RAJIV PLASTIC INDUSTRIES

RAJIV PLASTICS PVT. LTD

Process Flow Diagram

Item/Part
Masterbatch/Compound Process Responsibility CFT
Desc. SYMBOLS
Model Key Date 17/11/2021 TRANSPORTATION STORAGE
All customer'r/ OEM's
Core Team Date Original 15.12.2018 OPERATION INSPECTION
Document
RPI / SURANGI / PFD Date Revised - OPN & INSP. TOGETHER DELAY
No.

Process Description
Process Flow
OPN # (Operation/Inspection/ Incoming Source of Variation Product Chararcteristics Process Chararcteristics
Diagram
Transportation/Storage)
10 Receiving Inspection Variation in MFI, Tensile, Impact, Identification, Packaging and
Flexural Strength, Flexural Modulus, Physical & Mechanical properties operator's skills
Shrinkage, Filler Content, Weight, as per Supplier Test Certificate
Flammability, Thickness, Length, Width, or Incoming Inspection
Moisture Content, Density
20 Raw material mix-up, packaging Physical properties Location of storage, FIFO Board
Storing of Raw materials condition, improper identification
30 Weighing of Error in work instruction, weighing scale Color & Properties of finished Weightment as per work
polymer,additives, pigments not accurate, appraiser variation product instruction (Formulation)
and part of the filler

40 Machine Cleaning Cleaning/Purging

50 Mixing of ingrediants Wear and tear in mixing blades, Color of premix blend Sharpness of mixing blade,
insufficient mixing level, mixing time not mixing level, mixing time, mixing
standardised speed (RPM)
60 Feeding Wrong selection of Feeder, Feeder Gear Ratio, Screw Type, feed
calibration not done, wrong setting of factor, material level,
feeder set point, wrong selection of high
/ low weight level, variation in massflow
from bin activator
70 EXTRUSION Wear & Tear of screw elements and Adequate dispersion,inherent Barrel zone temp., Screw RPM,
liners, cooling line blocked, blocked or moisture content, color, physical Torque level / AC motor load in
leakage in vacuum line, & mechanical properties AMPS / Shear Rate, melt temp,
melt pressure, hopper build up,
vacuum presssure, Rate of o/p,

80 Variation in water temp., water level in Strand temp., uncut Water level, water flow, water
Strand Cooling bath temp., cleanliness of water,
roller condition.
90 Air-Blower / air knife Blockage in air knife water in strand Air knife condition,
100 Pelletizing More gap between bed knief and cutter, No Uncut / Long Strands / Pellet Pelletizer Setting, Cutter speed
cutter blade not sharp enough, variation size, moisture in granules, / RPM, Sharpness of Cutter
in strand temp. granule temp. Blade, strand temp when it
enters into pelletizer
110 Vibro-screen Big mesh size / big holes in mesh, Granules size ( Uncut / Long Screen condition, spring with
broken mesh Strands / Doubles) unbalance load
120 FG Silo (through vacuum Leakage in vacumm pipe system & suction of material & Level of Vacuum, presence of
loader) condition of magnet contamination in granule magnet
130 First-off clearance, Equipment / Appraiser Variation MFI, Filler Content, color Operators skill, parameters as
difference (delta E) as per the mentioned in testing procedures
customer requirement / Wis
140 Equipment / Appraiser Variation Physical & mechanical properties Operators skill, parameters as
(e.g., MFI, Filler Content, filler mentioned in testing procedures
In-process inspection & analysis, color difference (delta / Wis
Testing E), density, moisture%, etc) as
per the customer requirement

150 /160 Equipment / Appraiser Variation Physical & mechanical properties Operators skill, parameters as
(e.g., MFI, Filler Content, color mentioned in testing procedures
Final Inspection & Testing/ difference ( delta P,DE), TS, EB, / Wis
lay out inspection as per Flexural, impact strenght,
plan Shrinkage%, HDT etc) as per the
customer requirement

170 Packing /labelling Wrong Grade Name and Batch No on Correct Grade Name and Batch Stitching & Identification,
woven sack bags, malfunctioning of Number, weight of products per Packing and stacking as per
stitching machine bag Work Instruction
180 PDI Equipment / Appraiser Variation Physical & mechanical properties Operators skill, parameters as
(e.g., MFI, Filler Content, color mentioned in testing procedures
difference ( delta P,DE), TS, EB, / Wis
Flexural, impact strenght,
190 Despatch Non-availabilityofTaurpalin in Loading No of bags, damage of bags in FIFO as per WI, way of loading
Vehicle, mix up of FG bags. transit, moisture pick-up / & stacking
contamination in transit

Prepared By:Ami Bhatt Approved By:Alpesh Prajapati

RV:00 15.12.2018 TEC/FR/14