Solving Problems in Rubber Compounding and Processing

Course Number: AP4205
Date: 11/08/2013 - 11/08/2013
Time: 8:00 AM - 4:00 PM
Location: Houston, TX
Cost: $760 USD
SAVE $100 by taking with "Compounding for Performance" OR "Understanding the Global Supply Chain for the Rubber Industry".
SAVE $200 by taking with "Compounding for Performance" AND "Understanding the Global Supply Chain for the Rubber Industry".
Three courses for only $2,240 USD.
CEU's: 0.75
Instructor: John Dick

Course Overview

This course is crucial for anyone in the rubber compounding field. It provides an in-depth look at processing problems in mixing, extrusion, calendering and molding. Statistics and methodologies for solving factory problems and case studies are covered as well. Your current processing problems can be discussed with the instructor. This course includes a copy of John Dick's book, "How to Improve Rubber Compounds" (Hanser Gardner Publications).

Textbook Information:

How to Improve Rubber Compounds 1500 Experimental Ideas Problem Solving
Price US: $199.95
ISBN 13: 9781569903612
ISBN 10: 1-56990-361-1
Edition: First
Published: 2004
Hardbound 407 pages, 2 figures, 35 tables
Author: John Dick

Course Outline

Introduction to Factory Problems

• Plant receiving area
  • Cold flow
  • Stability of pre-powdered blends

Mixing

• Quality of mix
• Uncured elasticity (nerviness)
• Viscosity
• Dispersion
• Bloom
• Green strength
• Tackiness
• Stickiness
• Lump-mill bagging
• Mill back rolling

Extrusion

• Die swell
• Extrusion rate
• Appearance (surface smoothness of extrudate)
• Shear thinning

Calender Release

• Blisters
• Calender release

Molding

• Mold release
• Mold filling
• Non-fills
• Porosity
• Shrinkage of the cured part
• Backrinding

Statistics and Methodologies for Solving Factory Problems

• Basic statistical methods to identify special causes of variation
  • Important principles of Statistical Process Control
  • Random variation vs. special causes
  • Establishing control limits and specification limits
  • Methods to detect special causes of variation

Corrective Actions in the Short Term

• Develop a SOP for taking corrective actions for short-term problems
• Develop a strategy for establishing long-term solutions to chronic problems
• Brainstorming for solutions to problems
• Cause and effect diagrams

Six Sigma Techniques for Solving Chronic Rubber Factory Problems

• Methodology
• Statistical methods
• Examples of success in the rubber industry

Nature and Techniques for Solving Problems in Rubber and Compounding and Processing

• Changing one variable at a time techniques for improvement of a rubber compound
  • Advantages and disadvantages
• Applying a Design of Experiment
  • Advantages and disadvantages
• Interactions
  • Multiple response interactions of compound properties
  • Chemical interactions of compounding ingredients

Case Studies of Rubber Compounding and Processing Problems

Different case studies that include processing and compounding problems will be discussed and reviewed in interactive groups. Then overall discussions will take place to discuss possible solutions and methodologies.

The course textbook, "How to Improve Rubber Compounds", will be used throughout the course and during exercises.