Sustainability through Testing - MSME Perspective

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Jewel Shields
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1 Sustainability through Testing - MSME Perspective BY DR. K. RAJKUMAR Indian Rubber Manufacturers Research Association Affiliated to DIPP, Ministry of Commerce & Industry, Govt of India B-88, Road No. 24, Wagale Industrial Estate, Thane West, Maharashtra rk@irmra.org, director@irmra.org ; website :

2 Importance of testing MSME industries do not give importance to testing due to which they : - face huge rejection - face huge penalty - unexpected loss - not budgeted cost Less competitive

3 COST OF POOR QUALITY The rejection and rework - adds to cost of poor quality i.e Rejection and reworks leads to big loss in terms of time and economy. The lack of inspection / testing and absence of control measures at appropriate stage, leads to not only financial loss but also delay in execution of order.

4 Importance of testing to segregate quality

6 Environmental hazard?? Disposal of rejected materials - an environmental issue and hence, the industry has to face several consequences. All these issues make industry less competitive / loss of business / loss of customer and finally to closure of Industry. Solution : Testing of raw materials and in process materials at appropriate stage during manufacturing and will give benefit of becoming sustainable.

7 Reduce the Cost of Poor Quality Importance of testing to minimise overall cost of poor quality. IRMRA conducts several skill development & training activities for MSME sectors emphasising the role of testing and its importance to become sustainable.

8 Parameters to check Basic chemicals Appearance Volatiles content Ash content Solubility test Identity (IR spec) Assay ( GC/HPLC) or Chemical methods.

10 Materials Elastomer/raw rubber Fillers Plasticier Anti oxidant Function Basic components in rubber compounding Used for reinforced or modified the mechanical properties and also to reduced the cost To ease the processing, to modify the specific properties and also as extender To protect the rubber from ageing Accelerator Activator Vulcanization agent Other ingredients To increase vulcanization process and reduced the time of vulcanization To increased the accelerator efficiency Needed during vulcanization process to produced a crosslinking Used for specified purpose such as for coloring, as retarder etc

11 Chemical testing of Finished products Polymer Identification: Some of the basic polymer can be identified easily by this technique. Burning characteristics Beilstein Test (copper wire test) Action of 80% Sulphuric acid Action of Conc. Nitric acid Pyrolysis test

12 Identification of Rubber by chemical test

13 Acetone Extraction Test Apparatus : Soxhlet assembly. Test Method : ASTM D Need for Testing : Determination of the following ingredients: Polymer identification. Free sulphur. Antioxidants. Accelerators. Waxes, mineral oils.

14 Ash content Test Method : ASTM D Need for Testing Quality control, Inorganic filler determination. Zinc oxide determination Elemental analysis. Test Procedure : The samples are heated in a muffle furnace at 550 ± 250C (direct method). 900 ±250 C (indirect method). All organic matter will be oxidized and inorganic ash will remain

15 Sulphur Analysis Test Method : ASTM D Types of Determination : i). Free sulphur. ii).total sulphur. iii).combined Sulphur. Free sulphur is determined by using extracted portion of acetone extract. Total sulphur analysis is carried out on an untreated sample. Combined sulphur =Total sulphur Free sulphur

16 Liquid Swelling Test Method : ASTM D Methods of Testing : Gravimetric change. Volumetric change. Dimensional change. Parameter measured: 1. Change in mass 2. Change in volume 3. Change in hardness 4. Change in tensile 5. Color change of liquid

17 Need for liquid swelling Rubber products in service are subjected to various types of liquid environments. Due to absorption or extraction of rubber liquids, the rubber component will either shrink or swell. By swelling, mechanical and functional properties of the component deteriorate. Also dimensions of the component may change. The component will not be serviceable

18 Standard test oils ASTM oils, 1, (ap-124oc) ASTM oils 2, replaced by IRM 902 (ap-93oc) ASTM oils 3 replaced by IRM 903. (ap-70oc) ASTM oils 5(ap-115oC) LOW ANILLINE POINT THE MORE SEVERE THE SWELLING ACTION BY THE OIL

19 Standard test liquid Fuel A Iso octane 100 Fuel B Iso octane 70 Toluene 30 Fuel C Iso octane 50 Toluene 50 Fuel D Iso octane 60 Toluene 40 Fuel E Toluene 100 Fuel F Diesel fuel Fuel G Fuel D 85 ethanol 15 Fuel H Fuel C 85 ethanol 15 Fuel I Fuel C 85 methanol 15 Fuel K Fuel D 15 methanol 15

20 Effect of liquid swelling Solvent resistant rubbers NBR gasoline and oil-resistant applications Neoprene aliphatic Hydrocarbons.alcohol, glycol, slightly inferior than NBR as oil resistant Hypalon -extremely resistant to most chemicals, oils and greases and hypo chloride. resistance to micro organism and salt water (marine application) Viton- aliphatic, chlorinated solvents, animal and vegetable oils at higher temp.

21 Case study (1) Company Name Prduction Log sheet XYZ Rubber company Date shift Lot No. Batch No. Qty prodn cost? I I I I I II II II II II II II III III III III III III III III No. of days

22 Company Name Prduction Log sheet Case study 2 XYZ Rubber company Date shift Lot No. Batch No. Qty prodn cost? Segregated I I I I I Rejection II II II Rejection II II II II III III III Rejection III III III III III No. of days

23 Testing advantage case 2 Rs. In Lakhs per month Rs. In Lakhs Annual Total sales Total rejection Approved Profit 25% Can we eliminate the rejection? Through Testing and Inspection???

24 Case study (1) Company Name Prduction Log sheet XYZ Rubber company Date shift Lot No. Batch No. Qty prodn cost? I I I I I II II II II II II II III Supervisor thinks if one can produce III in one batch why not in entire operation? III III III III III III No. of days

25 Company Name Prduction Log sheet Case study 2 XYZ Rubber company Date shift Lot No. Batch No. Qty prodn cost? Segregated I I I I I Rejection II II II Rejection II II II II III III Fact is something III is different 5 >>>>>>> Rejection III III III III III No. of days

26 Thank you

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