The calender is a heavy-duty machine equipped with three or more chrome-plated steel rolls that revolve in opposite directions. 2Ĭalendering is a forming operation, in which the rubber compound is sheeted or spread evenly onto fabric. The obtained results concern mainly shortening of the setup time and reducing energy consumption in the process. This paper proposes a method for improvement of the examined production process using the assumptions of the SMED and PDCA approaches described in the literature and computer simulation modeling. On this basis, the research was prepared and carried out. The product forming process was indicated by the company as the area of searching for potential improvements. In the analyzed manufacturing company, a Comerio 2 calender is used.īased on the information from the company, it was found that the production capacity of the products did not match the orders received by the company. The machine is operated by several operators. Calenders usually have 3–6 cylinders with mutually parallel axes arranged in one vertical row or they are suitably offset. As a consequence of this process, to which thermoplastics are subjected, a film is obtained ( Choudhury, 2017). The pre-plasticized material in the rolling mill is once passed through several roll gaps, as a result of which a sufficiently wide web is obtained, which is collected on the cooling drums and coiled on the receiving shaft. The advantages of calendering include obtaining the special properties required for specific material applications, improving flexibility, improving the smoothness of the material, preventing crushing, and improving the appearance of the material.Ī multi-roll calender for rubber or synthetic plastic-material comprises a pair of rolls mounted at their ends in a calender stand, in which each end of the pair, the rolls are rotatably mounted in a bearing block. It consists of softening the material in an earlier processing, then shaping it under the pressure exerted by groups of shaping rollers called calenders.Ĭalendars are also used in various branches of industry, for example, for the production of plasticizable or non-plasticizable PVC (PolyVinyl Chloride) films, for shining and smoothing paper, for producing plastic films and fabrics or embossing patterns on them, for the production of floor coverings, vinyl tiles, board rubbers, cord materials, for friction honing and doubling materials. In the literature on the subject, this process is called calendering. The production process studied in the paper concerns the continuous forming of products from polymer materials. The above-mentioned conditions also require information of the current state of knowledge in the subject field, the use of adequate methods of researching the problem, and assessing the possibility of implementing solutions.
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Reconfiguration may apply to the entire system as well as to the quick setup of individual machines and devices in order to implement changing production orders.Īiming for continuous improvement of the implemented processes forces the use of methods and tools that will enable the verification of proposed improvements with the smallest possible interference in the execution of real processes.Īt the same time, these methods must enable the quantification of improvements, including their impact on process implementation costs, resource productivity, production order, execution time, etc. This includes, among others, the possibility of their reconfiguration, extension, and changes in the work organization of the operating personnel. It also requires the rational use of available resources and the continuous improvement of the implemented production processes.Īccordingly to the complexity of production processes, production systems must demonstrate a high degree of technological flexibility.
In production companies, the need to ensure the efficiency of production planning and control determine the method of organizing production processes. This applies to the strategic and tactical level as well as the operational level. Because of the globalization of the economy and the continuous increase in competitiveness, the effectiveness of enterprises is primarily determined by the rationality of decisions they make.
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