces$ The sa-ety and +aintainaility st"dy also e=hiited 6ero concern regarding the prod"ct design -ro+ the perspective o- serviceaility and +aintainaility$


)$)$11  Prod"ct Design 8ree6e

@

)$)

A cross5-"nctional tea+ consisting o- +e+ers -ro+ the design and develop+ent, pro.ect +anage+ent and +an"-act"ring depart+ents revie'ed the concepts 'hose asse+ly dra'ings 'ere released$ The tea+ analy6ed thoro"ghly every design and technical aspects s"ch as c"sto+er re9"ire+ents, properties o- the +aterial, serviceaility, accessiility and +aintainaility and +an"-act"ring -easiility -or each concept and arrived at a concl"sion$ A+ong all the concepts, the design o- concept ? 'as -inali6ed$ The Min"tes o- Meeting MoM4 o- the +eeting is as +entioned in the Appendi= 7$


)$)$1) 5 Dra'ing Release

@1

)$)

This activity +arked the releasing o- the dra'ings o- the +"ltiple the+e concepts y the design and develop+ent tea+$ The detailed dra'ings o- the approved concept 'ere prepared y the tea+ and 'ere distri"ted to the pro.ect +anage+ent tea+ and the +an"-act"ring tea+$ The asse+ly dra'ings and the dra'ings o- individ"al co+ponents 'ere stored -or -"t"re re-erence and are +entioned in Appendi= R and %$ The details o- the released asse+ly dra'ings and the dra'ings o- each co+ponent are as sho'n in the tale elo'F

E#K#EE8K# D8A0K# 8E"EASE 8E5L8D 5omponent 5onveyor "in. Assem&ly 7art #um&er 7art #ame

:;<18686 :;<18654

Ver,)o" @ 1 !aterial

P)" Pol$mer ?)" ;o"#ept 4 201 =20100 14 ar Pol$mer ;o"#ept 4 POM %omopol$mer

Tale 1F ngineering Dra'ing Release

Dra$ing #o

8686 8654


)$)$13 5 Mold Design %trategy

@)

)$)

Plastics are +an"-act"red y the process o- shaping -le=ile ra' +aterial 'ithin the cavity o- the +etal -or+, i$e$ +old$ Mold design and develop+ent is very critical activity in the develop+ent o- plastic prod"ct as the 9"ality o- the prod"ct is directly dependent on the 9"ality o- the +old$ Mold design 'as e=cl"ded -ro+ the scope "t the a"thors had designed +old to check the -easiility o- the co+ponent$ A strategy -or the design o- the +old 'as -or+ed y the pro.ect tea+ that involved identi-ying a cons"ltant -or the assistance in de-ining critical para+eters o- the +old design$ :hile designing the +old, so+e o- the para+eters 'ere not considered s"ch as geo+etric tolerances, shrinkage and +any other +old characteristics that are act"ally considered 'hile designing a +old$ The ai+ o- the a"thors 'as to highlight the +old appearance$


)$)$1? 5 Cons"ltant !denti-ied -or +old design

@3

)$)

The pro.ect tea+ re9"ired a cons"ltant -or the design and develop+ent tea+ that had e=cellent kno'ledge in the -ield o- +old design and e=e+plary e=perience in developing the +old$ The cons"ltant identi-ied y the +an"-act"ring depart+ent 'as Central !nstit"te o- Plastics ngineering and Technology C!PT4$ The tea+ e+ployed the e=pertise o- the personnel at the instit"te in the -ield o- design and develop+ent o- +old$


)$3$1  Man"-act"ring Process %elected

@?

)$3

The +ethods applied to +an"-act"re a prod"ct +"st e care-"lly analy6ed -or a ne' prod"ct or developed prod"ct$ The pro.ect tea+ care-"lly considered the +ost acc"rate and +ost econo+ical +ethod to +an"-act"re the poly+er conveyor elt link$ !n.ection +olding is the +ost 'idely "sed +ethod o - +an"-act"ring -or plastic prod"cts and an assorted variety o- plastic prod"cts$ 8ro+ the di+ensions and pro-ile o- the -inal prod"ct, its -"nction and the +aterial it 'as in-erred that the poly+er link sho"ld e +an"-act"red y !n.ection Molding Process$ The selection 'as in accordance to the cons"ltantEs advice$


)$3$) 5 !denti-ication o- -acilities re9"ired to +an"-act"re the prod"ct

@

)$3

!t 'as i+portant to identi-y the re9"ire+ents -or +an"-act"ring the conveyor elt links in5 ho"se$ The essential -acilities re9"ired -or +an"-act"ring the prod"ct "nder controlled para+eters are as listed elo'F •

8loor %paceF The -loor space re9"ired -or installing the in.ection5+olding +achine had to e identi-ied$ The -loor space also incl"ded the space -or storing the ra' +aterials and the -inished prod"cts$

•

;peratorF An operator had to e hired -or operating the in.ection5+olding +achine and another operator to asse+le the links together to -or+ the conveyor elt$

•

!n.ection Molding MachineF The in.ection5+olding +achine had to e p"rchased o- the re9"ired tonnage capacity -or a single cavity t'o5plate +old$

•

Tools and AccessoriesF The tools and accessories re9"ired to +an"-act"re the +old in5 ho"se 'ere ga"ges -or checking the di+ensions o- the -inished prod"ct s"ch as pl"g ga"ge -or checking inside dia+eter and snap ga"ge -or thickness$ The other accessories re9"ired 'ere the ins -or storing the ra' +aterial and the -inished prod"ct$


)$3$3 5 Preli+inary process planning sheets ready

@

)$3

A-ter the -inali6ation o- the +old para+eters, the process plan 'as created -or the +an"-act"ring o- the conveyor elt link$ 8ollo'ing inp"ts 'ere provided y the +old design tea+ in alliance 'ith the cons"ltant -or deciding the para+eters o- in.ection +olding +achineF )$3$3$1 5 Material processing properties availaleF The processing para+eters -or every plastic are di--erent and 'hile +an"-act"ring, these para+eters have to e considered$ The +aterial processing para+eters considered -or P;M >o+opoly+er 'ere as +entioned elo'F

Processing Properties o- P;M >o+opoly+er &roce''in( ) 5 3) 5 Average  )C< Te!perature )1 C ?1 8 &rade Co"nt  ) 1@ 8 &rade Co"nt  )1 )old Te!perature * C *r+in( @ C 1@ 8 &rade Co"nt  )1 Te!perature -ttpLwww.matwe.#om,ear#=pe#)()#Mater)al.a,pa,,"umO1280/

Tale 11F Processing properties o- P;M >o+opoly+er


@*

)$3$3$) 5 Process Control selectedF The in.ection5+olding +achine has 1 +onitoring points that control the prod"ct 9"ality and the +olding cycle$ All the controls are controlled y the controllers o- the +olding +achine$ The Acceptale Tolerance -or 7"ality Class Classi-ication AT7CC4 -or the in.ection5+olding +achine 'as deter+ined y the +an"-act"ring tea+, 'hich assisted the pro.ect tea+ in deciding the +olding cycle variales, +elt and hydra"lic -l"id te+perat"re, in.ection -ill rate, -ill and pack press"re and cycle ti+ers co"ld e controlled$ The analysis deter+ined the point 'hen control and process li+its sho"ld e tightened and 'hen co+ponents in the syste+ +"st e replaced or repaired$ The co+parison tale o- the +olding syste+ to the AT7CC standard +olding val"es is sho'n in Appendi= T$


@@

MilestoneF 3

3$1$1 5 Pro.ect Monitoring and control

3$1

This activity is si+ilar to the activity1 o- +ilestone ) 'ith the sa+e na+e and the stat"s report till +ilestone is +entioned in Appendi= G$

3$1$)F 7"ality Manage+ent Plan in accordance to de-ined 9"ality

3$1

To ens"re the 9"ality o- the prod"ct as desired y the c"sto+er, 9"ality para+eters 'ere de-ined and doc"+ented in the 7"ality Manage+ent Plan$ The 7"ality Manage+ent Plan -or the pro.ect as prepared y the pro.ect +anage+ent tea+ is as sho'n in the Appendi= V$ 8ollo'ing are the contents o- the 7"ality Manage+ent PlanF •

Pro.ect ;vervie'  !n the section, the -inal prod"ct 'as descried and the reasons that inspired the a"thors to "ndertake the pro.ect along 'ith the p"rpose o- the pro.ect$

•

7"ality Ass"rance Proced"resF The list o- all the ac tivities and processes that 'o"ld e "sed to +onitor the con-or+ity to the 9"ality criteria 'as +entioned$

•

Roles and responsiilities -or 9"ality +anage+entF A roles and responsiilities chart detailing the responsile tea+ +e+er -or a partic"lar 9"ality activity 'as prepared$

•

%ignat"resF This section contained the signat"res o- key stakeholders s"ch as pro.ect +anager, pro.ect sponsor and the c"sto+er to a"thenticate the plan$


3$)$1 5 7"ality Check para+eters de-ined

@

3$)

To ens"re that the 9"ality o- the end prod"ct is according to the c"sto+er re9"ire+ents, it 'as necessary to per-or+ 9"ality checks on the -inal prod"ct$ Certain aspects o- the prod"ct 'ere identi-ied y the design and develop+ent tea+ that 'ere critical to the s"ccess o- the prod"ct$ The 9" ality check para+eters 'ere identi-ied -or the critical aspects and listed as sho'n elo'F •

Mechanical TestsF The poly+er conveyor elt +"st e tested -or the +echanical properties s"ch as tensile strength, 'ear resistance and hardness$ The +echanical tests that +"st e per-or+ed on the link to check -or 9"ality are as -ollo'sF

•

5

!6od and Charpy !+pact

5

Rock'ell >ardness Test

5

Arasion Test

Physical TestsF The physical tests that +"st e per-or+ed on poly+er link to check the 9"ality o- the prod"ct as speci-ied y the c"sto+er are as -ollo'sF

•

5

8la++aility Test

5

:ater Asorption Test

Che+ical TestsF The end "se o- the conveyor link involved 'orking in the environ+ent 'ith +oist"re and che+icals s"ch as ca"stic soda, grease and oil$ >ence, che+ical tests +"st e per-or+ed on the -inal prod"ct 'hich are listed elo'F 5

Reaction 'ith ca"stic soda

5

Reaction 'ith alkalis

5

Reaction 'ith acids


•



2aoratory TestsF The poly+er link sho"ld also e tested -or electrical properties and the +aterial sho"ld e tested in a closed environ+ent "nder controlled conditions to achieve acc"rate res"lts$ The laoratory tests to e per-or+ed on the link are as -ollo'sF

•

5

%"r-ace resistivity test

5

Vol"+e resistivity test

Di+ensional TestsF Di+ensional rigidity o- the part 'as i+portant -or the application and th"s, it 'as i+portant to ens"re that the di+ensions o- the -inal link are as speci-ied in the engineering dra'ings$ The di+ensional acc"racy o- the co+ponent 'as checked 'ith the help o- ga"ges as +entioned elo'F 5

Pl"g &a"ge

5

%nap &a"ge


3$)$)  ngineering B;M availale

1

3$)

The engineering Bill ;- Material B;M4 'as created y the design and develop+ent tea+, 'hich stated the part n"+er, +aterial, di+ensions and the 9"antity o- each co+ponents that go into asse+ly$ The engineering B;M created -or the P;M conveyor elt is as sho'n elo' in taleF

E#K#EE8K# 6K"" L' !ATE8KA" K? eneral Knformation

ProNe#t "ameL ;o"e$or Helt e,)g"

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KK? 5omponent Details 5omponent #ame ;o"e$or ?)" A,,eml$ Sr? #o

1 2

7art #um&er

:;< 18686 :;< 18654

7art #ame

!aterial

Muantity

P)" Pol$mer ?)" ;o"#ept 4

201 =20100 14 ar

1

Pol$mer ?)" ;o"#ept 4

POM %omopol$mer

1

Tale 1)F Bill o- Material o- Conveyor link


3$)$3  Mold st"dy at the cons"ltantEs location

)

3$)

The +old st"dy 'as a t'o5day visit y the pro.ect tea+ +e+ers to C!PT, Panipat, !ndia$ D"ring this t"torial session, the a"thors gained kno'ledge a o"t the para+eters o- +old design -or the poly+er conveyor elt link$ The 'riters 'ere e=posed to the pro-essional +old design practice$


3$)$?  Mold Math Data Availale

3

3$)

The para+eters o- the +old s"ch as r"nner si6e, gate si6e and the length o- -inger ca+ 'ere calc"lated in order to design the +old that 'as -easile$ 8ollo'ing are the calc"lationsF 3$)$?$1 5 Circ"lar R"nner 8or calc"lating the si6e o- the r"nner, consideration in the shape o- the cross section o- the r"nner, the si6e o- the r"nner and the r"nner layo"t 'as done$ The cross5section shape 'as considered as -"lly ro"nd eca"se it provided a +a=i+"+ cross5sectional area$ The r"nner layo"t 'as not considered, as the +old 'as design 'ith one cavity$ The r"nner si6e 'as calc"lated as sho'n elo'F R"nner 2ength  1 ++ Ass"+ed4 Part :eight  1$3 g+s D  : =

?

2

3$*   1$3 = 3$*  )$@ ++  2.1 !!

?

1


?

3$)$?$) 5 Pin &ate A pin gate 'as "sed -or -eeding into the ase o- prod"cts and d"e its s+all si6e it 'as selected, as a -inishing operation 'as not re9"ired -or this gate$ The +olten ra' +aterial 'as in.ected -ro+ a single point -or 'hich the pin gate 'as s"itale option$ The dia+eter o- the pin gate is calc"lated in the -ollo'ing +annerF n  $* constant ased on +aterial gro"p P;M4 C $1*@ constant ased on 'all5 thickness t $*44 A @$?*=13 ++3 s"r-ace area o- +old4 D  n = C = ?A  $* = $1*@ = ?@$?*=13  1.2 !!

3$)$?$3 5 8inger Ca+ The -inger ca+s, 'hich are hardened circ"lar steel pins, are +o"nted in the -i=ed +old plate at an angle$ The splits, +o"nted in g"ides on the -i=ed +old plate, have corresponding angled circ"lar holes to acco++odate the -inger ca+s$ The acting length o- the -inger ca+ 'as deter+ined as -ollo'ingF M  1$ ++ split core +ove+ent

 1o Angle o- 8inger Ca+4 c 1 ++ clearance 2  MLsin W4  )cLsin ) W4  1L sin14  )=1L sin 34  ?$  ?  44.5$ !!




3$)$?$? 5 G Circ"it cooling The cooling syste+ provided in the +old 'as in the shape o- G, 'hich 'ere inter5connected internally thro"gh an internal drilling$ This syste+ o- cooling 'as selected eca"se it 'as e--ective -or cooling long and narro' cavities$ The shape in the +old o- poly+er conveyor elt 'as +odi-ied to s"it the application$

3$)$?$ 5 %plit core The split core design 'as "sed -or the co+ponent eca"se it had a n"+er o- side'ays holes that co"ld not e +ade 'ith a si+ple )5 plate +old$ The core 'as designed in s"ch a 'ay that it +oves to'ards the core 'hen the top plate is co+ing do'n, and +oves a'ay -ro+ the core 'hen the top plate is retracting$ The split core is nestled in a pocket +achined in the ase plate o- the +old$ The ack o- the split core 'as angled, so that the top plate co"ld provide it s"pport to ear the press"re d"ring in.ection process$

3$)$?$ 5 &"ide pillars &"ide pillars, also kno'n as leader pins 'ere +o"nted on the top plate so that the cavity and core 'ere kept in align+ent$ The si6e o- the g"ide pillars 'as kept s"ch that an align+ent 'as +aintained irrespective o- the applied +olding -orce$


3$)$  Mold CAD Develop+ent



3$)

The +old 'as designed y the a"thors on the Pro5ngineer 'ild-ire 3$ so-t'are$ The CAD +odel -or the individ"al co+ponents and the -inal asse+ly are as sho'n elo'F

8ig"re )F Mold Botto+ Plate

8ig"re )F Mold Botto+ Plate

8ig"re )*F %plit Core


8ig"re )@F Mold Asse+ly =ploded Vie' 1

8ig"re )F Mold Asse+ly =ploded Vie' )

*


3$)$ 5 Mold Dra'ing Release

@

3$)

The dra'ings o- the individ"al co+ponents o- the +old 'ere created$ These dra'ings 'ere +eant -or the distri"tion to the +old +aker$ The dra'ing sho's di--erent vie's othe co+ponent s"ch as iso+etric and orthographic pro.ections along 'ith the di+ensions$ This activity 'as +eant -or +anaging the dataase -or the pro.ect and trace the dra'ing o- respective co+ponent -or -"t"re re-erences$ The individ"al dra'ings o- the co+ponents are +entioned in Appendi= :, H, I and J respectively$ The details o- the dra'ing n"+ers 'ith the respective part is as sho'n in the tale elo'F

E#K#EE8K# D8A0K# 8E"EASE 8E5L8D 5omponent !old 7art #um&er

:;<11001 :;<11002 :;<11004 :;<11005

Ver,)o"  1 7art #ame

!aterial

Dra$ing #o

Mol Hottom Plate Mol :op Plate Mol =pl)t ;ore 1 Mol =pl)t ;ore 2

Ma#)"e Alum)"um Ma#)"e Alum)"um Ma#)"e Alum)"um Ma#)"e Alum)"um

1001 1002 1004 1005

Tale 13F ngineering Dra'ing Release -or Mold


3$)$*  Mold 5B;M availale



3$)

The engineering Bill ;- Material B;M4 'as created -or the +old$ The 5B;M contained general in-or+ation ao"t the pro.ect and the details o- individ"al co+ponent s"ch as part n"+er, part na+e, the +aterial and the n"+er oco+ponents "sed -or the asse+ly$ The engineering B;M created -or the P;M +old o- poly+er conveyor elt link is as sho'n elo' in taleF

E#K#EE8K# 6K"" L' !ATE8KA" K? eneral Knformation

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KK? 5omponent Details 5omponent #ame ;o"e$or ?)" Mol Sr? #o

7art #um&er

7art #ame

!aterial

Muantity

1 2

:;<11004 :;<11005

Mol =pl)t ;ore 1 Mol =pl)t ;ore 2

Ma#)"e Alum)"um Ma#)"e Alum)"um

1 1

3

:;<11002

Mol :op Plate

Ma#)"e Alum)"um

1

4

:;<11001

Mol Hottom Plate

Ma#)"e Alum)"um

1

Tale 1?F Bill o- Material o- Mold

3$)$@  Mold Details

3$)


1

A-ter the -inali6ation o- the design o- the +old -or poly+er conveyor elt link, the speci-ications o- the +old 'ere decided$ The speci-ications incl"ded the +aterial othe +old, li-e o- the tool +entioned in ter+s o- co+ponents and the total cost o- the +old$ The a"thors ass"+ed the +old cost a-ter cons"lting 'ith the +entor and the cons"ltant C!PT4$ The -inal speci-ications o- the +old are as +entioned elo'F •

Tool MaterialF Machined Al"+in"+

•

Tool 2i-eF ), co+ponents

•

Tool CostF Rs$ 3,


3$3$1  Costing

11

3$3

A-ter estalishing +a.ority o- the para+eters -or the design and +an"-act"ring othe poly+er conveyor elt link, the -inal cost o- the prod"ct 'as calc"lated$ :hile calc"lating the cost o- the prod"ct, the e=cise ta= 'as ass"+ed to e ) , overhead charges incl"ding electricity and laor charges 'ere taken as 1)  and the pro-it +argin 'as considered   o- the -inal cost$ The cost calc"lations are as sho'n elo'F 7arameter

Value

nit

500 0.0163 8.15 12 0.978 9.128 20 1.8256 10.9536 530000 250000 2.12 13.0736 2 0.261472 13.33507 6 0.800104

<,Kg gm <, * <,. <,. * <,. <,. <, "o. <,. <,. * <,. <,. * <,. <,.

1;?1;

The cost calc"lated in the aove tale 'as -or one co+ponent$ Conveyor elt othese types co+e in standard si6e o- 1 -t$ >ence, the cost o- the chain o- 1 -t elt 'as considered as the "nit cost o- the total cost o- the conveyor elt$ The "nit co st is calc"lated on the ne=t pageF


o. o( l)", )" 1(eet o. o( l)", )" 10 (eet o. o( p)", )" 10 (eet ;o,t o( o"e p)" :otal #o,t o( p)", :otal ;o,t o( l)", :otal ;o,t o( #o"e$or (or 10 (t

8 80 7 0.5 3.5 1130.814 1134.31

Th"s, the "nit cost o- the conveyor elt is ,'. 1134.31%10 -t o- cone+or

3$3$)  8inal Prod"ct speci-ications stalished

3$3

1)


13

A-ter the calc"lation o- the -inal cost o- the conveyor elt, all the para+eters had een estalished$ The a"thors prepared the -inal speci-ications o- the prod"ct and -ollo'ing are the speci-icationsF •

Di+ensionF The -inal di+ensions 'ere estalished a-ter doing +an"al calc"lations o- -orces and analy6ing the strength o- the co+ponent "nder dyna+ic conditions and per-or+ing CA analysis on the co +ponent -or vario"s stresses$ The -inal di+ension o- the prod"ct is as +entioned elo'F

•

5

2engthF 3@$1 ++

5

BreadthF @@$ ++

5

ThicknessF 3 ++

:eightF The 'eight o- the prod"ct 'as calc"lated -ro+ the -or+"laF :eight  Vol"+e = Density  1$1?@ = 1 = 1?)  $13 Kg  1$3 g+

•

CostF The cost 'as calc"lated in the activity 3$11 pg no 34 and the val"e o- the "nit cost 'as Rs$ 113?$31L1-t o- conveyor

•

2i-eF The li-e o- a plastic prod"ct depends on vario"s para+eters 'hich are as -ollo'sF 5

Iield strengthF The yield strength o- the +aterial +"st e signi-icantly higher than the stress acting on it so as to resist the -atig"e loading$ 8ro+ the +an"al calc"lations o- -orces pg ?14 and the +aterial selection tale pg ?4, the


1?

yield strength o- P;M is signi-icantly higher than the -orces acting on the conveyor elt$ 5

2"ricityF The property o- sel-5l"rication in the plastics help in red"cing the coe--icient o- -riction, th"s red"cing the 'ear and tear$ 8ro+ Tale @ pg ?4, the l"ricity o- P;M is the highest and th"s, the coe--icient o- -riction 'o"ld get red"ced and the li-e o- the co+ponent 'o"ld increase$

5

:ear resistanceF The 'ear resistance o- P;M is very high as co+pared to other engineering plastics$ Th"s y "sing P;M, the 'ear rate 'o"ld e red"ced res"lting in an increase in the li-e o- the -inal co+ponent$

By considering the aove para+eters, it 'as concl"ded that the li-e o- the end prod"ct 'o"ld increase and it 'as esti+ated y the a"thors that the li-e o- the prod"ct 'o"ld e @  1 years$ The esti+ation 'as +ade on the asis o- the in-or+ation given y the +entor and other so"rces s"ch as !nternet and co"rse ooks$


1

MilestoneF ? ?$1$1  2essons 2earnt Doc"+ented

?$1

At each and every stage o- pro.ect, the a"thors learnt ne' things that added to their kno'ledge and enhanced their skills$ 2essons learnt session 'as organi6ed y the a"thors a-ter the co+pletion o- the pro.ect$ The +ain o.ective o- the 'riters 'as to share each otherEs ideas and e=periences that 'e re gained d"ring the pro.ect$ These e=periences 'o"ld help the tea+ +e+ers to per-or+ e--iciently in their -"t"re pro.ects$ The lessons learnt o- the tea+ +e+ers are +entioned elo'F •

The a"thors "nderstood that +anagerial skills are o- e9"ally i+portance -or an engineer to +anage the pro.ect data and activities e--ectively$

•

The 'riters also learnt that a thoro"gh ackgro"nd st"dy sho"ld e done -or red"cing the +ishaps at the later stages o- the pro.ect$

•

The tea+ +e+ers learnt leadership skills y taking the responsiilities -or an assigned -"nctional area$

•

The a"thors also learnt ho' to co5ordinate 'ith the top5level +anage+ent o- the co+pany y visiting the co+pany and disc"ssing the pro.ect details 'ith the+$

•

The 'riters also learnt that the dataase o- the pro.ect sho"ld e +anaged properly -or e--ective res"lts and -or re-erence at the later stage$

•

The tea+ +e+ers also learned +old design para+eters -ro+ a visit to Central !nstit"te -or !nternational %t"dies$

•

The a"thors 'ere also a'are ao"t the +an"-act"ring process o- cold everages$

•

8ro+ the research on the 'orking o- the conveyor syste+ the 'riters gained kno'ledge on the sa+e$


1

Concl"sion 8ro+ the engineering analysis, the a"thors concl"ded that the poly+er conveyor elt 'as ale to s"stain the applied -orces$ The -"nctionality o- the prod"ct 'as also proved thro"gh engineering -acts and -ig"res otained -ro+ the calc"lations$ !t 'as also proved that the -inal co+ponent 'as ale to s"stain the +a=i+"+ traction -orce as sho'n in CA analysis Pg  *4$ The proaility o- -ail"re co" ld not e neglected, as the e--ect onat"ral -re9"ency o- the elt on its per-or+ance 'as not considered 'hile designing$ The 'eight o- the o- the poly+er conveyor elt link 'as 1$3 g+ as co+pared to that o- @? g+$ >ence, the po'er cons"+ption o- the +otor to drive the conveyor elt 'o"ld e red"ced, as po'er is directly dependent "pon the 'eight o- the prod"ct$ >ence, y replacing the stainless steel conveyor elt 'ith the p oly+er elt, the organi6ation 'o"ld record s"stantial savings$ !n addition to this, the +aterial handling co st 'as also red"ced and th"s res"lted in increased sa-ety$ The po'er re9"ired -or each ele+entary section is sho'n in Tale ? and !nd"ction Motor less than 1$1 k: co"ld e "sed -or less po'er cons"+ption$ The cost o- the poly+er conveyor elt 'as calc"lated to Rs$ 113?$31L1 -t o- the conveyor elt$ Th"s, it 'as consideraly cheaper than the stainless steel elt and having etter 9"ality$ The li-e o- the poly+er conveyor elt 'as esti+ated -or @  1 years as co+pared to * years o- stainless steel$ Th"s, the poly+er conveyor elt 'o"ld last +ore than stainless steel "nder the sa+e given conditions$


1*

The graph co+paring the three aspects o- 'eight, cost and li-e o- the poly+er and the stainless steel conveyor elt that s"pports the aove +entioned points 'as generated y the a"thors and it is as +entioned elo'F 0eig%t 5omparison 100

) m g ( t % g i e 0

84

80 60

We)gt -gm/

40 20

16.3

0 Pol$mer

=ta)"le,, =teel !aterial

8ig"re 3F :eight Co+parison "ife 5omparison 8.5 8 8

s r a 7.5 e E 7

?)(e -$r,/ 7

6.5 Pol$mer

=ta)"le,, =teel !aterial

8ig"re 31F 2i-e Co+parison


1@

5ost 5omparison 10000

8000

8000

) s 8 ( 6000 t s 4000 o 5 2000

;o,t -<,10 (t #o"e$or #a)"/ 1134.31

0 Pol$ mer

=ta)"le, , =teel !aterial

8ig"re 3)F Cost Co+parison

Reco++endations A-ter going thro"gh the prod"ct develop+ent process, the a"thors 'ere in the position to reco++end the -ollo'ing thingsF •

The a"thors reco++ended that the engineering ."sti-ication and calc"lations "sed in this report co"ld e "sed -or designing a conveyor link -or c"sto+i6ed application$

•

!t is also reco++ended that other para+eters s"ch as noise, viration and dyna+ic loading +"st e considered -or the design o- conveyor links$

•

The 'riters reco++ended "sing the analytical so-t'are s"ch as Ansys, >yper+esh and Ada+s -or virt"al validation and opti+i6ation$

•

The poly+er conveyor elt co"ld e "sed in the R&B plant and the ne' ."ice plant

•

To red"ce the 'ear and tear on the poly+er conveyor elt, it 'as reco++ended that silicone ased l"ricant sho"ld e "sed$


•

1

The 'riters also reco++ended that the +aterial o- the 'ear strip sho"ld e changed -ro+ nylon to a 'eaker +aterial s"ch as P or PP eca"se the 'ear and tear o- P;M links 'o"ld increase y contin"o"sly r"ing against nylon, 'hich has +echanical properties e9"al to P;M$

&lossary

A/ra'ion ear  Friction F :hen there is +otion et'een parts, gears, earings,

p"lleys, contact s"r-aces, and other co+ponents, care-"l selection o- +aterials is re9"ired to red"ce arasion and 'ear$ The -orces on +aterials 'ith contin"o"s or inter+ittent contact generate a PV val"e that is "sed to select +aterials 'ith coe--icients o- -riction s"itale -or the application$

A''u!ption' F An event or action elieved to e tr"e$

enc!arin( F !t is identi-ying the highest standard o- e=cellence, learning and

"nderstanding those standards, and -inally adapting and applying the+ to i+prove per-or+ance$


11

6)F !t is the detailed list o- all the individ"al co+ponents that are asse+led together

to -or+ the -inal asse+ly$

A8: CA is the engineering analysis o- a prod"ct to -ind o"t the loads, press"re,

centri-"gal and dyna+ic -orces, +o+ents and stresses acting on the prod"ct "nder 'orking conditions$

oe--icient o- inear Ter!al 8"pan'ion F All +aterials 'hen heated or cooled

e=perience a linear and vol"+e change in di+ensions$ Plastics e=perience greater ther+al contractions and e=pansion than do +etal$ :hen they are attached to or +ated 'ith +etal or other dissi+ilar +aterials, the design tea+ +"st consider their e=pansion and contracting rates$

o!!unication &lan F !t doc"+ents the types o- in-or+ation need the stakeholders have,

'hen the in-or+ation sho"ld e distri"ted, and ho' the in-or+ation 'ill e delivered$

on'traint' F Anything that li+its the actions o- the pro.ect tea+$

&)F The longest path thro"gh the pro.ect +ade "p o- activities 'ith 6ero -loats$

ritical Succe'' Factor' F The pro.ect deliverales or re9"ire+ents that asol"tely +"st

e co+pleted correctly to consider the pro.ect a s"ccess$


111

*en'it+ F Density is the +ass per "nit vol"+e o- a +aterial$ The 'eight calc"lated -ro+

the density is "sed as a 9"ality and process control checkpoint d"ring the +olding operation$

*F)8A: Design 8ail"re Mode --ect Analysis is a risk +anage+ent tool to appraise a

design -or ro"stness against potential -ail"res and to prioriti6e action plans considering the severity o- the risk, its occ"rrence and the aility to detect in reg"lar operations$

*ielectric Stren(t *ielectric on'tant F Dielectric strength +eas"res the ins"lating

capaility o- a plastic s".ected to increasing voltage ."st prior to reakdo'n$ Variales that can a--ect the res"lts are te+perat"re, sa+ple thickness, +oist"re concentration, and rate o- applied voltage and test ti+e$ Any conta+ination on a sa+pleEs s"r-ace or porosity in the +olded prod"ct 'ill lo'er a resinEs dielectric strength$ These can ca"se arcing or a cond"ctive path thro"gh the sa+ple, res"lting in pre+at"re -ail"re$

*i''ipation Factor F :hen polari6ing reversals occ"r rapidly 'ith alternating c"rrent,

>6 cycles per second4, heat is prod"ced in the test sa+ple as the +olec"les are activated y rapid changes in their polari6ation$ The +eas"re o- the heat dissipation in the sa+ple is reported as the dissipation -actor D84$ D8 is e=pressed as the ratio o- the energy lost as heat, co+pared to heat trans+itted -ro+ the sa+ple and is +eas"re at 1 Mh6 or other speci-ied -re9"encies$

*uctilit+ F D"ctility o- a +aterial allo's the +aterial to e p"lled, rolled, or stretched into

another shape 'itho"t destroying the +aterialEs physical property integrity$ !t is a


11)

-"nction o- the +aterialEs elongation and the rate o- applied -orce to alter the +aterialEs shape, "s"ally 'ith the application o- heat$

8la'ticit+ F lasticity is the +aterial property that descries a +aterialEs aility to ret"rn to

its original shape and si6e a-ter eing de-or+ed y a -orce$

Filler Speed F Rate o- -illing li9"id in ottle$

FloatF The a+o"nt o- ti+e that can delay the early start o- a task 'itho"t delaying the

-inish date o- the pro.ect$

Friction F Plastics do not ehave according to the classic la's o- -riction$ Adhesion and

de-or+ation characteri6e -rictional -orces et'een a +etalLplastic inter-aces$

;antt art' F They are easy5to5read charts that display the pro.ect sched"le in task

se9"ence and y the task start and -inish dates$

ardness o- a +aterial is the +eas"re to resist 'ear and tear$

eat De-lection te+perat"re is the te+perat"re at 'hich

an A%TM standard test ar, s"pported at each end and loaded in the center, "nder a constant stress o-  or )? psi, has de-lected $1 in$ as the test speci+en is s"+erged in an increasing te+perat"re controlled oil ath$


113

-irst is to protect the +aterial -ro+ s"r-ace o=idation 'hen e=posed to elevated te+perat"res$ The second type o- +aterial is "sed to protect the resin d"ring processing$

>od  arp+ !pact F !6od and charpy i+pact tests +eas"re a +aterialEs aility to

asor i+pact energy at a +olded5in or +achined notch in a test sa+ple$ The di--erence et'een the t'o tests is that the charpy test i+pact point is a kni-e5edge that i+pacts the test speci+en$ The i6od test "ses the -lat side o- the i+pact pend"l"+ s"r-ace against the test ar$ The test has a pend"l"+ ar+ -alling thro"gh an arc 'ith the head i+pacting the speci+en 'ith the energy asored y the +aterial on i+pact recorded on the dial scale$

u/ricit+ F Ther+oplastics have an inherent l"ricity that is the load5earing

characteristic o- a +aterial "nder relative +otion$ Plastics 'ith good l"ricity have a lo' coe--icient o- -riction val"e +eas"red y dyna+ic and static tests$ Adding +odi-iers, additives and -illers can increase it$

)eltin( &ointF Melting point is the te+perat"re at 'hich the solid plastic +aterial starts

changing the state to li9"id$

)entor: A 'ise and tr"sted co"nselor or teacher$

)oi'ture 8--ect ?water a/'orption@: All resins +"st e dried to lo' +oist"re levels

e-ore processing< other'ise the e--ects o- +oist"re d"ring processing ca"ses the +olec"lar chains to reak 'ith a drastic lo'ering o- the +aterialEs physical properties$


11?

Notc Sen'itiit+ F #otch sensitivity is the ter+ "sed to descrie the ease 'ith 'hich a

crack can propagate thro"gh a +aterial$ !t is reported on data sheets as notched !6od i+pact$

&la'ticit+ F A +aterial that does not ret"rn to its original shape "t instead -lo's or creeps

"nder a -orce e-ore -ail"re has plasticity$

&roect arter F !t is the o--icial pro.ect kicko-- doc"+ent$ !t gives the pro.ect +anager

the a"thority to proceed 'ith the pro.ect and co++its reso"rces to the pro.ect$

&roect oncept *ocu!ent F Provides -irst overvie' o- pro.ect design, +ain

co+ponents, environ+ental and social i+pacts and loan a+o"nt$ 8or+al +anage+ent approval o- PCD re9"ired e-ore pro.ect preparation can egin$ #ot disclosed, "t sho"ld e re9"ested$

Bualit+ Function *eplo+!ent: 7"ality 8"nction Deploy+ent is a planning tool "sed to

-"l-ill c"sto+er e=pectations thro"gh disciplined approach to prod"ct design, engineering and prod"ction$ !t is also kno'n as the >o"se o- 7"ality or Voice o- C"sto+er$

Srina(e' F :hen ther+oplastics are heated, they eco+e -l"id and e=pand$ :hen

cooled, they solidi-y and shrink -ro+ their original +olten vol"+e state$ This change in +aterial vol"+e and density going -ro+ a li9"id to a solid is kno'n as +aterial or +old shrinkage$


11

S)A,TF %MART is acrony+ -or U%+artEF goals sho"ld e speci-ic and stated in clear,

concise ter+s< UMeas"raleEF &oals sho"ld e +eas"rale< UAcc"rate and Agreed ToEF The goals sho"ld stated acc"rately and sho"ld e agreed to< URealisticEF &oals +"st e realistic< UTi+e Bo"ndEF &oals +"st have a ti+e -ra+e that theyEre co+pleted 'ithin, that is, an estalished end date$

Sur-ace ,e'i'tiit+ F The +eas"re+ent o- c"rrent -lo' across the s"r-ace o- a +aterial

d"e to s"r-ace conta+ination, especially +oist"re, is a +eas"re o- s"r-ace resistivity$

Ten'ile Stren(t F Tensile strength o- the +aterial is the strength o- the +aterial, 'hich

can resist any de-or+ation$

Ter!al Stre''e' F A prod"ct s".ected to a -orce has physical +aterial stresses in the

str"ct"re$ :hen a prod"ct is anchored in place and restricted in its +ove+ent, and then heated or cooled ther+al stressed are created in the prod"ct$ To"ghnessF To"ghness is the aility o- a +aterial to asor physical energy 'itho"t -ail"re$ nergy is asored y either elastic or plastic de-or+ation$

Traction Force F !t is the -orce that is e=perienced et'een a driven +e+er and the

s"r-ace it is een driven "pon$

Volu!e re'i'tiit+ F ho' 'ell a +aterial cond"cts an electrical c"rrent cond"ctivity4 is a

+eas"re o- the electrical resistance o- the +aterial 'hen a direct potential is applied to it$


11

This +eas"re+ent, kno'n as vol"+e resistivity is the resistance +eas"red in oh+s ti+es the are o- the s+aller electrode divided y the thickness o- the speci+en$

SF !t is a tool "sed to graphically display the deliverales o- the pro.ect in a

hierarchical -ashion$

Re-erences

Acetals n$d$4, retrieved on ("ne 1, )* -ro+ httpFLL'''$cctplastics$co+Lacetals$ht+l

Alloy 5 Ther+al Properties n$d$4, retrieved on May ), )* -ro+ httpFLL'''$good-ello'$co+LcspLactiveLg-MaterialTales$cspNsort1*

Dale >$ Bester-ield, Carol Bester-ield5Michna, &len >$ Bester-ield, Mary Bester-ield5 %acre, Total 7"ality Manage+ent, Third dition, )34, Pearson d"cation, !nc$, Delhi

8le="ral %trength Testing o- Plastics n$d$4, retrieved on ("ne 13, )* -ro+ httpFLL'''$+at'e$co+Lre-erenceL-le="ralstrength$asp

Ki+ >eld+an, Pro.ect Manage+ent ("+p %tart, BPB P"lications, #e' Delhi


11*

M$ (oseph &ordon (r$, !nd"strial Design o- Plastics Prod"cts, )3, (ohn :iley  %ons, !nc$, #(

;- 8inite le+ent Analysis, Unique Characteristics of Plastics Stress Analysis, n$d$4, retrieved on ("ne 1@, )* -ro+ httpFLL'''$pitechinc$co+L-ea5-a9s$ht+

;vervie' 5 Acetal >o+opoly+er, Gnrein-orced n$d$4, retrieved on ("ne 1, )* -ro+ httpFLL'''$+at'e$co+LsearchL%peci-icMaterial$aspNassn"+;1)@

Polya+ide  #ylon  n$d$4, retrieved on ("ne 1*, )* -ro+ httpFLL'''$good-ello'$co+LcspLactiveLg-Material!n-o$cspNMAT!DAM3

Poly+er Data 8ileF Polya+ide  PA #ylon4 n$d$4, retrieved on ("ne ), )* -ro+ httpFLL'''$tangra+$co$"kLT!5Poly+er5PA$ht+l

Poly+er Data 8ileF Polyo=y+ethylene  P;M Acetal4, n$d$4, retrieved on ("ne 1, )* -ro+ httpFLL'''$tangra+$co$"kLT!5Poly+er5P;M$ht+l

R$ &$ :$ Pye, !n.ection Mo"ld Design 8o"rth dition4, 1@, 2on g+an %cienti-ic  Technical, >arlo'

Roert 2$Mott, Machine le+ents in Mechanical Design, 8o"rth dition, )3, (ohn :iley  %ons, !nc$, #(

Conveyor Belt design for bottling plant of Coca Cola

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