Incharge - Compounding

Department Manufacturing Technology

Position Incharge -compounding

Reports to Scetion Head- Compounding

Sl No Role Activity

1 Ensure safety culture Near miss identified and report and taken the corrective action.

2 Execute Activities For Process Scrap Reduction Rework Reduction

Collect Rework Data from inventory.

Analyse the data by consumption of work away from previous day mixed compound as per outlet.

If excess rework generation give the outlet for consumption as per R&D; guidelines.

If rework outlet is beyond the guidelines, then arrange the repass for maintaining the allowable quantity in mixing shopfloor.

Incoming Rework classification with CFT and circulate report

Circulate Mixing work away inventory for further action

Scrap Reduction

Compound scrap classification done in Solid tire with Production and Technical CFT members. Do why why analysis and initiate corrective action with area owner.

Compound scrap classification done in strip winding process ,Monitor Overaged compound in all subsequent area and ensure disposition as per Technical Guidelines

Compound scrap classification done in Mixing with Production and Technical CFT members. Do why why analysis and initiate corrective action with area owner.

All scrap compound classification to be done at mixing area with CFT team

Declare as Scrap Compound after classification with CFT team

If not declared as scrap (semi cured compound) send to solid tire for workaway usage

Circulate the compound scrap report to all CFT members.

Root cause analysis done for generation of non moving ,NC Scrap material.

3 Carryout Continuous Improvement activities in Manufacturing Process (Mixing) Implementation of specification in mixing shopfloor and update in SAP with reference to Corporate R&D; specification

Feeding the specification in the Mixer and Chemical scada.

Ensure the recipe values in the scada are as per R&D; Specification

Compound mixing cycle monitoring in SCADA during mixing.

Compile monthly report of weighted average mixer cycle time and Spread ratio.

Circulate the raw material supplier change report as per raw material changeover.

Master compound Process

Ensure Master stage compound raw material (polymer,chemical ,carbon ,process oil weighment) are as per plant specification





Check the TCU temperature ,Ram pressure,compound temp,cooling fans working condition as per technical standard

Check Compound Carbon black dispersion in TSR Compound sheet with white paper.

After mixing master compound properties ensure results are within the specification.

If properties are not found within the specification range adjust the sequence in the same lot itself or in the next lot.

Final compound Process

Ensure before Final compound mixing, master compound lab approval, final chemical identification and EVA bag sealing

Ensure Master compound skid blending and weighment , final chemical and work away weighment

Ensure Final compound results in the lab test are within specification, if it is out of specification adjust the mixing sequence in Master and final SCADA.

Check Non Conformities in Final batch heldup compound and initiate corrective action .

Periodically check Mill temperature , Booking temperature and compare with ambient temperature. If there is any deviation, initiate corrective action in consultation with Engineering department

SCADA analysis

Check the report and analyse Weighment of all ingredients batchwise . If any abnormalities in the report, initiate corrective action with concern department

Check the Mixer SCADA batchwise and look for abnormalities in parameters, if any. Then initiate corrective action by adjusting squence.

Check Compound properties out of specification in Specific gravity and Mooney Viscosity.If there is any abnormalities (Unmixed or semi cured scrap), find out root cause from the Trend chart scada Analysis and ensure problem is solved .

Reduce Drop door rubber jamming mixerwise issues through why why analysis and initiate corrective action

Compile SCADA analysis report, identify top 3 main issues, initiate action plan with CFTs and close the loop within the Target date.

Process trouble shooting

Monitor Critical compound viscosity for subsequent process,



adjust the viscosity to achieve the required target viscosity.

Attend Daily upstream co ordination meeting with other process technical team and discuss processing issue, initiate corrective action.

Trouble shoot Technical related issues in mixing and kneader area.

Participate in PQR audits along with Quality assurance team.

Initiate corrective action for NCs , if any raised in PQR audit in consultation with CFT members

Initiate corrective action for NCs , if any raised in CPQ audit in consultation with CFT members

4 Execute activities related to recent raw material/new supplier industralization Trial planned as per R&D; trial intimation note in shop floor and select compound code for taking a trial.

Trial communication given to CFT team.

As per R&D; phr recipe, change plant trial specification for mixer capacity and update in SAP .

As per trial specification , setting done in chemical SCADA and Mixer SCADA

As per trial specification compound mixing followup done in mixer.

Weighment followup done in Chemical and mixer during mixing .

R&D; trial report & compound hand over to respective area .

Feedback from customer end and evaluation report compiled report sent to R&D.;

Participate review meeting fortnightly with R&D; team.

5 Execute activities related to new machine industralization Ensure the machine technical parameters as per machine manual.

Machine setup specification preparation as per the manual and process requirements.

Validate the mixer through Inprocess standard,MSS , SOP & compound mixing specification and then issue trial specification

Avoid contamination in compounds by cleanout process

Take Initial pilot trial for 5 batches and evaluate compound properties test result

If pilot trial is satisfactory bulk trial taken and compound properties test result evaluation done

If bulk trial is ok machine released for regular mixing and regular specification to be released

Discuss the technical points in Minutes of meeting

6 Carry out Continuous Improvement activities in TQM & TPM kaizen implementation in manufacturing process.

TPM Implementation activities in DM Piller.

Participate in the TQM projects.

Daily routine management activities

QCC Project implementation

5S implementation in office

📌 Shift In-charge - Compounding - (Assistant/Deputy Manager ) (Tirunelveli)
🏢 Yokohama-ATG
📍 Tirunelveli