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Contents
1. Function of QC Engineering
7. Abstract Card
-Explanation of Abstract Card
-Example of Abstract Card
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QC Engineering Function (answer to questions from NPGD)
QC engineering function is very important function like a bridge between technical dept.
and production dept.
1.Main subjects of this function are as follows;
(1)Preparation of PWS (including both for new product and revision/improvement for existing product)
Translate technical formula to production formula, including setting operating conditions such as
grinding parameters.
*preparing PWS for new product is a part of FLC activities.
(2)Implementation of FLC activities
FLC activities include RM-QA, DR activities, pre lab test, PWS preparation, attending production
preparation meeting, first batch making observation, evaluate the result of the first batch including
improvement/countermeasures for the following (2nd) batch, etc.
(3)Reaction to abnormality including customer's complaint
Investigate causes of the problem.
*If the problem is customer's complaint, then need to cooperate with technical dept (S&M dept) to investigate
the causes of the problem. This case, QC engineer need to investigate from the view point from production.
(viewpoint from technical should be investigated by technical dept.)
Sometimes, need to run lab test to confirm reproducibility/repeatability of the problem.
(4)Preparation of AB Card
Through activities mentioned the above, need to prepare technical report especially for any lab test
into AB Card. Then from here, also try to extract information for DR List.
**Our case in NPC, QC engineering group doesn't take care of "application analysis for customer".
(This is technical service matter)
3.Evaluation of activities
Especially evaluating the performance of QC engineering function,
if this function is working well, then as a result, probably,
(1)less mis-operation due to inappropriate instruction on PWS
(2)High success ratio of first batch due to FLC activities (including RMQA and DR)
(3)Many AB Cards DR items are generated.
*When I was in QC engineering department, my boss evaluated my performance by how many
AB Cards I prepared, how many DR items I listed.
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o investigate
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Process Engineering parameters
1.PC
PC: Pigment Content=Content of pigment in pre-mix formula
PWC: Pigment Weight Content
PVC: Pigment Volume Content
Value of PWC is easy to get compare with PVC.
Normally, PC=PWC (theoretically, PVC is more meaningful )
2.VS
VS: Vehicle Solid=Content of solid in total vehicle of pre-mix formula
*exclude pigment from both content of solid and vehicle of pre-mix formula
VS= (Total Solid Content in vehicle of pre-mix formula)/(Total Vehicle weight in pre-mix formula)
P/R= (Total Pigment Weight in pre-mix formula)/(Solid Weight in vehicle of pre-mix formula)
V=DπR/60
V: tip speed (peripheral velocity) [m/sec]
D: diameter of impeller [m]
R: rotation (revolution) speed [rpm]
5.Residence time
Residence Time: the time/length of one particle of pigment stay inside of a mill during grinding.
RT=Ve*FR
RT: residence time [min]
Ve: volume of mill vessel where mill base is able to exist inside of a mill [L]
FR: flow rate [min/L]
Ve=Vv-Vm-Vd-Vs
Vv: total mill vessel volume [L]
Vm: total true volume of media [L]
Vd: total volume of disks [L]
Vs: volume of rotating shaft [L]
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Vm=Mw/St
Mw: total weight of media [Kg]
St: true density of media [Kg/L]
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Example
1.Calculation of PWC,VS
example1 example2
Formula Formula by Technical
Material Ratio NV(%) Material Ratio NV(%)
[Pre-mix] Sol a 10
Sol a 2.3 Sol b 15
Sol b 2.3 Resin a 30 60%
Resin a 15 60% Resin b 20 70%
Resin b 10 70% Addtv a 0.5 80%
Addtv a 0.4 80% Addtv b 0.5 50%
Pig a 5 Pig a 5
Pig b 7 Pig b 15
Pig c 8 Total 96
Total 85
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-when batch size of pre-mix=1920L : Total grinding time=
-grinding flow rate to get grinding residence time =15min: flow rate (sec/L)=
The same condition above and when flow rate=15L/min and total grinding
time=16hours then number of turn=
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Example
1.Calculation of PWC,VS
example1 example2 Formula for Production
Formula Formula by Technical Material Ratio
Material Ratio NV(%) Material Ratio NV(%) [Pre-mix]
[Pre-mix] Sol a 10 total pigment=5+15=20 Sol a 4
Sol a 2.3 Sol b 15 PWC=40%=0.4 20/X=0.4 X=50 Resin a 25
Sol b 2.3 Resin a 30 60% X: total amount of pre-mix Addtv a 0.5
Resin a 15 60% Resin b 20 70% Y=50-5-15=30 Addtv b 0.5
Resin b 10 70% Addtv a 0.5 80% Y: total vehicle of pre-mix Pig a 5
Addtv a 0.4 80% Addtv b 0.5 50% VS=50%=0.5 S=30*0.5=15 Pig b 15
Pig a 5 Pig a 5 S: total resin solid in total vehicle of pre-mix subtotal 50
Pig b 7 Pig b 15 S/R=60%=0.6 15/R=0.6 R=25
Pig c 8 Total 96 R: amount of "Resin a" required for pre-mix [Let-down/after-mix]
5+15+25+T=50 T=5 Sol a 6
Subtotal 50 PWC=40% VS=50% T: amount of rest of ingredient for pre-mix Sol b 15
Resin for grinding: Resin a Resin a 5
[Let down] Solvent for grinding: Sol a Resin b 20
Sol a 5 Add both additives in pre-mix Total 96
Resin a 10 60% Determine formula for grinding (=pre-mix)
Resin c 20 50%
Total 85
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shaft frequency=900rpm
tip speed m/s=0.3*3.14*900/60=14.13[m/sec]
The same condition above and when flow rate=15L/min and total grinding time=16hours
then number of turn=15*16*60/1920=7.5
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Grinding Method Comparison
grinding method
item Pass Circulation [CANS]
mill base viscosity high (75-100KU) low (55-80KU)
required pre-mix time longer than CANS(60min) shorter than Pass(30min)
agitation during grinding better to agitate must agitate
flow rate slow fast
required number of turn N/A >6turns (10turns)
mill pressure low high
particle size distribution narrow broad
required mill type open/closed type closed type
mechanical seal,
required type of shaft seal lip seal, mechanical seal double mechanical seal
easiness of handling relatively hard easy
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Grinding mill type
grouping 1 grouping 2 grouping 3 grouping 4 typical mill
non-media N/A N/A N/A colloid mill
type
roll mill
basket mill
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Grinding Media Comparison
media material density price major use [unsuitable] reason of impropriety remark
inexpensive
natrium glass 2.50 [ED paint] Na + ion
(\a/kg)
expensive
special glass 2.74 any product ----- ex. Hi-Bea
(\7~10a/kg)
expensive
zircon 3.85 any product ----- ex. ER120S
(\7~10a/kg)
very expensive
zirconia 6.05 any product -----
(\60~90a/kg)
expensive
steel 7.85 [light color product] contamination
(\7~10a/kg)
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Grinding media information
classification manufacturer/dealer product name particle size (nominal) component SG (tru) hardness
soda-lime PottersBallotini (Toshiba) GB501M 0.84 - 1.19 m/m SiO2 72%
glass Na2O 2.5 Mohs 6.5
K 2O 13.5
GB502M 1.00 - 1.41
CaO 9 (ap.1.5) Vickers 570
GB503M 1.41 - 2.00 MgO 3.5
Al2O3 2
Nippon Fine Particle 0.7 m/m 0.71 - 0.87 m/m SiO2 72.4
Glass / Asada Iron Works 1 0.84 - 1.03 Na2O 13.9 2.5 Mohs 6.5
1 - 1.25 1.03 - 1.27 CaO 8
1.5 1.44 - 1.92 MgO 3.4 Vickers 570
2.0 1.92 - 2.50 Al2O3 0.9
3.0 2.36 - 3.35
special glass Ohara Hi-Bea D24 0.60 - 1.00 m/m SiO2 42-52
/ Morimura Bros.,Inc. Hi-Bea D20 0.80 - 1.20 Al2O3 13-23
Hi-Bea D16 1.10 - 1.50 CaO 10-25 2.74 Mohs 7
Hi-Bea D15 1.30 - 1.70 MgO 6-22
Hi-Bea D11 1.60 - 2.00 others (ap.1.68)
Hi-Bea D10 1.90 - 2.30 TiO2 ZrO2
B2O3
Bright Signage AlphaBeads0.3 0.3 - 0.5 m/m SiO2 55.1
/ Asada Iron Works AlphaBeads0.5 0.5 - 0.8 CaO 22.5
AlphaBeads0.8 0.8 - 1.0 Al2O3 13.5 Mohs 7
AlphaBeads1.0 1.0 - 1.3 B2O3 6.7 2.6
AlphaBeads1.3 1.3 - 1.5 MgO 1.0 Vickers 534
AlphaBeads1.5 1.5 - 1.7 K 2O 0.4
Na2O 0.3
zircon Sepr ER120S 0.6 0.6 - 0.8 m/m ZrO2 68
ER120S 0.8 0.8 - 1.0 SiO2 31 3.8 Mohs 7
ER120S 1.0 1.0 - 1.25 others
ER120S 1.25 1.25 - 1.6 Al2O3 (ap 2.3) Vickers 750
ER120S 1.6 1.6 - 2.0 Fe2O3
ER120S 2.0 2.0 -2.5 TiO2
zirconia /Asada Iron Works 0.5 m/m 0.35 - 0.65 ZrO2 >99
(zirconium 0.8 0.65 - 0.95 SiO2 0.44 6.05 Mohs 8
oxide) 1.0 0.8 - 1.2
1.25 1.05 - 1.45 (ap.3.75) Vickers 1250
1.5 1.3 - 1.7
2.0 1.8 - 2.2
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Preparation of PWS for good observance
3.Revision of PWS
As a result of monitoring the first batch making, if there were points which were inappropriate
instructions, able to implement but difficult to observe or gap between instruction and actual result
is too wide, these points are necessary to revise the PWS by the time of making the second batch.
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And it is necessary to generate a hard copy of suitable PWS for batch making.
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Grinding
Premix
1)selection of ingredients for premix
-resin
select suitable resins within the formula for grinding (some resins are not suitable for grinding)
If resins not suitable for grinding are used, just after grinding looks OK,
but storage stability might be poor , for example.
-additive
consider purpose of additives
(need to be charged at premix or after-mix for not to ruin an effect of the additive)
-solvent
generally, low flash point solvent is not suitable to add at premix stage
Grinding
1)mill type
-sand grind mill /ball mill / others
-vertical mill / horizontal mill
-open type / closed type
2)grinding method
-pass/circulation
3)media
-type/material
-diameter
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-charging amount/ratio
4)grinding condition
-flow rate (residence time)
-paste temperature
-cooling water temperature
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Instruction items on PWS/BT (Grinding)
(ipc=in-process check item)
1.Pre-mixing
1)tank size (volume, diameter/tank #) ---*
2)agitator (HP, type of impeller, diameter of impeller/agitator #) ---*
3)charging (order, speed, under/without agitation, RPM, mixing time, position of impeller, etc.)
4)type and amount of solvent for rinsing tank
5)mixing time/RPM after charging all the ingredients
ipc: viscosity, (S.G.)
*:equipment (tank/agitator) # is enough if it is able to specify the conditions shown above
are fixed by the equipment #.
Instruct the RPM for mixing if mixer has variable speed.
2.Grinding
1)mill type, size/mill #
2)method (pass, # of pass, Cans)
3)media(type, diameter, charging amount)
4)flow rate
5)temperature
6)discharge amount before start grinding
7)type and amount of material to squeeze the mill after grinding
8)with or without agitation during grinding, method
9)method of cleaning mill after grinding (type of solvent, method)
ipc: fineness, viscosity, (S.G.)
3.Let down
1)tank size (volume, diameter/tank #) ---*
2)agitator (HP, type of impeller, diameter of impeller/agitator #) ---*
3)charging (order, speed, under/without agitation, RPM, mixing time, position of impeller, etc.)
4)mixing time/RPM after charging all the ingredients
ipc: viscosity, (S.G.)
*:equipment (tank/agitator) # is enough if it is able to specify the conditions shown above are
fixed by the equipment #.
Instruct the RPM for mixing if mixer has variable speed.
4.Filtration
1)type of filter, size (mesh/microns)
5.Filling/Packing
1)discharge amount before start filling
2)circulation method, root and time before start filling
3)dirt check method before start filling
4)crater check method
5)filling container
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6)filling unit (Kg/L/cc etc.)
7)filling weight
8)indication on label, sticker, lot etc.
9)required sample (retain/inspection/technical/customer/others)
10)container type/size for each sample
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Process control (Grinding process)
1. Premix
1)Fixed formula and operating condition for premix
Especially, be careful about rinsing solvent.
Rinsing solvent should be utilized from the materials in premix formula.
(Premix formula should be fixed including rinsing solvent for premix process)
{material/quantity for rinsing}
2)Premix viscosity
Check the viscosity of mixture at the end of premix process.
Confirm premix viscosity is as usual.
*If not, investigate cause of unusual.
2. Grinding
1)Drain the remained materil inside of the mill.
3)Initial discharge
Discharge required quantity of initial coming out material from the mill
according to the instruction, if required.
{discharge quantity of first coming out material from the mill}
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After adjusting the flow rate, wait for more than residence time of the flow rate,
then check the fineness.
*If you check the fineness too early (less than residence time of the flow rate
after adjusting the flow rate), then you will misjudge the fineness.
If the fineness is not within required range, then adjust the flow rate within the
given/required range of the flow rate.
If you cannot achieve the fineness within the required flow rate range, do not adjust
the flow rate out of required range nor run more than required number of passes
to achieve the required fineness.
[Circulation method]
After adjusting the flow rate to the required range, then grind for required grinding time.
After the required grinding time, check the fineness.
If you cannot achieve the fineness within the required grinding time range, do not
extend the grinding time to achieve the required fineness.
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{material/quantity for flush}
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Grinding Media Control
Maintain amount of grinding media is one of important items to be controlled for grinding process.
If you have enough data to determine the additional media and timing for a grinding mill, then you may set a SOP
for media control for a mill according to the data.
If you don't, then following procedure may be one of practical method to control grinding media.
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Dispose of small size of media.
Keep media caught on the sieve, and utilize for additional mentioned at item 2.
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PRODUCT: BLACK DISPERSION S FORMULACDS0005T-01DATE ENT: DATE DUE: BATCH SIZE: 220 GAL INCHARGE:
SEQ NO: LOT NO: OBT #:CDS0005T-01-01 CONTAINER: SIGN: PAGE: 1/1
GROSS WEIGHT:
NET WEIGHT:
APPROVALS
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GRAND TOTAL FACTOR=33.2
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PRODUCT: BLACK PASTE-2 FORMULATS0005T-01DATE ENT: DATE DUE: BATCH SIZE: 220 GAL INCHARGE:
SEQ NO: LOT NO: OBT #: TS0005T-01-07
CONTAINER: SIGN: PAGE: 1/1
[FILL IN DRUM]
AFTER QC OK'D THE DIRT CHECK, PROCEED
WITH FILLING.
[FILL IN TOTE]
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AFTER QC OK'D THE DIRT AND CRATER
CHECK,PROCEED WITH FILLING. APPROVALS
GRAND TOTAL
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[Example of Stationary Equipment List]
DISSOLVER #10 125 HP+30HP INOUE(HSD) 2ND FL WITH INOUE MIXER PRE-MIX
DYNO MILL # 5 45 L CB MILLS 1ST FL PRIMER AREA OP-5,BIG BATCH WHITE TINT
DYNO MILL # 6 45 L CB MILLS 1ST FL PRIMER AREA OP-5,BIG BATCH WHITE TINT
DYNO MILL # 7 25 L CB MILLS 1ST FL W/B AREA W/B DARK COLOR TINTS
DYNO MILL # 9 45 L CB MILLS 1ST FL PRIMER AREA S/B BLACK, DARK COLOR TINTS
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K DISSOLVER #19 750 GAL HOCKMEYER 2ND FL TBD
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[Example of Portable Equipment List]
PORTABLE POTS
POT NAMED MAX.VOLM STD.VOLM JACKETED/ TARE WT.
NO. SIZE 6" FM TOP 8" FM TOP NON JCKTD WITH LIDS REMARK
1 85G 91GAL 84GAL J FOR KONEL
2 85G 91GAL 84GAL J FOR KONEL
3 160G 146GAL 134GAL NJ
4 160G 146GAL 134GAL NJ
5 160G 146GAL 134GAL J
6 160G 146GAL 134GAL J
7 240G 224GAL 208GAL NJ 626
8 240G 224GAL 208GAL NJ 626
9 240G 224GAL 208GAL NJ 626
10 240G 224GAL 208GAL NJ 626
11 240G 224GAL 208GAL NJ 626
12 240G 224GAL 208GAL J
13 240G 224GAL 208GAL NJ 626
14 240G 224GAL 208GAL J
15 105G 83GAL 78GAL NJ
16 105G 83GAL 78GAL NJ
17 58G 48GAL 45GAL NJ
18 58G 48GAL 45GAL NJ
19 240G 224GAL 208GAL NJ
20 240G 224GAL 208GAL NJ
21 240G 224GAL 208GAL NJ
22 240G 224GAL 208GAL NJ
23 240G 224GAL 208GAL NJ
24 240G 224GAL 208GAL NJ
25 240G 224GAL 208GAL NJ
26 240G 224GAL 208GAL NJ
27 240G 224GAL 208GAL NJ
28 240G 224GAL 208GAL NJ
29 58G 48GAL 45GAL NJ
30 58G 48GAL 45GAL NJ
31 105G 83GAL 78GAL NJ
32 105G 83GAL 78GAL NJ
33 58G 48GAL 45GAL NJ
34 58G 48GAL 45GAL NJ
35 240G 224GAL 208GAL NJ
36 240G 224GAL 208GAL NJ
37 240G 224GAL 208GAL NJ
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38 240G 224GAL 208GAL NJ
39 240G 224GAL 208GAL NJ
40
33/48
[Example of Production Capacity List]
PRODUCTION CAPACITY
PRODUCT # OF PRODUCTION CAPACITY(G/M)TOTAL
LINE EQUIPMENTS EQIP MAIN PRODUCTS G/BXB/DYXBCH/MNTH CAPACITY
5L DYNO MILL 1
10HP DISSOLVER 1
10HP DISSOLVER 1
10HP DISSOLVER 1
10HP DISSOLVER 2
750G RT 1
45L DYNOMIL 3
3000G TT 1
TOTAL 48360G/M
58G POT 2
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[Example]
present
Group c
Group e
Group b
Group d
Group a
Group f
previous
Group a A B B C C D
Group b B A B C D E
Group c B B A C D D
Group d C C C A C C
Group e C D D D A E
Group f E D D C E A
Cleaning method
A: not required (unnecessary)
B: [previous solvent 60kgX10min]+[present solvent 60kgX10min]
C: [previous solvent 60kgX10min]+[present solvent 60kgX10min]Xtwice
D: method "B" + exchange media
E: prohibited
Product group
a:
b:
c:
d:
e:
f:
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First Lot Control Process Flow Chart
Production Prdctn Planning Purchasing QC Engineering / QC Technical Sales & Marketing Customer
Design Review
-review transferred
materials
-check DR List
-Pre Lab Test
RM QA
Extract Q-KY
items
Discuss
N Need to revise Y
Formulation
Sheet
issue PWS/BT
PWS/BT preparation
QC Check Y
First Lot Product
OK?
Monitor First Lot First Lot
Y,N line trial line trial
Need to take
N measures for
next batch?
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A
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To : Technical
From :
CC : Sales & Marketing
Date: 11-14-1997
We would like to implement First Batch Control Procedures for both finished products and
intermediates. We suggest that following the systematic approach already in place at the Aichi
Plant (NPC) may be a good strategy.
Key elements of that approach include:
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After this, if everything is OK, then formula is released for Regular Batch Production.
Please share with us your thoughts on this important subject.
c.f.: Definition of the First Batch is not only new products but also include formula change.
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REQUIRED MATERIALS WHEN TRANSFER FORMULATION AS A PRODUCTION BATCH
MATERIALS TO BE OBTAINED
FROM TECH. PRELIMINARY ITEMS TO BE CHECKED OR CONFIRMED BY QC REMARK
1 FORMULATION SHEET (1),(2) a:Check easy or careless mistakes.(ex. miswriting, forget to fill a box, etc.) Do not react by oral information.
b:Is there any particular reason for the procedure shown on "Production Always get official "Formulation Sheet
procedure" box? (1),(2)".
c:Are QC check items , spec range and frequency reasonable? Have any questions or unclear points,
d:Are test methods clear for QC? ask and discuss with Tech.
e: Etc.
2 STANDARD PANEL a:Is the formula of the sample ,which the standard panel was made, the same If not, discuss with Tech. to resolve the
formula with the "Formulation Sheet (1)" ? problems before start batch making.
b:Is the panel making condition ,which standard panel was made, the same with
shown on the "Formulation Sheet"s?
3 STANDARD LAB SAMPLE & a:Is the formula of the standard lab sample the same formula with the a,c,d,e:If not, discuss with Tech. to
EVALUATION RESULT DATA "Formulation Sheet (1)"? resolve the problems(ex.change spec
b:When was the sample made? range etc.) before start batch making.
c:Are all the items on the "Formulation Sheet (2)" tested by Tech. and are the
results all in spec ?
d:Are the test result run by QC using standard lab sample meet the specs shown
b:Are the panel making conditions the same with on the "Formulation sheet"s ?
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c:Are the visual evaluation results of the panels match with the data and meet
specs ?
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Production Preparation Meeting Check List Date of Meeting: Filled in by:
Name of Product:
*Mark one of the box for the each item on the right columns whether each item below decided/ need to be
is decided/confirmed and recorded on a copy board at the meeting or not confirmed checked
1. Outline of the product
(1) Who is the customer, where to ship, apply for what
(2) Demand forecast
(3) Schedule after the first trial at the customer (if any)
2. Key points of Quality
(1) Securement of sales/strong points
1) Condition of production process
2) Properties of Quality
(2) Result of line/field trial with the product/sample made by technical (if any)
(3) Weak points and those countermeasures
(4) Confirmation of quality data including color (technical sample, QC pre lab sample)
3.Procurement of Raw Materials
(1) Confirmation of new raw materials. (Internal material codes are determined?)
(2) Raw materials whose consumption changes drastically
(3) Raw materials whose lead time for procurement are long
(4) Confirmation of stock/inventory of raw materials (availability of R.M.)
4.Formula, Standard panel, Standard sample
(1) Date of determination of the formula
Whether product name is agreed with the customer or not (If IU product)
Whether internal product code is determined or not
(2) Is there any difference between transferred formula and sample making formula
If any, what is the reason?
(3) Is standard panel approved by the customer? (If IU product)
(4) When is the date able to obtain the standard panel?
5.Production schedule for the First Batch
(1) The date of formula and other standards transfer from tech to production (QC)
The date of registration to the system and the issuance of the PWS
(2) How much is ordered quantity from the customer? (Confirm order entry)
(3) How much is the minimum quantity for the first batch? (batch size for the 1st batch)
(4) The date of availability of raw materials
(5) The date of start and completion of the first batch
(6) The date of QC inspection and shipment
(7) The date of availability of line/field test result of the first batch
6.Production schedule for the Second Batch
(1) The process/method for the second batch by the shortest process time of the batch
The date of start and completion of the second batch
*start date of the 2nd batch should be immediately after getting the 1st batch result
(2) Batch size for the second batch
7.Actions for Inspection
(1) Whether submission of Certificate of Analysis to the customer is required or not
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(2) What are the items for COA?
(3) Due date of COA submission to the customer (especially for the first batch)
8.Osolete product
(1) Is there any product become obsolete due to this product?
(2) How to treat stock product which become obsolete?
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AB (Abstract) card
2. Viewpoints
How detail you describe on AB card need to be considered.
Some viewpoints are as follows;
1)Even the person him/herself who prepared the AB card will forget the detail what actually
done after 2 - 3 months later.
Prepare AB card detail enough for the person who prepared the AB card can remind later
what actually done.
2)Normally, AB card is reported to the boss of who prepared AB card.
The boss is not familiar in detail as a person in charge.
Prepare AB card detail enough even the boss can comprehend what actually done.
3)If the others want to duplicate the experiment, they need detail procedure/information
for duplication.
Prepare AB card detail enough for others can duplicate the experiment.
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3. Structure
Meaning or what need to be described on each item is as follows;
S Q: Summary & conclusion
Describe summary of the AB card including conclusion.
*Not the title of the AB card.
B P T: Background, situation.
Describe the background/situation why this experiment/investigation etc.
is required/necessary.
H P: Assumption, hypothesis
Describe assumption/hypothesis or strategy of procedure or point of confirmation
through the experiment.
D D: Criteria
Describe criteria of success/failure of assumption/hypothesis described at "P".
*Tendency of human nature is make judgment success or failure after knowing
the result of the experiment.
But it is important to determine the criteria of success/failure beforehand.
R O: Result/data
Describe the result/data of the experiment.
I Q-O: Consideration
Describe the consideration through the experiment.
ex. Why succeeded/failed.
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Remained issues.
Strategy/"P" for next experiment. (if the result is not satisfactory)
4. Additional benefit
Logical thinking is essential to technical related activities such as
investigating causes of problem, designing new formula, revising formula, etc.
To prepare AB card will be good training to think matters logically.
*Not only successful result, but also failure result is also important for others
in the future.
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Example of Abstract Card
Q: Using ceramic beads for grinding Nax Acrylic 320#202 Super Black couldn't shorten the grinding
time from current grinding time using glass beads.
P T: To grind Nax Acrylic 320#202 Super Black taking 3-4 passes at production using glass beads
as grinding media.
To improve grinding efficiency, according to the mill manufacture, it is hard to increase
apparent filling ratio of media from 50% (current condition) to 70% with our operating
condition which is not having chiller system.
Need to study the way of improving grinding efficiency by other methods.
P: To confirm whether using ceramic beads as grinding media, with the same apparent filling ratio
with glass beads, is able to improve grinding efficiency or not.
A&I: Using the same with current premix formula of Nax Acrylic 320#202 Super Black,
grind a premix sample with glass beads and ceramic beads individually,
and see whether grinding time by ceramic beads is faster than by glass beads.
D: grinding speed to achieve fineness<=10 microns: ceramic media<=80% grinding time of glass beads
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O: Sample1 sample2
Premix Visc KU 76 77
SG 0.95 0.95
Grinding FN/tmp 20min >100 microns/48C >100 microns/40C
40min 80 microns/40C 80 microns/41C
60min 65 microns/42C 65 microns/43C
80min 50 microns/40C 50 microns/43C
100min 40 microns/42C 40 microns/43C
Visc KU N/A N/A
SG N/A N/A
Q-O: There was no difference in grinding speed using glass beads/ceramic beads.
It would appear that viscosity of premix paste is too low to show the difference on grinding
time.
Change the premix formula to increase viscosity of premix paste, then compare the grinding
time with current premix formula whether increasing premix viscosity can shorten the grinding
time than current or not.
48/48