Abstract:
The aim of this research is to reduce Rework in production line in plastic sheet
manufacturing process due to discoloration during production. The production history before
studying in 2008 found that there was the Rework of plastic sheet due to discoloration of product
was 226,701.58 yards long which is equal 43.38% of total production per month with Rework
cost 21.76 million Bath per year. This is directly affected to high production cost, wasting time
for re-process and reducing in total productivity in factory. Root cause of the discoloration was
from inappropriate temperature of PVC compound and pigment during mixing process, to find
out the solution and solve this problem, temperature transmitters in mixing process were installed
to record working temperature and also sampling on plastic sheet from difference working
temperature to find out appropriate temperature of this Calendering Process. As per experiment
on vary working temperature and recording from October 2009 January 2010 found that the
Rework of plastic sheet due to discoloration was reduced to137,083.20 yards or 24.28 % with reprocess
saving cost at 5,284,140 Bath per year.