The goal of all quality conscious companies is zero defects. This is achieved through the use of capable processes and statistically based monitoring; it cannot be achieved by inspection.
Continual improvement is needed to increase the capability of processes. In today’s rubber industry, this capability is relatively low and many aspects are difficult to monitor. For example, rubber is pliable and dimensions such as cylindrical diameters often cannot be gauged quickly and accurately. In mixing, dispersion cannot be easily checked; in preparing blanks, actual volume cannot easily be measured; and in moulding, the injection process is often more sensitive to material variation than any existing rheometer.
Rubber materials crosslink and are time and temperature sensitive. This results in significant viscosity variations during flow. Friction heat through mould gates and channels creates differences between material and mould temperatures which cannot easily be measured.
Despite such problems, much progress has been made in recent years through the emphasis on consistent processing and with modern computer-based injection presses which are self-adjusting, within limits, to material variations.
At present, world class levels of internal rejects should not be assumed in rubber but they can be achieved through careful design and adherence to the procedures outlined above. Across the industry, internal reject rates run at a typical but unacceptable level of 2%, but rates of 500 ppm (0.05%) – well within world class levels (Anderson Report) – can be sustained across a range of parts, materials and machines.
Clearly, any single part with well designed processes can achieve lower ppm reject levels. As more and more parts are designed on the right basis, and continuous improvement is applied to processes, capabilities will rise and reject levels fall.
It is important to consider present capabilities. The following is intended to provide a general guide using typical results, but every material, machine and process has its own capability and these can vary considerably.
"ONGC - Oil and Natural Gas Corporation Limited" - Our complex drilling application where Shaft was eccentric and application was robust & muddy. Replacement was never easy. Mech Spares designed Oil seals resolved difficulty. This gave a complete joy to my maintenance team.
"Mr Mohammed Al Duaigy" of (Kuwait National Petroleum Company) : We tried several diaphragms from renown worldwide Rubber manufacturing companies. We found Mech Spares technical know how and product to be of great durability and lasted 3 times more then anticipated. They have accurate understanding of there products.
"McCafferty BM Design Ltd, KENT United Kingdom" - Most of the O rings manufacturing company suggested to use larger diameter and expensive elastomers. We learnt with Mech Spares that elastomer being weaker compare to metal and alloys and needs appropriate back up for high pressure or high vacuum applications. Further not necessary the most expensive elastomer is the best for all applications. We trust Mr Nilesh chodhari completely for all our O rings designing applications.
"Dr. A. Singh" of BARC: The electric Insulation mat manufactured by MECH SPARES as per IS 15624 tested at ERTL and found to withstand 40 Kv and still didn't tear. We have been using since 5 years and still didn't generate any fatigue. They arranged bulk delivery in short period.
"Tata Steel" - One of our old machines started making loud noise and disturbed the entire village. We were compelled to stop the machines which lead to huge production loss. With the help of Mech Spares designed bellows in two part we could retain the lubrication and eliminate the noise.
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