2. LITERATURE SURVEY

2.1 DELTA BLOWPACK INDUSTRIES

Delta Blowpack Industries & group of companies are in the Business of

manufacturing and marketing of HDPE Containers & Articles. The mission of the

company is profitability through Total customer Satisfaction. M/S. Delta Blowpack

Industries & group of companies have tried to touch the customer’s heart by making

Products. As per standards set by Indian Institute of Packaging and manufactured from

Prime Virgin grade material and qualified to keep Edible Oil, Dairy Products,

pharmaceuticals liquids and Semi-Solids fresh.

Moreover the company manufactures their products on latest fully automatic and

sophisticated machines, the shapes are registered with Government of India under “The

Patent and Design Act.” The virgin grade material is used that meets specification of

international stranded. Thus the company has taken most of the measures towards

Quality and Customer Satisfaction.

For ensuring above, the company insists on continuous R&D and Staff Training.

In future (also with any new project) they would not like to compromise with Customer

Satisfaction level.

2.2. CAR A/C DUCT

Car A/C Ducts are manufactured using high grade raw material and posses a

capacity to maintain seal under temperature and pressure changes. The company’s range

of product is widely appreciated for its various distinctive features such as accurate

dimension, high tolerance, durable, excellent finish and high functionality.

2.2.1. Parts of a Car A/C Duct

2.2.1.1 Air Inlet Duct

Air Inlet Duct is generally considered an essential part for improving the

efficiency of the engine. This duct also has a diffusion section above the compressor to

change the ram air velocity into high static pressure at the face of the engine. The thrust

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of the engine can be high only when the duct supplies the required airflow at the highest

possible pressure.

2.2.1.2 Centre Duct

Components like Center Duct Assembly that is widely used in the automobile

industry. These are made from fiber reinforced plastic that is of high quality. Further,

these are offered in various specifications to suit the needs of the clients and are highly

appreciated by clients for the superior quality, durability and effective functioning.

2.2.1.3 Left Hand Duct

Left hand air duct is an extension to the left hand side of the car air duct

assembly. This satisfies the function of the heating, cooling, ventilation to the driver’s

side of the car (India), and to the co-driver’s side in the foreign countries, based on the

steering wheel arrangement in the cars.

2.2.1.4 Right Hand Duct

Right hand air duct is an extension to the right hand side of the car air duct

assembly. This satisfies the function of the heating, cooling, & ventilation, to the co-

driver’s side of the car (India), and to the driver’s side in the foreign countries, based on

the steering wheel arrangement in the cars.

2.3 MANUFACTURING PROCESS FOR THE PRODUCTION OF AIR DUCTS IN COMPANY (BLOW MOULDING PROCESS)

Delta Blowpack Industries are mainly concentrating on the production of Air Ducts,

as their main product, which are used in the automobile air conditioning system and

automobile air-circulating system.

Now, the air ducts that are produced are not single piece manufacturing. Air Duct,

as an assembly consists of the center air duct part, left end air duct part, right end air duct

part and assembly of all these.

The process which is followed in manufacturing of each part of the air duct will be

explained in detail through the flow table.

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Blow molding (also known as blow moulding or blow forming) is a manufacturing

process by which hollow plastic parts are formed. In general, there are three main types

of blow molding: extrusion blow molding, injection blow molding, and stretch blow

molding. The blow molding process begins with melting down the plastic and forming it

into a parison or preform. The parison is a tube-like piece of plastic with a hole in one

end in which compressed air can pass through.

The parison is then clamped into a mold and air is pumped into it. The air pressure

then pushes the plastic out to match the mold. Once the plastic has cooled and hardened

the mold opens up and the part is ejected.

2.3.1 Types of Blow Moulding Processes

2.3.1.1 Extrusion blow molding

In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube

(a parison). This parison is then captured by closing it into a cooled metal mold. Air is

then blown into the parison, inflating it into the shape of the hollow bottle, containeror

part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected.

Continuous and Intermittent are two variations of Extrusion Blow Molding. In

Continuous Extrusion Blow Molding the parison is extruded continuously and the

individual parts are cut off by a suitable knife. In Intermittent blow molding there are

two processes: straight intermittent is similar to injection molding whereby the screw

turns, then stops and pushes the melt out. With the accumulator method, an accumulator

gathers melted plastic and when the previous mold has cooled and enough plastic has

accumulated, a rod pushes the melted plastic and forms the parison. In this case the

screw may turn continuously or intermittently.

2.3.1.2 Injection blow molding

The process of injection blow molding (IBM) is used for the production of hollow

glass and plastic objects in large quantities. In the IBM process, the polymer is injection

molded onto a core pin; then the core pin is rotated to a blow molding station to be

inflated and cooled. This is the least-used of the three blow molding processes, and is

typically used to make small medical and single serve bottles. The process is divided into

three steps: injection, blowing and ejection.

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The injection blow molding machine is based on an extruder barrel and screw

assembly which melts the polymer. The molten polymer is fed into a manifold where it is

injected through nozzles into a hollow, heated preform mold. The preform mold forms

the external shape and is clamped around a mandrel (the core rod) which forms the

internal shape of the preform. The preform consists of a fully formed bottle/jar neck with

a thick tube of polymer attached, which will form the body.

The preform mold opens and the core rod is rotated and clamped into the hollow,

chilled blow mold. The core rod opens and allows compressed air into the preform,

which inflates it to the finished article shape.

After a cooling period the blow mold opens and the core rod is rotated to the

ejection position. The finished article is stripped off the core rod and leak-tested prior to

packing. The preform and blow mold can have many cavities, typically three to sixteen

depending on the article size and the required output. There are three sets of core rods,

which allow concurrent preform injection, blow molding and ejection.

2.3.1.3 Stretch blow molding

In the stretch blow molding (SBM) process, the plastic is first molded into a

"preform" using the injection molding process. These preforms are produced with the

necks of the bottles, including threads (the "finish") on one end. These preforms are

packaged, and fed later (after cooling) into a reheat stretch blow molding machine. In the

SBM process, the preforms are heated (typically using infrared heaters) above their glass

transition temperature, then blown using high pressure air into bottles using metal blow

molds. Usually the preform is stretched with a core rod as part of the process. In the

single-stage process both preform manufacture and bottle blowing are performed in the

same machine. The stretching of some polymers, such as PET (polyethylene

terephthalate) results in strain hardening of the resin, allowing the bottles to resist

deforming under the pressures, formed by carbonated beverages, which typically

approach 60 psi. The main applications are bottles, jars and other containers.

Advantages of blow molding include: low tool and die cost; fast production rates; ability

to mold complex part; produces recyclable parts

Disadvantages of blow molding include: limited to hollow parts, wall thickness is hard to

control.

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2.3.2 Process Flow for Air Duct Manufacturing

Here, we will see the process that is involved in the manufacturing the air duct,

from the raw material. The air duct is basically divided into three main sub-parts, i.e. the

center part, the left hand side duct and the right hand side duct. Also, the process that is

involved in the assemblies of these part to form the main air duct, i.e. our final product,

which is ready to dispatch. We will see, one by one the flow of the process of each

product.

2.3.2.1 Process Flow for Center Duct Manufacturing

The above gives a clear operation description and process flow, that are followed in

sequence for the manufacturing of the center duct.

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2.3.2.1 Process Flow for Side Duct (Left Hand) Manufacturing

The above gives a clear operation description and process flow, that are followed in

sequence for the manufacturing of the side duct, left hand.

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2.3.2.1 Process Flow for Side Duct (Right Hand) Manufacturing

The above gives a clear operation description and process flow, that are followed in

sequence for the manufacturing of the side duct, left hand.

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2.3.2.1 Process Flow for Assembly of the Center Duct with Left Hand and

Right hand Air Duct.

The above gives a clear operation description and process flow that are followed in

sequence for the assembly of the center duct with left hand duct and right hand duct.

Dionisis Kandris, Nikos Papadimitriou, Nikolaos Pantazis, Romanos Fais, Giannis

Psaros,Giorgos Pantouvakis, Spyros Spyropoulos, has approached towards one of the

most common industrial quality control problems, which are involved in manufacturing

of plastic molded receptacles, that is of leakage detection. They begin with an

introduction to the characteristics and the quality problems of the blow molding method

for the production of plastic receptacles. Next, the existing methodologies and

technologies for quality control of such products are presented along with their

corresponding advantages and disadvantages. After their comparative collocation, the

‘pressure control’ method is adopted. [1]

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Serge Monteix, Yannick Le Maoult, Fabrice Schmidt, Jean Paul Arcens deals with

an application of blow moulding process applied to PET bottles forming. The most

important stage of this process is the radiative heating step which is realised with

infrared ovens using powerful halogen lamps. To validate a 3D thermal control volume

software, called Plastirad, developed in our laboratory, temperatures maps were needed

on the plastic performs as well as convective heat transfer coefficient inside the oven.

This measurement has been performed with two different methods : IR thermography

and hot wire anemometry. These two methods have been investigated and results are

compared to focus on the interest of IR thermography. [2]

P. Naughton, P. Shembekar, A. Lokhande K. Kauffman, S. Rathod, G. Malunjkar

The performance and design criteria for seat systems require that the seat be lighter for

reduced fuel consumption while still meeting the safety requirements as required by

legislation. The safety requirements for seats include headrests and seat back static and

dynamic structural performance, seat belt anchorage and luggage retention capability,

child seat anchorage and top tether requirements as defined by pertinent regulation. The

interior space constraints require that the seat be thinner. The seat design is expected to

address the growing concern for environmental friendliness. In addition to these main

criteria, various additional features such as adjustable and stow-able design are required

for customer delight. All these design objectives should be met within a given cost

target. [3]

K. Szczepański*, D. Kwiatkowski, J. Koszkul The main purpose of the performed

investigations was a multi-aspect analyzes of the blow moulding process in a mould

which takes two-stage nature of the process and the occurrence of uncontrolled

phenomena which influence the shape, size and quality of the products into

consideration. [4]

Sherry L. Baranek Blow mold design and build requirements—as well as challenges

and how to overcome them—through the use of a new rotary blow molding wheel

system. With a majority of the population constantly on the go, the market for single-

serving containers (plastic bottles) of both beverages and foods is exploding. While

designing and building blow molds is challenging, it is a niche worth exploring. [5]

2.4. QUALITY IMPROVEMENT TECHNIQUES

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There are various techniques that improve upon quality for betterment of higher

productivity with less rejects as compared to the process of the one without quality

improvement technique.

Quality improvement is a characteristic of quality management and it is the

continuous improvement of the output of products and services using management

systems.  There are various quality management systems available. Many Quality

improvement tools today are used due to a high demand for large volumes of high value

products and services using cheaper materials in production during the second world

war. Present systems such as Kaizen, Total quality management (TQM), Quality circles

and Six Sigma have shown the power and effects a team-base improvement system can

have on production. Process capability design is at the forefront when using Six Sigma.

Some improvement tools includes Control charts, Lot sampling, Process

capability, Value Analysis (VA). A sustainable and continuous  improvement program

in a company has to be part of the companies’ cooperate culture, and staff should be

trained on the system adopted for this type of management and improvement.

2.4.1 Six Sigma:- Six Sigma is a business management tool developed by the

Motorola Company in the mid 80’s. It seeks to improve the quality output and efficiency

of companies by identifying the probable defects in a given process and minimizing the

variability in output.  This process uses a set of methods including statistical methods

creating an infrastructure of people within the organization. Each Six Sigma project

process in an organization follows a laid down sequence with the aim of reducing cost

and maximizing profit.

2.4.2 Total Quality Management (TQM):- TQM uses teams made up of

workers from all sectors in the company to solve issues. The teams undergo training in

the use of basic statistical tools that are used in the collection and analysis of data.

2.4.3 ISO 9000:- ISO 9000 is a standard of quality systems. The ISO 9000 family

of standards ensure that organizations meet the needs of customers and other

stakeholders. This process deals with the basics of quality management, emphasizing on

eight principles on which the family of standards is based.

2.4.4 Quality Control Circle (QCC):- Quality control circle is a small group of

workers who come together to discuss ways of identifying, analyzing, solving and

selecting work related issues.

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2.4.5 Failure Mode and Effect Analysis (FMEA):- Failure Mode and Effect

Analysis is a very important tool to improve upon the quality. In this tool, the failure

modes are earlier checked upon and necessary actions are taken to prevent that to avoid

the re-occurrence of the failure.

M.Y. Lam, Gary K.K. Poon and K.S. Chin has tried to establish a relationship between

organizational learning capability (OLC) and TQM culture (TC) based on a case study of

a leading vocational education institution of Hong Kong, and to develop an

organizational learning transformation model for vocational education in the context of

TQM culture. [6]

Jose´ Carlos Pinho analyzed the importance of developing a quality

management approach as a way to enhance the bottom line results of small and medium

sized enterprises (SMEs). The main goal is to examine the synergistic relationships

between TQM, performance, consumer orientation and innovation. [7]

Silvia Helena Boarin Pinto, Marly Monteiro de Carvalho and Linda Lee Ho has

identified the relationships as to complementarities and redundancies of the main quality

programs in large Brazilian companies by a comparative and critical analysis of their

implementation in those companies. [8]

Djoko Setijono and Jens J. Dahlgaard has presented a proactive quality costs

measurement methodology, which describes the value of quality improvements and the

implication of this value on customers’ perception regarding the value of the product. [9]

Alessandro Brun, Donatella Corti and Alessandro Pozzetti has provided a

methodology aimed at improving the setting up of air-jet looms by clarifying the

function which links different important variables involved in the setting procedure and

by proposing a method to measure the quality of fabrics depending on the factor values.

[10]

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2.5 FAILURE MODE AND EFFECT ANALYSIS

The first stage of an FMEA exercise is to decide on the type(s) of analysis

required, depending on the maturity of the design and decisions to be made, but this may

include: - System FMEA, Design FMEA, Process FMEA

The FMEA process uses rating scales to assess, the severity of the possible

consequences of specific types of failure (Severity). The Probability, that the causes of

failure will occur (Occurrence). The possibility, of detecting a problem, using the

current procedures, and intervening to avoid the consequences of failure (Detection).

Appropriate rating scales should be chosen for each project, and consistently applied.

Published standards1 include recommended rating scales for automotive

applications, and these may be adapted for general use as shown in The effects of

potential failures are assessed using a ‘Risk Priority Number’ or RPN that is calculated

by multiplying the individual scores together, so that,

RPN= Severity x Occurrence x Detection

Particular care must also be taken to address concerns that could cause serious

or fatal injury, even if the risk of occurrence is small. Especially in high volume

manufacture the statistical probability of “at least one failure” should always be

considered, and appropriate action taken to prevent that failure mode or mitigate

the consequences of failure. It is important that the rating scales established for a

particular project are applied consistently throughout the analysis and answers are not

fudged to become politically acceptable.

Dr. Ravikant and Bhavik Pathak has represents the results of the analysis of causes

and modes of failure of the automotive radiator as a part of the cooling system of vehicle.

Based on detailed review of the structure and operation modes of the observed object and

other relevant data, FMEA discovered the weak processes in the manufacturing of

radiator, and then after necessaries improvements we repeat investigation which gave

positive results. They concluded that the paper presents possible applications of FMEA

to identify the possible product enhancement points for automotive radiator. [11]

Dobrivoje Ćatić, Slavko Arsovski, Branislav Jeremić and Jasna Glišović has stated

that FMEA can be applied at all stages of the life cycle of one technical system.

However, its effectiveness is the largest, if applied at product development phase by a

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team of experts from various companies’ functions. Therefore, conceptual, design and

process FMEA is discussed in this paper. A detailed description of the relations between

these methods and the order of application is considered. Based on FMEA working plan

it was formed the algorithm procedure of application of design FMEA method. The

specific steps of FMEA procedure starting from the formation of FMEA team until

documenting of the analysis is explained. [12]

Namdari M., Rafiee Sh., Jafari A., has aimed to reduce fuel consumption in moldboard

plowing using the failure mode and effects (FMEA) method. FMEA is a new

methodology to analyze potential reliability problems in the development cycle of the

project, making it easier to take actions to overcome such issues, thus enhancing the

reliability through design or process. FMEA is used to identify actions to mitigate the

analyzed potential failure modes and their effect on the operations. Application of FMEA

in this study revealed that plowing speed, soil moisture content and plowing depth are

the most important factors in tillage fuel consumption, with 640, 480 and 420 RPN

respectively. [13]

Joseph Barkai, has describes a project to convert the results of Failure Mode and Effects

Analysis information into a diagnostic knowledge base. Combined with a diagnostic

expert system, this knowledge base produced an effective diagnostic system for an off-

highway vehicle. [14]

Thomas A. Carbone and Donald D. Tippett proposes the extension of the

Failure Mode and Effects Analysis (FMEA) format to quantify and analyze project risks.

The new technique is labeled the project risk FMEA (RFMEA). The RFMEA is a

modification of the well-known process, product, and service FMEA technique. In order

to use the FMEA format for projects, the detection value of the standard FMEA is

modified slightly for use in the project environment. [15]

Yiannis Papadopoulos, Christian Grante & David Parker has analysis the compile

lists of component failure modes and try to infer the effects of those failure modes on the

system. System models, typically simple engineering diagrams, assist analysts in

understanding how the local effects of component failures propagate through complex

architectures and ultimately cause hazardous effects at system level. [16]

Riccardo Mariani, Gabriele Boschi, Federico Colucci proposes an innovative

methodology to perform and validate a Failure Mode and Effects Analysis (FMEA) at

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System-on-Chip (SoC) level. This is done in compliance with the IEC 61508, an

international norm for the functional safety of electronic safety-related systems. [17]

Lars Dittmann, Tim Rademacher, Stephan Zelewski, aims to introduce an approach

that integrates a technique of knowledge engineering (Ontologies) and a technique of

quality engineering (Failure Mode and Effects Analysis). An approach will be set up that

shows the potentials of combining IT-based systems of knowledge and quality

engineering. Particularly with regard to the quality engineering technique, the paper aims

to demonstrate the advantages of this approach. [18]

3. SUMMARY

The other relative works of my dissertation to be done are shown on the next page in the

form of GANTT CHART.

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