Case study on Minimizing the over consumption of Special Boiling Point 80/100 solvent in tire manufacturing

Abstract

Tire manufacturing process is a long process which consists many number of transformation activities. Ingredients of this process are mainly categorized as Bill of Material and Non Bill of Material category. Bill of material category includes all raw materials which are directly related with tire manufacturing process such as compounds, beads, steel. Non bill of material category items are indirectly associated with tire manufacturing which includes chemicals associating with tire manufacturing, polythene and etc. SBP 80/100 solvent known as white petrol, is Non bill of material category raw material which accounts significant value at the tire manufacturing. This study focused on the overconsumption of this material in tire manufacturing company. The study was conducted to specific area of the company and primary data were collected through observations, measurements and through specially designed worksheets. Secondary data were obtained from company SAP system. Five whys analysis followed by a brainstorming session identified major causes and some solutions for the problem. The height between tap of the barrel and tank stand significantly contributed for the wastage of white petrol. Setting a flexible hose for the barrel and fix valve at the end of the hose; fix level scale for the petrol tanks and set the supportive arm for the barrel was the most feasible solution. Some of the limitations of the study are, there is no proper mechanism to measure the evaporation, and in some processes usage of white petrol is user centric. Researching for alternatives to white petrol may need due to high cost, health hazard to users, environmental hazards, and inflammable ability. This research can extend to find and reduce the consumption of other solvents that are indirectly used in tire manufacturing process.