CFP 2010 Pres

Slide 1:

CFP Plant Report Performance Overview – Benjamin Wang Production – Gary Morgan Maintenance – Wes Wallace Technical – Dr. Rong Cheng

BEO1 BLACK AND BLUE FILM:

BEO1 BLACK AND BLUE FILM Project Scope Reduce Customer Complaint Increase Production Yield

MAJOR CUSTOMER COMPLAINTS:

MAJOR CUSTOMER COMPLAINTS Breaking (Including holes) - 4, 484 lbs. in 2008 - 4, 991 lbs. in 2009 Blocking - 4, 991 lbs. in 2008 - 11, 340 lbs. in 2009

PROCESS COMPARISON OLD AND NEW RESIN:

PROCESS COMPARISON OLD AND NEW RESIN OLD RESIN NEW RESIN BAD FLOW – The screen required to change by 1 ½ days BAD EDGE – The die bolts are required to be adjusted about every hours to make good edge COLOR of film – distribution not even and ugly GOOD FLOW – The screen required to change over 14 days. GOOD EDGE – The die bolts are only adjusted first time until next start up. COLOR of film – beautiful and very even on color distribution.

IMPROVEMENT RESULTS:

IMPROVEMENT RESULTS Customer Complaints Total weight (lbs ) Percentage (%) 2008 15,121 1.62 2009 17,713 1.47 2010 1,261 0.17 Yield Total Production Yield (%) Scrap on line 2008 1,044,204 90.27 101,601 2009 602,858 88.18 71,257 2010 752,152 97.69 17,374

TOTAL COST SAVINGS:

TOTAL COST SAVINGS With reduced amount of scrap from hold, we saved labor cost. Improved the yield from total production, save material $ 36, 829 Reducing customer complaint, saved $ 11, 152 Earning good reputation, PRICELESS!!!

BEST PACK BE03:

BEST PACK BE03 Project Scope Reduce Workload Enhance Operability

BE06 Lay-on Roll Modification:

BE06 Lay-on Roll Modification Project Scope: Gap in lay-on roller caused bad quality of film Improvement Project: Moved lay-on cylinder out of cabinet and installed it directly behind the lay-on roll. Added a second cylinder to even out pressure.

Results:

Results

Reclaim Filling Station:

Reclaim Filling Station After Before

Reclaim Gaylord Routing:

Reclaim Gaylord Routing Red is old path Green is new

Silo #8 Pipe Addition:

Silo #8 Pipe Addition BE06 access to Silo #8 Source for .5 MI Enable Improved EL blend using this resin BE06 capability to reach materials for Prestretch

Water Contamination:

Water Contamination Resolve scrap and downtime causes associated with water contaminating our resins.

Research Conditions and Causes:

Research Conditions and Causes Identified Conditions Suspected Causes BE03 wet resin when pulling from silo #9 BE07 multiple instances of wet resin, no discernable pattern BE08 occasional moisture found in feed hoppers All lines experienced some form of similar contaminate within the last year Resin contamination Silo leaking Vacuum pipes leaking Condensation in transfer or storage systems Hopper contamination from overhead piping Material exposure prior to use

Findings:

Findings Flexible lines due to limited silo access exposed to water Submerged joints on vacuum lines Significant water collection inside of silo bases

Corrective Measures -1:

PVC pipe bridges to elevate exposed line Corrective Measures -1

Corrective Measures - 2:

Caulking all joints and silo piping Corrective Measures - 2

Corrective Measures -3:

Corrective Measures -3 Route flex lines Inside silo bases PVC pipe bridges to elevate exposed line Add “weep-holes” in silo bases to drain condensate Caulking all joints and silo piping

Additional Countermeasures:

Additional Countermeasures Insulating overhead pipes to protect hoppers Shutting off feed throat cooling during downtime to prevent condensation Redistribution of some permanent pipes and/or silo usage in order to improve service to lines.

Results:

Results No instance of water contamination in resin since completion of project in Oct-2010

BEO7 & BEO8 Winder Airshaft:

BEO7 & BEO8 Winder Airshaft Problem Shaft sticking repeatedly on BEO7 generating down time and scrap. Approximately 20 to 30 times a month. Each time problem occurred, caused around 15 minutes down time and one index of rolls scrapped.

Yield With Tap Magic:

Yield With Tap Magic

Production with Tap Magic:

Production with Tap Magic

VISUAL AID TRAINING PROGRAM:

VISUAL AID TRAINING PROGRAM SAFETY QUALITY INSTRUCTIONAL GRAPHS Displayed in break room on TV

Visual Training Aids - Safety:

Visual Training Aids - Safety

Visual Training Aids - Quality:

Visual Training Aids - Quality Countermeasures Adjust the die bolts in the area of concern. Check vacuum settings Check winding tension as high tension can appear as a gauge band. Gauge bands

Visual Training Aids - Instructional:

Visual Training Aids - Instructional Shut off switch Resin Hooper Drain Cap Vacuum Line for

Visual Training Aids - Graphs:

Visual Training Aids - Graphs

BE02 Reclaim Force Feeder Project Scope:

BE02 Reclaim Force Feeder Project Scope Originally, BE01-BE05 utilized a small reclaim extruder that is mounted on the side of the main extruder feed zone. The purpose of the reclaim extruder is to feed the regrind fluff (edge & bleed trim) from the grinder and reintroduce the scrap back into the extrusion process. The wide range of fluff density of different product types causes inconsistent feeding due to frequent clogging and bridge-over in the hopper. These problems cause the output of the main extruder to surge hindering higher production outputs.

Improvement Plan:

Improvement Plan Remove the reclaim extruder. Designed & fabricated a force feeder screw & hopper mounted on top of the main extruder feed throat. The fluff is forced into the main extruder and mixes with the virgin resin. After perfecting the new design on BE05, the project was installed on BE03 & BE04 and has been in operation for several years. In 2010, the improvement project was installed on BE-02.

Results:

Results Eliminated the main extruder from surging due to clogging & bridging since inception Increase in production output No more dc motor, extruder barrel & screw and associated controls, thus reduction of maintenance expense & downtime

Cost Savings & Benefits:

Cost Savings & Benefits Eliminated high maintenance expense of $13,470 in spare parts Cost savings per year $4,580 In house design saved cost on parts, fabrication, and installation. Initial cost of $5,500 per line. BE01 will be the next 7 final line for modification in 2011

BE05 Weighing & Blending System Project Scope:

BE05 Weighing & Blending System Project Scope BE01-BE05 uses the PCC “Gravimetric” loss in weight weighing/blending system. The equipment has been in operation for more than 18 years. Over the past several years, the equipment has become unreliable resulting in frequent breakdown, high maintenance expense, and compromising the finished product quality.

Improvement Plan:

Improvement Plan According to our QC department, the largest customer complaint on BE05 for 2010 was due to “ NO CLING ”; 13KLBS (.14%) & is directly related to the skin layer configuration . Therefore, a B1 improvement project was implemented to replace the PCC systems on BE04 & BE05. After researching several vendors, the Witmann system was chosen. Since we still plan to utilize the PCC loading system for the Witmann weighing system, we must separate the equipment. A new metal platform structure was designed & fabricated “in house”. The structure includes stairs to access the loading system for safe, fast, and easy resin line connection & maintenance. The new system was completed on BE05 12/7/2010. BE04 replacement is schedule for latter part of February 2011.

Problems of the PCC System:

Problems of the PCC System The loading system is mounted directly on top of the PCC “gravimetric” weighers. Resin lines connected to the loaders will sometimes surge and whip when refilling resulting in movement of the whole system The movement causes inaccuracy of the material being weighed & dispense. This problem has direct effect on the skin layer configuration and the formula resulting in quality issues of the finished product. The miniopp controller is obsolete and has to be upgraded. Very expensive. The network communication is unreliable and causes equipment to shutdown often. Calibration & parameters are stored by battery that does not last very long The Drive & Weigh module PCBs fails often due to weak power supplies. The auger dc gear motor’s life is very short; motor overheats often The augers bend easily Difficult to operate & maintain Very high expense to maintain & upgrade (PCC) Breakdown is very high

PCC Expenses & Breakdown for 2010:

PCC Expenses & Breakdown for 2010 Total expense of PCC parts use on one line is $68,319 Total parts expenses incurred from Jan – Nov are approximately $51,000 Total breakdown Breakdown incurred from Jan-Nov is 71 Hours.

New Witmann “Batch” Weighing & Blending Features:

New Witmann “Batch” Weighing & Blending Features - The above pictures show the HMI LCD color touch screen. - Software supports up to 8 components - Quick start sequence by entering material ratio in % Uninterruptible adjustment of all ingredients during cycle Real Time Live Scale for batch-to- batch consistency 100 Recipe local memory Continuous graphic display of running recipe, target weights deviation, process rate and batches processed Ethernet & USB Ports for data export

New Witmann Weighing System:

New Witmann Weighing System Pictured from Left to Right: New metal platform structure New metal platform shows organization of vacuum & resin hose connections to the loading receivers New 5 component blender; Ext A & C 1000lbs/hr, Ext B 1980lbs/hr

Results:

Results Since inception 12/7/10, the film quality produced has greatly improved due to the optimum performance & accuracy obtained from the new Witmann Weighing System No breakdown of equipment Reduce expensive PCC spare parts. Parts removed will be used on the other remaining lines.

Cost Savings & Benefits:

Cost Savings & Benefits * No quality complaints related to formula and/or skin configuration The total cost of this B1 project was $70,000 The total cost increase from improvement was $16,371/yr and cost decrease after improvement will be $20,110/year The yearly benefit from this project is $3,739

BE07 & BE08 Winder Airshaft Project Scope:

BE07 & BE08 Winder Airshaft Project Scope Two major problems to overcome for the DS winder are “Airshaft Sticking” & “Core Deformation”. Airshaft sticking problem will be covered by production department. Air shaft Core Deformation is the primary focus of this improvement project. When BE08 changed over from machine film (thicker wall core) to hand wrap film (thin wall core), operators began experiencing quality problems with the finished product. The problem is due to core deformation from the air shaft. The deformed cores are caused by the air pressure in the air shaft too high resulting in excessive vibration (bouncing) between the spindle and contact roller. The vibration causes bad roll edges.

Problem of the Airshaft related to Core Deformation:

Problem of the Airshaft related to Core Deformation The airshaft consist of two parts: Power chuck actuator (Lugs & Spring Plungers) Core shaft (Lugs & Air Bladder) Theses two parts are not only fastened together but share the same air supply via internal air hose. The designed input air pressure is 90psi. This high pressure is to ensure that the expandable lugs of the power chuck actuator is properly engaged inside the winder chuck housing when inflated. To prevent core deformation, operators lowered the input air pressure to 50psi; however, this led to other serious machine problems & premature failure of parts. The actuator no longer had a firm grip inside the winder chuck housing and allowed the airshaft to slip. The high start up torque was now transmitted to the four spring plungers & locking hub ring. This excessive force caused damaged to the locking hub ring and broke spring plungers constantly. Operators were having to replace the spring plungers about 4 times a shift. This caused extensive downtime, scrap generation, and high replacement part expense.

Airshaft Locking Hub Ring Wear vs New Ring:

Airshaft Locking Hub Ring Wear vs New Ring Left PIC shows the damage to the locking hub ring; holes are worn out due to lowered air pressure causing slipping. Replacement locking hubs from OEM $11,000 each x 4 per line. Right PIC shows a new locking hub ring made at IBS Machine Shop. The cost is $2,500 each x 4 per line.

Airshaft from Winder:

Airshaft from Winder Lugs Power Chuck Actuator Lugs Spring Plungers Air Input

Improvement Plan:

Improvement Plan We needed a way to lower the air pressure on the core shaft while maintaining the required 90psi pressure for the power chuck actuator. An air regulator was installed internally between the two parts of the air shaft. An air regulator was modified to fit inside the airshaft. We found that 32psi air pressure was the best for the core shaft lugs.

Air Regulator Installation:

Air Regulator Installation Left PIC shows the new improvement modification for the core shaft end. The air pressure is set to 32psi (about 3 bar) Right PIC shows the incoming 90psi ( about 6 bar) air pressure into the power chuck actuator with the improvement. Once the air pressure regulator is set to 32psi , the regulator is locked & the gauge is removed. The regulator is inserted into the power chuck actuator side.

Results:

Results Since inception on 11/30/10: Eliminated core deformation, thus reduced vibration Improved film quality Prevent machine failure, scrap, and unneeded expense Before Improvement Spring Plunger breakage Sep: Broke 6 times, 4 hours downtime, $433 in parts Oct: Broke 9 times, 16 hours downtime, $1079 in parts Nov: Broke 12 times, 6 hours downtime, $866 in parts After Improvement: No Locking Hub wear & No Spring Plunger Breakage!

Cost Savings & Benefits:

Cost Savings & Benefits Cost of improvement for 4 airshaft improvements $1,400 Cost of 4 new locking hub rings made at IBS Machine Shop $10,000 Since improvement was installed on BE08 (11/30/11) *No spring plunger breakage *No wear of locking hub ring *No quality problem *No related downtime *No related scrap; therefore, yield has increased The yearly benefit for this improvement is $8,400.

AMTOPP CFP:

AMTOPP CFP QC & Technical 2010 Performance Review

2010 Quality Overview:

2010 Quality Overview Target 2007 2008 2009 2010 Offline Reject 0.15% 0.15 0.23 0.26 (MW- 0.49%; HW- 0.08%) 0.25 (0.1) (MW- 0.48%; HW- 0.09%) Hold Reject <1 % 1.04 0.83 1.20 (MW -2.23%; HW 0.40%) 0.64 (0.56) (MW -1.13%; HW- 0.28%) Customer Complaint < 0.50% 0.54 0.68 0.71 (MW- 1.05%; HW -0.19%) 0.47 (0.24) (MW 0.74%; HW 0.16%)

Major Improvement in Process and Film Quality:

Major Improvement in Process and Film Quality Abnormal rate Drops from 1.46% to 0.89% Quality complaint reduces from 0.71% to 0.37%

More Effective Audits:

More Effective Audits Adjust audit frequency accordingly to focus more on problematic films Year 2009 2010 Offline Inspection rate (%) 4.09 3.75 Hold Inspection rate (%) 2.68 1.32

Focus on Training and Root Cause Analysis:

Focus on Training and Root Cause Analysis Reviewing quality complaints weekly, quarterly and yearly to help production to keep track of quality level. Doing so would also remind every personnel of their responsibility of maintaining premium quality in every aspect of production. Involving line coordinators on testing complaint return films to help identify root cause and generate corrective actions as well as improvement projects

Complaint Analysis by Defect:

Complaint Analysis by Defect

Compliant Analysis by Film Type:

Compliant Analysis by Film Type

Other Major Improvement:

Other Major Improvement Working with FPC on Resin Yellow Index improvement PR Film Formula and process finalize HLG and HLF Film Development

2011 QC/Technical Target:

2011 QC/Technical Target Target: Offline Reject Ratio – MW < 0.40% & HW < 0.1% Hold Reject Ratio – MW < 0.5% & HW < 0.10% Customer Quality Complaint Ratio < 0.10% Focus: Enhance Product Quality Control (Product spec; Effective Audit and testing; Training;) Reduce customer complaint (Database, Machine films, communication, Analysis )

2011 QC/Technical Target:

2011 QC/Technical Target Target: Offline Reject Ratio – MW < 0.40% & HW < 0.1% Hold Reject Ratio – MW < 0.5% & HW < 0.10% Customer Quality Complaint Ratio < 0.10% Focus: Enhance Product Quality Control (Product spec; Effective Audit and testing; Training;) Reduce customer complaint (Database, Machine films, communication, Analysis )