Document ZB2k5m9Bbn8B7yp3agVzaoNrJ

G. C. Eggleston cc: C. G. Stelchek J. W. Bird JuDe 30, 1969 PRELimiiAKY STUDIES FOB PLASTICS STANDARDS FILE: 20-1-6-1 Preliminary studies in the Plastics Shop indicate that an opportunity exists for methods improvement and corresponding substantial savings. The following proposals are submitted for consideration, ranging from extensive automation of lines doTM to improvement of present machinery and methods. These pror.ossl:; are bas'.-* on Class A estimates of costs, savings, and time recuiremc-rtn. V7e recommend two char.-ter, that vculd be an integral part of all three alternate proposals. 1. Tr j hr"ling cycle can be cut considerably * y setting the outer skin of the Vail chilled water then removing the pipe from the head and. insert 5.ng nr end plug to stow shrinkage. Me have successfully reduced cooling or. 3" from .fC minutes to .20 minutes with a 0. C. plug gage and 6a3 water. believe that with an oversize plug this car he further reduced. Cooler water *-ro?.d reduce still further. 2. Eliminate the weighing of pipe, it serves no 7ur330.se. The operator controls the material usage- 'ey wall thickness measurements, and a more meaningful materiel usage figure can be obtained from the- book weight of pipe pro duced versus monthly inventories of raw materials, scrap, etc. This change, in conjunction with Proposals 1 and 2 that follow, will have the extruder operator picking up pipe one time and asiaing it directly to the belling ramp - instead of transferring pipe to the scale, from the 3C&le to a dolley, from the dolley to belling ramp. Proposal number 1 Description This proposal requires the least amount of additional equipment and modifi cations to present eauipment but is a "necessary minimum" prior to working Up fi, incentive standard. First, the present chamfering machines are inadequate. Every set-up for each different sine is a series of frustrating trial and error adjustments. The chamfer machine should be modified in the following ways? 1. Redesign the air tube arrangement for positive and -quick adjustment fo- all s-i 7,esthe present copper tubes have to be bent back and forth, to a precise position, the tubes soon break and have to be replaced from behind a flywheel - a complete chamfer Bet-up frequently takes two hours. ..Vi MTC 010594 Page Two - Preliminary Studies for Plastics Standards June 30, 1969 2. Make T^ariable O.D. mandrels for quick adjustment to pipe I.D. and ovalness variations. The operator now selects a mandrel and sorts back pipe that won't run on that mandrel, then later uses 1/2" strips of tape to build up or reduce size of mandrel. Variable O.D. mandrels could be made any of several ways: angle split mandrels, chuck type mandrels, Alternate layers of metal and rubier that can be contracted or expanded, an air bladder; Hollis may have even better ideas. 3. Move marking wheel so as to operate on same mandrel as chamfer tool; this would eliminate several motions now being made in moving the pipe to a chamfering mandrel, taking pipe off of mandrel and moving backwards to a marking mandrel, then taking pipe off marking mandrel and moving it past the original mandrel. h. Put bearings in marking wheel and arms to maintain alignment. 5. Move air clamp actuater to the lever that moves air clamp,or to a foot pedal. 6. In lien of the above modifications, design a chamfer machine like the I: i>. C lathe, mo chuck in I.D. of pipe and automatically feed, chamfer, and mark. After the chamfer :r.?.ch:\u-.. te^n made efficient, we recommend moving It tc a position past the .o .her. The ceeumulation ramp car be extended out even with the edge cf the do:" and the oil immersion tank for spare heads. The storage racks on the r.:v h. ...11 era* he vouch to the old vacuiv. forcing area zo make more unitizing roe;. it). tne chamfer machine in this position, the extruder operators will oner, aoi 1e their pipe directly to the ceiling ramp ar.d eliminate double handling. The b .11 or operater "ill cycle pipe through the hsl" . r for 6 hours. The ckanfertr- ur.it in er vil.1 chamfer one or two layers of r . return that many plug: to . liar, and ui.it:..:e one or two layers of pipe, then return to the chs'dfer nacnire. To make this proposal veri: we must bo aele to dtuign a chamfer oa.chine that will not bottleneck the helling liu:. Vith this proposal, the three extruder operators 'rill be relieved of vet ski:*' and recording .-^pht:-, cl ever;. 1 ^ ; . _e cc scales then to del lev. ill row grind scrap ss it csr.es cli ti.e :achine eliminating need for scrap accumu lation area and reducing exposure to contamination (start-up rejects cun ce accumulated at take-off until in goon production, then grourc.). The operators will also make up ''mic'-ey rouse'' fittings internal, and when running adapter stock cut it up as it cemos off the machine. To furtner reduce operator tori: load a large refrigerator c sulc running of acetone tost... bcugr.t, y.lezed in the department fer quick MTC 010595 Page Three - Preliminary Cindies for Plastics Standards June 30, 1969 Cost of Proposal reassign chamfer machine Move chamfer machine, extend ramp Make end plugs (20 per size or 120 plugs) ?. afriterator Make downdraft table portable _ TOTAL $ Savings Potential aca n - in.0 Corc-cir"c cf 7,000,000 He. .Lie sections nor nice sc be belldfe :e as -^i1i1uvs: ULJ . c c_or.s 1-1/: 2-1/2 15,5l6 171,412 23-650 73,7c1* :;i.i73 13,204 935.2 1597.9 TOTAL :;0l7.. 5-1".4 teeaB Aulovu)'Z : cnsnge-cr.-er;.. 52i5. 4 x j-Oo = 5,o4o toca.L .elling ncurs required by propsic-'l methoa. Me ire presently running 2 I'.nes rays per week,cr ^p.-)CSag 12,09b hours, of which 're estimate 8Cy is actual!;' baling pipe (other 207 is stem: -inding scrap, making fittings, etc.). 12,C?6 x 807 = 9677 hours] ine ne . r.e-:-kod reduces '.caller hours by 4C29 hours C .82 per hour,or $23fTL savings attributed tc method and standard. Proposal ZhrMoer 2 tescripts on It. is proposed to purchase an Anger automatic in-line, cut-ofi. , CCTiCL chamfer machine. The pipe would come off the ereruder line with all thich sections on the same end, the in-line machine cuts out the transition section for regrinding, then chamfers the plain end. of pipe. The operator will aside pipe directly to the belling ramp, grind his own scrap as it comes off machinecut up own fitting stock when scheduled, etc., as in Proposal Humber I above. 2y eliminating chamfbring at teller the unitizer now has spare time in which he can set up the ilo . 2 heller internal (will run only one beller at .a time) so that as one line is csught up, the beller operator can move to the Ho. 2 with no downtime. T'he unitizer can also jvAe up "mickey mouse" fittings internal. The down draft station can be moved to the unitizing area. This proposal appears to have advantages over Proposal limber 1 in that the work loads are not as tight. The unitizer. picks up cementing fittings from the extruder operators and can set up the other belling machine. Also,the possible shift of control to the chamfer-unitizer does, not exist as,in Ho. d. MTC 010596 Page Four - Preliminary Studies for Plastics Standards June 30, 1969 Cost of Proposal The cost of this proposal is as follows: 3 Anger in-line, cut-off, and chamfer units @ $11,170 = Belling End plugs (same as in Proposal I?o. l) Regrigerator (seme as in Proposal No. l) Move downdraft table to unitizer area = = = $33,510 (+installation and freight) TOTAL $ Savings Potential The Savings Potential is virtually the same as in Proposal No. 1 except that some beller downtime can ce eliminated by having the unitizer set up the other line internal. Also, by having the unitizer cement fittings,the extruder operator will have more available time for mis qg^laneous jobs such as grinding o ~n scrap, cutting up cr.r.i idling stock, etc. fe F~1 Estimated r-avinrs ll.Vii. I la .* Si {. ? - ,v n'1! ,, Vi. `oy^-.zsa 1 e:;Cu-,:i tl.r': 1' O .. J u C' ?V. o i_ -Vi cct-Is-i. tir.snccti' - in j automatic in-line chars.er aacli.-e .tec in-line bn - I...:;n an in-linn jelling unit tint is >utc..ated . .. n . time other 'Iru. set-up? Iz ears .:.u no oreicclip Iran si em . 1. crn.'^. - . 1d: sjc-i-rn a econ , -preceding ti.n -_-cdio" vers ,.i:p ip tie time itj ;:i 'e _l.c :el bp . c.-cjv . forced cuts a. .-.end, n c:.idled auc- cooled end iu.-. and oft c.rco "..vj. ^ticali--. The extruder curve:on -crld iucpect " o--n i.-v' ' < - ' '. h r.u a full duties. ripe ar.n put it directly into a unit .. ,'r U. .0. : ... .1. U do ' V - 1. . li. is u .iuiuer 'oj.1v ncj : i .p: n..i .er;d'r other r. is c; id run-eon :,J PY. ;; CU .-ro'.'-c J ' J. r: :u: ,il:.t:ca freight) ran duel u. : c n..- r. MTC 010597 Page Five - Preliminary Studies for Plastics Standards June 30, 1969 Potential Savings The savings from this proposal would he 8 or 9 men or around $5^,000 to $6l,000 (based on a Joint Moulder's year-to-date earnings). J. V.Bird By: A. 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