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The Ultimate Guide to Asset Management

If you had read my earlier post “A New Hope: Top 6 Things I Learnt At NRC 2015 Mumbai“, then you would have also read my learning from Naushad Shikalgar of J.N.Engineering – ‘Proactive Machinery Maintenance is not an expense and is an investment that has long-term benefits’.

Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it.

Traditionally, maintenance has been viewed as a cost center in an organization because it costs you money to hire maintenance technicians and purchase the spare parts to keep your systems running smoothly. Too often, senior executives ignore the value-add that maintenance can bring to your organization. These include:

  • A reduction in reactive maintenance costs
  • Reducing costs to restart production after a breakdown
  • Limiting production scrap
  • Costs of downtime such as missed orders and lost revenue
  • Customer perception/satisfaction
  • Improved quality of products
  • Reduced environmental impact

 

By definition, Asset management is a systematic process of deploying, operating, maintaining, upgrading, and disposing of assets cost-effectively.

During his talk, Naushad spoke extensively on Asset Management Strategy-Plan-Execution including the various approaches to maintenance that I found interesting and hope you too would like it when you read. Hence, I have reproduced the 34 slides (click on the picture below) here that effectively forms a comprehensive guide on asset management.

Asset Management

Click on Image

Summarizing, asset management focuses on assuring your people, parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.

Do you agree? How do you look at Asset Management?


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Skills Required For An Rubber Extruder Operator: What No One Is Talking About

To a layman and HR Department of most organizations, an extruder operator is a person who operates and maintains this rubber machinery. Period!

Is that it?

Operator

An Image From Web

Depending upon your final product, rubber extrusion could be either a very important or the most critical manufacturing aspect of your operations. Thus the skills required for your extruder operator are paramount.

Extruded rubber products differ from those produced through moulding. In extrusion, parts are forced through a die of the required cross section under pressure of an rubber extruder. The extrusion process begins when you feed the unvulcanized rubber compound into the extruder. The rubber travels over the flutes of the revolving screw into the die, with the pressure and temperature increasing as the compound gets closer to the die. And when it reaches the die, the built up pressure forces the material through the die-opening, where it will consequently swell in various degrees based on your compound and hardness.

Most extruded products are unvulcanized before extrusion. This leaves the the rubber in a soft and pliable state post-extrusion. Hence they need to be vulcanized before they are they are rendered usable. During the vulcanization, the extruded rubber will swell or shrink in both its cross section and its length (again based on the type of rubber compound used).

Hence, the cost of errors or omissions could turn out to be very high when extruding rubber. You need a skilled operator.

Rubicon-Halle Extruder

Image of Rubicon-Halle Extruder

Here are the skills required for an rubber extruder operator.

Monitoring and Control Of Operations – The most important skill of your extruder operator should be to have a keen eye for watching gauges, dials, or other indicators in the control panel to make sure the extruder is working properly. Your extruder operator should be able to adjust screw speed, set water flow to the required rate, operate temperature control unit (TCU) or the metal detector in cold feed extruders, observe the extrusion parameters and ensure adherence to SOP (temperature or die swell). He has to ensure that the extruder, dies and its allied downstream equipment are kept clean, safety features are functional, and all accessories are ready.

Quality Control Analysis – Conducting tests and inspections of products, services, or processes to evaluate quality or performance is a desirable basic skill that your operator should have. This could be as critical as preventing wastage (from scorch of your rubber extrudate) to as trivial as sending the sample to lab for testing.

Critical Thinking, Judgement and Decision Making – Operating a rubber extruder requires critical thinking skills because your operator should use logic and reasoning to identify alternative solutions, conclusions or approaches to problems he faces while extruder is in operation. There could be many problems while extruding rubber like die-swell, melt fracture, or poor appearance amongst others. While all of them may not be extrusion related, your operator should be able to judge the gravity of the error and also decide what to do about it – whether to fine tune the extruder operating parameters, or escalate to supervisor or raise a service visit request of the manufacturer’s engineer.

Troubleshooting, Repairing & Maintenance – Your operator is the first point of contact with your extruder in operation. Hence, he should have the experience or knowledge on extruders to determine the causes of any operating errors when they occur. Performing routine maintenance and determining when and what kind of maintenance is needed is an important skill that your operator should posses. He should be able to use the required tools to both repair and assist repair of your extruders when needed in the most urgent manner.

Complex Problem Solving – As a addendum to the above skill, your operator should develop skills to identify and solve complex problems when they occur at site and support maintenance department effectively over a period of time. This will reduce the downtime of your extruder and ensure maximum availability at site.

Speaking – Your operator should be able to talk to you (or his supervisor) to convey information effectively be it to report data/problems/incidents as applicable in a timely manner.

Reading Comprehension – Extruders have an operating and maintenance manual supplied by the manufacturer. This is a crucial document that requires a reading by your operator for his safety, training as well as equipment safety. Again your extrusion process would have specific work related instructions or SOP. Your operator should be able to understand written sentences and paragraphs in these documents. Hence, reading skills is very important for a successful operator. It is not necessary (while it is preferred) that they read English, because you could translate these documents to your operator’s local language for ease of reading.

Active Learning – Your operator should display active learning skills.  This is because, the sophistication of the rubber extrusion machinery has risen over the years. Automation and new controls might get introduced or new parameters of extrusion could be introduced further too –  all of which he might have to learn or get trained in.

Summarizing, your rubber extruder operator needs high level of skills to give you maximum output. Hence, its wise that either you hire a skilled operator or train your operator to upgrade his skills. Your extruder operator must stay up-to-date on current and developing technologies and techniques. He must also have a solid understanding of safety techniques and practices.


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7 Must-Ask Questions When Buying Used Rubber Internal Mixer

An Internal Mixer, whether it is a Banbury mixer or Intermix mixer, is the heart of your rubber processing plant. The market for used rubber internal mixer is wide with sellers spread across. You can find an excellent quality pre-owned rubber mixer that can produce high-quality compound mix, without spending excessively.

Rebuild Farrel F270 Mixer From Pelmar Engineering Ltd

Rebuild Farrel Make F270 Mixer – Pelmar Engineering Ltd

Your purchase decision on used or pre-owned machinery has to be thoughtfully made. Because you will see that even in the secondary market for internal mixers, the costs are relatively high considering there could be additional rebuild costs (if not already refurbished by the rebuilder). In any case, you are making a significant investment from your affordability standards and hence you need to consider a variety of factors to help assess the mixer’s value to your rubber compounding requirements and, ultimately, to your bottom line.

Here are 7 Must-Ask Questions when buying used rubber internal mixer that will help you appraise the second-hand or rebuilt mixer value and usefulness to your rubber compounding operations.

  1. What are my mixer requirements?

You need to have a clear idea of what you wish to buy. This entails knowing capacity, the mixing process for your rubber compounding requirements, matching upstream and downstream machinery availability in your rubber mixing room and the remaining useful life of the equipment you are willing to live with.

(Read my post on the Internal Mixer Selection Questionnaire where you can also download a template. You can modify this template to clarify your needs and refine your decision process).

  1. What is my budget?

Your budget will be a crucial purchase factor including the brand, exact model and vintage of the mixer that you can buy. You should have clarity of breakup of costs associated with your batch mixer purchase.

This includes the cost of additional space required (in case you are expanding operations), cost of dismantling (if mixer is running at a particular location) and transporting the mixer to your factory, actual cost of mixer, its controls and accessories to be paid to the seller; plus various duties applicable, to name a few.

  1. Should I partner the right people – the pre-owned equipment sellers?

Given the global nature of rubber compounding business, there are internal mixers available across the key global markets. Hence, it is not possible for you to be informed about the best deals out there in terms of overall cost and mixer quality. This is where pre-owned equipment sellers or dealers come in to help you.

I think, a good dealer will be able to present you with multiple options and help you select the best used mixer for your requirement.

  1. Is the mixer I am considering to buy in Good Working Condition?

Whether buying used or rebuild mixer, you must always test them whenever feasible or you should ask for a start-up guarantee assurance. This is a precaution to be sure that the mixer is in good running order before your final purchase decision.

If you are buying a running mixer, you can easily test them on-site before dismantling. Or if you are buying from a warehouse, many of the reputed used rubber machinery dealers provide arrangements to allow you to test the mixer at least on a test-bed (if not on-site) to help you make a quick purchase decision.

Else, the last resort is a start-up guarantee assurance from the seller. Reputed used machinery dealers  will be transparent on the condition of the mixers they sell, but it is always smart that you check.

When buying with motor and controls, you should verify the operations and safety of electrical components and software licences along with its adaptability to your country of installation. (If not working properly of found unsuitable, you need to factor in the cost of its replacement into your purchase cost)

Another key aspect to check is whether the pre-owned mixer that you propose to buy comes with complete set of manuals, schematics and diagrams. (You may read my earlier post on mixer maintenance here.)

  1. Should I do Visual inspection?

Absolutely. Though the internet has made your communication easy and you can conduct a lot of your business communication online. You can even demand pictures and videos of your mixer in consideration through email. However, there is no alternative to physically inspecting the machinery you are going to purchase.

Used mixers are usually not warranted. This means you need to know the extent of rebuild or refurbishment, and get an idea of the actual state of the internal mixer.

You should insist on a test run of the mixer in your presence and keep your eyes and ears open for tell-tale signs of machine ill-health such as unusual vibrations or noise. Question the maintenance practices of the previous owner and keep your eyes open for worn out parts and leakages.

Additionally, your visual observation of the machinery empowers you to negotiate better with the seller.

  1. Should I Buy a Standard Model of a Brand Name?

When it comes to buying pre-owned mixers, brand plays an important role. Buying standard models of branded and reputed manufacturers of used mixers can assure you about its quality. In addition to this, you will find it very easy to get spares and servicing for a standard internal mixer models in case of future repairs.

On the other hand, if you go for non-branded or non-standard rubber internal mixer, buying and maintaining the spares can prove a difficult task.

Kobelco Make Mixers

Kobelco Make Mixers – Image From Web

  1. Should I get everything on paper?

I think this is a very important step whether you are buying new or used rubber machinery.

You should get everything on record, from the first formal quotation, the details of the rubber machinery, the accompanying accessories, delivery terms, mode of payment, extent of buyer liability, seller liability, etc. It could be an exhaustive document or a simple set of key clauses basis your comfort – either way they are critical to your purchase. (You may wish to explore the rubber machinery purchase and sale agreement here. Preview – Rubber Machinery Purchase and Sale Agreement Template  To buy the full agreement kindly email me directly.)

Once you have answered these questions satisfactorily and determined which factors are most important in your current purchase decision, you can confidently negotiate and purchase a pre-owned mixer that will meet your rubber compounding requirements.

Summarizing, when buying used rubber internal mixer, you need to conduct a proactive due-diligence; identify and partner the apt seller for your needs, and have proper documentation in place. When you make an informed used or pre-owned internal mixer purchase, you avoid buyer’s remorse. 

Happy Buying!


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Top 15 Skills Required For An Internal Mixer (or Kneader) Operator

Rubber Mixing is a capital and energy intensive operation. And mixing machinery are the mother equipment. This could be an Internal Mixer (Banbury or Intermix) or Rubber Dispersion Kneader depending on the size of your organization and/or products manufactured.

Hence, the cost of errors or omissions are very high when compounding a batch in a mixer. You need a skilled operator. Ever pondered on the skills that make a mixer operator successful?

Internal Mixer Operator

Here is the list of top 15 skills for an successful batch mixer (or kneader) operator. (Updated on 23rd Dec 2015: Flip through this post in our digital edition and download here)

  1. Control of Operations – Your mixer operator should be able to adjust ram pressure, control the mixing process, set parameters and ensure its completion as per SOP (temperature or time or energy as programmed/specified).
  2. Monitoring Operations – The most important skill of your operator should be to have a keen eye for watching gauges, dials, or other indicators in the control panel or HMI to make sure the mixer is working properly. He has to ensure that the mixer is kept clean, safety features are functional,  upstream and downstream equipment along with all accessories (like cooling water, hydraulic/pneumatic system, temperature control unit (TCU), lubrication system, etc) are ready
  3. Active Listening – Your operator should be a skilled listener. He should actively listen to the sounds of the mixer and its motor during a mixing cycle; pay full attention to what his supervisor (or you) or his colleagues on the mixing room safety are saying, take time to understand the points being made, and ask relevant questions.
  4. Speaking – Your operator should be able to talk to you (or his supervisor) to convey information effectively be it to report data/problems/incidents as applicable in a timely manner
  5. Reading Comprehension – An operating and maintenance manual is normally supplied together with the rubber mixer. This is a crucial document. Again your compounding process may involve specific work related instructions or SOP. Or there could be a training manual in some instances. Your operator should be able to understand written sentences and paragraphs in these documents. Hence, reading skills is very important for a successful operator. It is not necessary (while it is preferred) that they read English, because you could translate these documents to your operator’s local language for ease of reading.
  6. Troubleshooting, Judgment and Decision Making – Your operator is the first point of contact with your mixer in operation. Hence, he should have the experience or knowledge on mixers to determine/read the causes of any operating errors when they occur, judge the gravity of the error and also decide what to do about it – whether to reset the mixer, or escalate to supervisor or raise a service visit request of the manufacturer’s engineer.
  7. Critical Thinking – Operating a rubber mixer requires critical thinking skills because your operator should use logic and reasoning to identify alternative solutions, conclusions or approaches to problems he faces while mixer is in operation.
  8. Quality Control Analysis – Your operator should have basic skills on quality control with an outlook to meet your set mix quality parameters in every batch. This may involve need for appropriate fine tuning like helping you fix the batch weight, or sending the sample of specified compound/ batch in specified form to lab for testing.
  9. Social Perceptiveness – Emotions could run high in the rubber mixing room. Your operator should display “awareness” of others’ reactions and understanding of why they react as they do in a particular circumstance.
  10. Repairing – Your mixer operator should be able to use the required tools to both repair and assist repair of mixers when needed in the most urgent manner.
  11. Time Management – Your operator should manage his own time and display sensitivity to the time of other co-workers involved in the mixing room.
  12. Mixer Maintenance – Performing routine maintenance on mixer and determining when and what kind of maintenance is needed is an important skill that your operator should posses.
  13. Active Learning – Your operator should display active learning skills. This is because, mixers get upgraded, automation and new controls might get introduced or new methods of mixing could be introduced all of which he might have to learn or get trained in.
  14. Writing – If you could get an operator who could communicate effectively in writing to you (or his supervisor) or to other departments, then I would say you have a great asset.
  15. Complex Problem Solving – Your operator should develop skills to identify and solve complex problems when they occur at site and support maintenance department effectively over a period of time. This reduces the downtime of your mixer.

Do you agree the above listed 15 skills, required for an Internal Mixer or Kneader Operator, are comprehensive? Let us know.


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