A Method to Minimize Rework Amount Using Mean Particle Diameter: A Case Study of Activated Carbon Manufacturing

Abstract

Rework is a major determinant of activated carbon manufacturing industry. This study investigated rework as a case study by determining its severity by identifying its causes. The considered work categories included only the rework of particle size preparation process. The objective of this research was to suggest a method to minimize the rework amount of size category and analyze the root causes for it. The analysis was done mainly over two objects, the crusher machine and particle size distribution process. Feed materials were categorized into two size combinations in the crushing process. The mean particle diameter analysis was done for both. The study found that activated carbon crushing process needed separate gap settings for each size combination. Further, feeding those two size combinations separately, would give more benefits. Further, it would maintain the specified product range at a higher level. Improving the quality of raw materials, checking the size distribution of the materials before feed, adjusting the new gap settings, replacing the rollers after checking attrition, conducting employee awareness programs and systemizing the procedure of issuing bin for feed were suggested as possible solutions along with the feasibility analysis. Thus, the technical team staff, engineers or mechanics can implement suitable programs or methods of gap setting procedures using their knowledge based on these findings.