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Plastics Chamber Regional Workshop

Plastics Chamber Regional Workshop. Plastics Chamber, merSETA Version – 30 April 2011. General industry value chain. Introduction to the value chains. Why do we use value chains?. Identify each point in the manufacturing process where value is added

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Plastics Chamber Regional Workshop

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  1. Plastics Chamber Regional Workshop Plastics Chamber, merSETA Version – 30 April 2011

  2. Plastics Chamber Regional Workshops – Ver. 2011-05-18

  3. General industry value chain Introduction to the value chains Plastics Chamber Regional Workshops – Ver. 2011-05-18

  4. Why do we use value chains? • Identify each point in the manufacturing process where value is added • Each node in the value chain generally has work attached to it • A job • The job must deliver a product or a service • Requires skills • Requires training – formal and informal Plastics Chamber Regional Workshops – Ver. 2011-05-18

  5. Purpose of the workshop Find agreement on what are the industry value chains What are the jobs? Where do the quality issues arise? Where are the skills gaps Can we address these through training? Plastics Chamber Regional Workshops – Ver. 2011-05-18

  6. Based on this we can then confirm and refine current information • We have a common starting point • We can get agreement on where the priorities lie • We can link jobs to OFO codes • We can make it easier to complete WSPs • Improve the quality of information • The chamber can then more confidently • Develop projects, incentives, to address the skills gaps • Measure progress • Also would link to the future • New industrial strategies will generally involve plastics • Allow industry to take advantage and grow as a result Plastics Chamber Regional Workshops – Ver. 2011-05-18

  7. Overview of industry and where it fits in High level value chains Plastics Chamber Regional Workshops – Ver. 2011-05-18

  8. The full plastics life cycle Petrochemical industry Chemical industry Compounders Converters Customers Plastics Chamber Regional Workshops – Ver. 2011-05-18

  9. The generalised plastics value chain • Polymer compound-ing • Conversion Finishing • Assembly • Packing • Dispatch • Installing... • Conversion into complete components • Pigments • Additives • Fillers • Reinforcing agents • Processing aids • Foaming agents, gases… Compounds Masterbatches Expanded beads Pre-pregs… • Extrusion • Film • Sheet • Pipe • Profile • Coating • Laminating • Cable covering • Moulding • Injection • Blow • Injection-blow • Rotational • Compression • Thermoforming • Foaming • Casting • Laminating… Cutting Slitting Bending Machining Decorating Printing Trimming Conditioning Adding inserts fittings, accessories Cross-linking… Fabricating Joining Welding Gluing Clipping/snapping together Bolting … Plastics Chamber Regional Workshops – Ver. 2011-05-18

  10. Market-driven the value chain – the influence of the market on plastics manufacturing • Customer • Marketing • Consumer • Product design • End Use • Material develop- ment • Material design • Tooling design • Tooling mnf • Origination • (pre-press) • Graphic design • Polymer compound-ing • Conversion • Finishing • Assembly Plastics Chamber Regional Workshops – Ver. 2011-05-18

  11. Vary greatly from company to company Processes supporting the Plastics Value chain Plastics Chamber Regional Workshops – Ver. 2011-05-18

  12. Map 01 - Receiving, dispatch, logistics • 01 • Purchasing Managing • Storeman • 02 • Logistics Manager • 03 • Storeman Receiving Stores Stores Dispatch Conversion • 08 • Truck driver • Truck driver’s assistant • 05 • Picker • In-mould label clerk • 07 • Wand Scanner • Scale operator • 04 • Receiving clerk • 06 • Crane driver • Forklift operator • Tow motor driver Material reclamation Plastics Chamber Regional Workshops – Ver. 2011-05-18

  13. Map 02 Mould and tooling manufacture, repair and maintenance • 01 • Engineering manager • Tool room manager • 03 • Tool room supervisor/foreman • 04 • Metals • Tool maker • Electrician • Composites • Patternmaker Product design • 02 • Engineering analyst • Industrial designer • Product designer • Cost estimator 10 • Tool setter?? Tooling manufacture, repair Heat treatment Tooling design CAD/CAM Assembly Installation • 08 • Heat treatment operator • Composites • Post cure operator • See Map 09 Composites • 06 • CAD/CAM programmers • 05 • Draftsperson • 07 • Metals • Milling /turning operators • EDM / Sparking operators • Polishers • Tool maker’s assistant • Composites • Mould Builder • Mould repairer • see Map 09 Composites Disassembly cleaning • 09 • Metals • Toolmaker’s assistant • Composites • Mould cleaner /polishersee Map 09 Composites • Composites • Mould cleaner /polisher • Mould Builder • Mould repairer • Skills similar to/embedded in production process – see Map 09 Plastics Chamber Regional Workshops – Ver. 2011-05-18

  14. Map 03 - Printing, decorating, labelling • 01 • Printing manager • 02 • Artwork Controller Stores • 03 • Printing foreman • Trade printer • 04 • Quality controller • Inks • Blankets • Consumables Origination (Pre-press) Stores • 06 • Screen maker • Plate maker Printing Finishing Product finishing Graphic design • 09 • Finishing equipment operator • 08 • Printing machine minder Ink preparation • 05 • Graphic designer (Generally out-sourced) Drying varnishing • 07 • Ink mixer Flexo, litho, screen, pad printing Hot foiling Varnishing Labelling… Plastics Chamber Regional Workshops – Ver. 2011-05-18

  15. Map 04 - Quality Management • 01 • Quality Assurance Manager • Quality Assurance Supervisor • Internal Auditor • 03a • see Map 09 Composites, & • 10 -T-plastic Fabrication • Inspector - Pressure Vessels • Competent Person • Third Party Inspector Stores Acceptance testing Conversion Product checking Stores • 03 • Quality Inspector • Quality viewer/checker • 02 • Laboratory supervisor Laboratory testing • 04 • Laboratory technician Plastics Chamber Regional Workshops – Ver. 2011-05-18

  16. Map 05 - Polymer compounding • Production manager • Quality Assurance Manager • 01 • Compounding manager Product design Formulation • 02 • Chemist • Plastics or rubber technologist • Cost estimator • 03 • Compounding Supervisor Testing Material preparation Compounding Pelletising Packing Quality Stores • 06 • Packing assistant • 04 • Material mixer • 05 • Compounding operator Mixing Blending Pre-heating Plastics Chamber Regional Workshops – Ver. 2011-05-18

  17. Maintenance • Electrician • Electrician Assistant • Electronic/CNC/ Megatronic technician • Electrician Assistant • Fitters • Fitter’s Assistant • Riggers Technology • Plastics technologists • Plastician • Engineer • Engineering technologists • Engineering technician • Food technologist • Packaging technologist Procurement • Buyers • Supply chain managers Human Resources Management • HR, manager / specialist • SDF • HRD manager • Trainer • HRD administrator Firm infrastructure • Marketing • Export • Public relations • Sales • Finance • Administration • Management • Safety, Environment, Risk, Quality • Consumer Protection Plastics Chamber Regional Workshops – Ver. 2011-05-18

  18. Plastics manufacturing value chains Plastics Chamber Regional Workshops – Ver. 2011-05-18

  19. Map 06 - Packaging conversion (volume production, longer runs) • Production manager • 01 • Operations manager • Production manager • Production planner • 02 • Production supervisor • Team/cell/gap leader • Machine setter • Mould changer • 03 • Finishing supervisor Material preparation Conversion Printingdecorating Finishing Quality Stores • 06 • Finishing equipment operator • Barcode labeller • Palletiser • 04 • Raw Material mixer • 05 • Production operator/packer Material reclamation 07 Granulator operator • Film blowing • Cast film • Moulding • Injection • Blow • Injection/ stretch • Thermo-forming… Slitting trimming bag making laminating stretching, orientating assembly welding… Plastics Chamber Regional Workshops – Ver. 2011-05-18

  20. Map 07 - Engineering conversion (custom moulding, jobbing) • 01 • Production manager • 03 • Assembly supervisor • 04 • Finishing supervisor • 02 • Production supervisor • Machine setter Material preparation Conversion Assembly Finishing Stores Quality • 08 • Finishing equipment operator • 05 • Raw Material Mixer • 06 • Production operator • Packer • 07 • Assembly worker Material reclamation • 09 • Granulator operator • Moulding • Injection • Blow • Injection/ stretch • Thermo-forming • Roto • Compression • Extrusion • Pipe/profile • Sheet • Cable / wire • Pultrusion • Filament winding Trimming Drilling Machining Grinding Marking Conditioning Annealing Post-curing … Mixing Blending … Plastics Chamber Regional Workshops – Ver. 2011-05-18

  21. Map 08- Industrial rubber conversion • 01 • Production manager • 02 • Production supervisor • Machine setter • 03 • Assembly supervisor • 04 • Finishing supervisor Material preparation Conversion Assembly Finishing Stores Quality • 05 • Raw material mixer • Assistant mixer • 06 • Production operator/packer • 07 • Assembly worker • 08 • Finishing equipment operator Material reclamation • 09 • Grinder operator Mixing Milling Compounding • Moulding • Injection • Compression • Extrusion • Tube/ pipe/profile • Sheet • Cable / wire Fabricating Joining Welding Gluing Clipping/snapping together Bolting… Trimming Drilling Machining Grinding Marking Curing… Plastics Chamber Regional Workshops – Ver. 2011-05-18

  22. Map 09 - Polymer composites (GRP, FRP, advanced composites) • 01 • Production manager • 03 See Quality Map + • Inspector Pressure Vessels (Authorised Inspection Authority) • Competent person • Third party inspector Site installation • 02 • Workshop supervisor Reinforcement preparation Resin preparation Lay-up Cure Finishing Assembly Stores Quality Mould preparation • 07 • Assemblyworker • 06 • Finishing worker • Polisher • Grinder • Fairer • Spray painter • 04 • Laminator • 05 Specialisations of laminator • Material /glass cutter • Resin batcher • Mould repairer • Mould Polisher / Release applicator • Gel coater Attaching Gluing Screwing / bolting Laminating Installing of components… Trimming Drilling Machining Grinding Marking Post-curing… Cutting Mixing Cleaning & polishing Room temperature cure Autoclave Hand lay up Spray up Vacuum-bagging … Plastics Chamber Regional Workshops – Ver. 2011-05-18

  23. Map 10 - Thermoplastic Fabrication • 03 See Quality Map + • Inspector Pressure Vessels (Authorised Inspection Authority) • Competent person • Third party inspector • 01 • Production manager • 02 • Workshop supervisor Material preparation Fabrication Finishing Assembly Quality Check Logistics Installation Component preparation • Assemblyworker • Finishingworker • Welder • (Assistant) Joining Bolting Bonding Clipping together, … Marking Cutting Preheating… Trimming Drilling Machining Grinding… Welding Bonding… Plastics Chamber Regional Workshops – Ver. 2011-05-18

  24. Map 11- Installation, repair and maintenance • 01 • Construction supervisor Servicing & Repair Site preparation Installation Commission-ing Handover • 03 • Fitter • Engineering Technician • Laminator • Welder • QC Inspector 02 Generally out-sourced • 03 • Fitter • Engineering Technician • Laminator • Welder • QC Inspector Digging Levelling Barricading Scaffolding.. Erecting Testing Connecting … Bringing on-line Stress testing… Training Developing SOPs … Plastics Chamber Regional Workshops – Ver. 2011-05-18

  25. Map 12 –Recycling Post-consumer • 01 • Production manager Collection • 02 • Collection agent • Collector • Sorter/segregator • 03 • Production supervisor Material reclamation Packing Quality Check Stores Material preparation Compounding Pelletising • 05 • Extrusion operator • 04 • Equipment operator • 06 • Packer Shredding Washing Drying Collection Post conversion • 07 • Sorter/segregator Plastics Chamber Regional Workshops – Ver. 2011-05-18

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