DMAIC Approach to Improve Carbon Weighing Compliance of Banburry Machine

Abstract

The research work done for improvement in carbon weighing compliance of mixing system of banburry machine is presented in this paper. As the carbon is one of the essential raw agents used in process of tire manufacturing. The carbon handling and transporting system used in banburry machine mixing process is one of the critical processes. Carbon weighing compliance is also known as efficiency of carbon usage. Plant optimization pillars are used for process improvements, new product developments, reducing breakdowns and improving product quality. This research work is mainly focused on the application of DMAIC phases (Define, Measure, Analyze, Improve, Control) along with terotechnology to improve the value of carbon weighing compliance of mixing system by reducing the carbon breakdowns which occur repetitively. The top five carbon breakdowns were identified by analyzing the data of carbon breakdowns of year 2017 thoroughly. Application of DMAIC phases helped in creating new inspection checklists for the effective preventive maintenance of the carbon handling and transporting system of banburry machine. The average value of carbon weighing compliance is increased by 7.5542% (from 89.35 to 96.91%) and the reduction in average downtime is 16.92% (from 490.33 to 407.33 min).