Pneumatic Fender is a form of shock-absorbing cushion specially developed and applied to wharf collisions for submarines and some ships in contact with the cushion below sea level.

75 Rubber One member Company Limited (Z175) has successfully researched and manufactured Pneumatic Fender designed in accordance with ISO 17357:2002(E). The product has a circular cylindrical profile, an inflatable compartment in the middle, a hemisphere at both ends, and the buoyancy and characteristics of the mattress can be adjusted.

Pneumatic Fender has many advantages compared to other types of anti-collision fender such as:

• The buoyancy can be easily adjusted, so the point of contact between the Pneumatic Fender and the vessel can be changed. Can be disassembled and moved on the water, so the process of use is very flexible. The maintenance of the mattress during use is simple. Can be disassembled and moved on the water, so the process of use is very flexible. The maintenance of the Pneumatic Fender during use is simple.

Installation pictures Pneumatic Fender

• In addition, the Pneumatic Fender has the ability to absorb large amounts of energy, and the compressive reaction is small. The mattress has good weather resistance, good resistance to tropical marine environments.

The basic structure of a Pneumatic Fender consists of an outer layer of rubber that is resistant to the environment and sea water, in the middle, there are layers of reinforcement and an inner layer of rubber with high air permeability. The rubber layers and the reinforcement layer are closely linked together into a unified block to create durability for the Pneumatic Fender.

* Pneumatic Fender Specifications Ф2000×4000

– Working conditions: Impact resistant, stable in sea water environment.

– Working temperature: 0-60⁰C.

– Specifications:

(Table 1:Pneumatic Fender Specifications Ф2000×4000)

*About the outer rubber layer

The rubber layer of the Pneumatic Fender is made of synthetic rubber material, with high mechanical and physical properties, good environmental resistance, and good sea water resistance. The mechanical and physical properties of the rubber layer are according to Table 2.

(Table 2: Mechanical and mechanical properties of the outer rubber layer)

The image of a Pneumatic Fender is completed at the manufacturer of 75 . Rubber One Member Co., Ltd

A rubber conveyor belt driving station is usually structured and driven as follows:

• The rubber conveyor belt is driven by a motor, through an external transmission set
• Belt transmission set: The belt is connected through the small pulley to the large pulley, through the reducer.
• The reducer and coupling connect to the drum.

Here, the rubber conveyor belt is connected to two guide drums:

• Active and Passive drum.
• Because the distance between the two drums is quite far, the belt is put on the supporting roller on the machine stand. The belt tensioner (screw 1) must ensure enough friction between the belt and the drum to prevent the belt from overlapping when loading the material.

CONVEYOR BELTS DRIVING SYSTEM’S CHARACTERISTICS:

• high transport capacity,
• continuous transport,
• a large distance and wide range of transport.

Can transport bulk materials or articles into bales applications such as:

coal conveyor belts,

cement conveyor belts,

soil and rock conveyor belts,

Rubber conveyor belts in beverage, tea, coffee, chemical, food industries�,

and single items such as bags, boxes, boxes, parcels … to meet each production line requirement.

Depending on the production conditions to decide whether to use a conveyor or a combination of multiple conveyors together with other conveyor equipment and automation equipment in production to improve productivity and reduce labor intensity.

On the other hand, the investment cost of manufacturing equipment and conveyors is not very large, on the basis of simple structure and not too much use of specialized and expensive special materials.

ADVANTAGES OF CONVEYOR BELT DRIVING SYSTEM:

• Simple structure, durable,
• Capable of transporting materials in horizontal, inclined (or a combination of both) over great distances,
• Quiet, low productivity.

DISADVANTAGES OF CONVEYOR BELT DRIVING SYSTEM:

• recommended to run at medium speed â€?not high,
• Small inclination ( < 240 )
• Cannot be transported in the direction of the curve (need extra motor and frame to change direction)

WORKING CHARACTERISTICS OF CONVEYOR BELTS:

• The device continuously rests on the roller, so it must regularly check and maintain the roller.
• working thanks to the friction force between the belt surface and the guide drum-roller
• Can transport bulk goods such as sand, crushed stone, coal from the wharf to the ship, barge

Some figures of new rubber conveyor belt production lines invested and put into production

EFFECTIVENESS OF KAIZEN-5S PROGRAM IMPLEMENTATION
AT 75 RUBBER COMPANY LIMITED (Z175 FACTORY)
Colonel, MSc. Phan Chien Thang
Director of the company

The application of innovative tools to improve productivity, create quality products, reasonable prices, and meet the needs of customers is an urgent requirement of businesses. Therefore, over the past time, Z175 Factory, the General Department of Military Industries and Manufacture has applied the Kaizen -5S Quality Improvement Program and it has brought practical results.

Lieutenant General Nguyen Manh Hung – Political Commissar of the General Department of Military Industries and Manufacture visited and worked at Factory Z175

5S Principle is a method and model applied in businesses with the purpose of creating a clean, scientific, neat and convenient environment when using. Kaizen is a philosophy applied to promote continuous improvement activities in personal life, family, society and even working environment. When applying Kaizen in the working environment, it means continuous improvement related to everyone, from leaders and commanders to officers and employees. Every member of the organization is encouraged to make even the smallest improvements in their work to increase productivity and reduce operation costs.

Founding the effectiveness of the Kaizen-5S program in the production and business process, in October 2016, Z175 Factory cooperated with the Vietnam Productivity Institute to organize training classes and implementing practical application of 5S into the production and business processes of the Factory. In the initial period of application, the factory encountered many difficulties, such as: infrastructure, environment is not really guaranteed; machinery and equipment have not been rationally and scientifically arranged; working tools are still untidy and hard to find; the electrical system is entangled, not easily identifiable; the workshop area is difficult to clean, the lighting and ventilation system is still inadequate; documents of departments and divisions are still confused, difficult to find�Besides, the awareness of officials and employees about 5S practice is not complete, there are also thoughts of being afraid of changing.

Aware of the advantages and disadvantages, the Party Committee and Board of Directors of Z175 Factory have proposed many solutions to implement the 5S program with the spirit of “change for development”. Initially, the factory held a ceremony to deploy 5S practice program, general cleaning of the working area. Next, establishing a 5S Committee to supervise the implementation; directing departments and workshops to make the implementation plan. Organizing a contest to write slogans applying the 5S Program, in order to improve the initiative, creativity, awareness and responsibility of all officers and employees in the factory. Through the contest, there were more than 200 slogans about 5S program practice drawn from the process of labor and creativity of officials and employees. On the other hand, the factory actively researched, rearranged the system of equipment – device, machinery, technology premises, rationalized production; renovating and upgrading factories, creating a cool, green, clean and beautiful working environment landscape.

Determining that product quality is the survival of the Factory, the association of 5S with Kaizen is the foundation for all improvement activities to improve productivity and product quality and production and business efficiency. In October 2018, the factory continued to coordinate with the consultant to apply the 5S Program in combination with Kaizen into the production and business process. Launching organization of the Kaizen-5S Program. Establishing the Factory’s CI and Kaizen team; at the same time, directing the Kaizen team to develop a plan to open Kaizen at the center of each production line; mobilizing officials and employees to focus on improving technology, machinery and equipment, automation, waste reduction, productivity improvement and product quality. The Factory’s 5S Committee regularly inspects, evaluates, scores each department, rewards and punishes severely, puts the performance results of the collective, the commanders of the departments, and workshops into the emulation targets and factory salary regulations.

Over a period of time implementing the Kaizen-5S Program, the factory has achieved outstanding results, gradually promoting production capacity, improving competitiveness and occupying the market; creating a basis for the factory to develop a technology investment strategy, effectively exploiting equipment and machinery, linking research into new materials and new products, material technology with product technology, new technology with traditional technology. In which, the factory has well performed 03 key Kaizens (conveyor production lines, spare parts production, rubber processing) of CI group, which has completed 7/8 of the goals on the production lines. For example, a rubber conveyor belt production line, after implementing the Kaizen Program, the output increased 1.8 times, the cost of materials on average volume = 3%; reducing time by �6 minutes/batch; increasing OEE by �6%; grade-I product quality increased to �90%; energy consumption can be measured, the number of workers on the line is reduced by �10%; average income of workers on the line increased by �5%. The number of Kaizen of officials and employees applied to production is 420 people. Labor productivity increased on average 1.5 times on the lines. The rate of waste and quality has decreased sharply, many products have a waste rate of up to 0%. Consciousness and responsibility of officers and employees of the factory changed markedly. Along with that has created a clean, green and environmentally friendly industrial hygiene environment; The technology ground is arranged scientifically and conveniently. Every month, the main equipment of the line is evaluated for efficiency using the KPI tool expressed through the OEE index (operating efficiency of equipment). The results of working environment monitoring of Z175 Factory assessed by ETECH Company in 2019 are that the microclimate, light, noise, dust and toxic gas concentrations on the production lines meet the requirements in allowed limit. The psychophysiological index of workers at the beginning, middle and end of the shift is quite good.

Through the practical implementation of the application of the Kaizen-5S Program in production and business, Z175 Factory has drawn a number of learned lessons, which are:

Firstly, when implementing S1 (Sorting); S2 (Screening) it will discover many unreasonable points in production that need to be changed and improved and, at this time, it is appropriate to launch Kaizen in the whole unit. The combination of 5S implementation with Kaizen has created a support to promote the program faster and more practical. Currently, the factory is applying to spend 15 minutes per day, one day per month for 5S, one day every six months for general cleaning of the workplace.

Secondly, Kaizen – 5S system standards are the same, but each unit’s way of implementation may be different depending on the reality of each unit; therefore, before implementing the Kaizen-5S Program, it is necessary to assess the situation to apply accordingly so as to gain the high efficiency.

Thirdly, there is a need for drastic leadership and direction of the Party Committee, the Board of Directors, especially the head when implementing the Kaizen-5S Program. It is the reason that when applying Kaizen – 5S, it is to make changes, there will be risks, so it is necessary to take measures to manage and identify risks.

Fourth, regularly paying attention to the leadership and direction of adequate investment for the implementation of Kaizen – 5S; effectively maintaining the Kaizen- 5S practice management system which switch from self-discipline to form habit. Continuously seeking new ways of implementation, creatively applying advanced management tools to maintain and continuously improve, raising standards in management effectively, safely and minimizing waste.

Fifth, promoting scientific and technological creativity, initiatives and technical improvements in order to boost productivity, product quality and ensuring safety, giving priority to select to use chemical materials with a high environmental friendliness index. Doing well in preliminary work, summarizing, rewarding, building and replicating advanced examples. Promoting the role of mass organizations, creating emulation movements between departments.

It can be said that the implementation of the Kaizen-5S Program by Z175 Factory has really made a difference in all aspects, bringing the values of a clean, tidy and neat working environment; productivity and quality of technical rubber products are increasingly improved, equivalent to similar products in the region and the world, providing jobs and stable incomes for officials and employees of the Factory.

Since the implementation of the Kaizen-5S Program, the factory’s labor productivity has increased by 1.5 times on average. The rate of waste and quality has decreased sharply, with many products with the waste rate reduced to 0%

       Thoroughly grasping and strictly implementing directives and instructions of the Standing Party Committee of the General Department; Z175 Party Committee’s plan on organizing the Party Congress for the 2020-2025 term, Z175 Party Committee actively prepared reporting documents before the Congress to ensure strict, thorough, specific and timely data; selecting the governing body of the congress, the assisting committee and assigning the branches to prepare the opinions of the congress to ensure closeness and quality; paying attention to the propaganda, promotion and decoration of the Congress according to the instructions.

       At the Congress, the Party Committee summarized and assessed the leadership situation in implementing the Resolution of the Party Congress for the term of 2015-2020; determining the direction, goals, tasks and leadership solutions for the 2020-2025 term; reviewing the leadership of the Party Committee; discussing the formulation of the Resolution and the Action Plan to implement the Resolution of the Congress; promoting democracy, gathering wisdom to discuss, contributing ideas to the draft documents submitted to the 13th Party Congress and political reports submitted to the 10th Party Congress of the General Department of Military Industries and Manufacture.

       Speaking and directing the Congress, Major General Nguyen Dac Hai- Vice Chairman of the General Department highly appreciated the leadership role of the Party Committee for the 2015-2020 term, recognizing the achievements of the factory’s collective during the term which contributed to the overall achievement of the General Department’s Party Committee. At the same time, the task orientation of the Executive Committee of the Party Committee for the 2020-2025 term should clearly define specific directions and solutions in leading the performance of tasks in the next term.

      The objective of the research is to systematically study to improve the quality of 02 types of heat-resistant rubber conveyor belts, polyester mesh along with manufacturing and testing 2000 m long conveyor belts of all kinds to meet the new needs of the market.

(Following the implementation of topic content) Figure: Huu Tuyen

       With the experience of basic research and application orientation of the scientific employees, on the basis of the Z175 Factory’s achieved results so far, the topic systematically researched the influence of factors on materials as well as technology to improve the mechanical properties, adhesion and heat resistance of conveyor belts.

(Officers and workers of Z175 Factory participated in the project) Figure: Huu Tuyen

     The obtained research results show the influence of the proportion of rubber components in the blend, the processing oil content, the content of promoters, the anti-aging agent, the co-vulcanizing agent and the vulcanizing system on the properties of product. Although the nano/submicro-sized additives such as nano-silica, nano clay, fly ash, etc., do not significantly affect to the mechanical properties or adhesion to the core before aging, they change the thermal conductivity and improve the heat resistance of the product. The optimization of the components in the single mix has not only increased the mechanical properties, adhesion and resistance to thermal aging but also allowed to shorten the conveyor processing time, thereby making it possible to energy cost savings during actual production.

      The physical and mechanical strength of the fabricated rubber blends is more than 24.5 Mpa for tensile strength, elongation is more than 500%, adhesion to reinforcement is greater than 15d ± 15 and greater than 7.2 kgf./cm with polyester screen, together with aging coefficient reached in the range of 0.7 – 0.92 after aging 168 hours at 150⁰C.

         (Deploying the topic at project) Figure: Huu Tuyen

      However, the product of project is not only improving the existing quality of the conveyor belt but also most importantly, obtaining a data system that allows the company’s technical staff to adjust quickly and flexibly mechanical and thermal properties of the conveyor belt depending on customer requirements.

In the coming time, the research results will be widely applied in practice, meeting the needs of the market, increasing competitiveness with major brands in the world. Key application in the production of building materials (cement, iron and steel, bricks, etc.)

      The technology of manufacturing foam corrugated iron requires high precision and aesthetics, the indispensable technological equipment in the production line is corrugated iron conveyor belt �which is responsible for conveying corrugated iron through the PU foam injection system.

      Vietnam is one of the countries producing foam corrugated iron production lines and exporting to Thailand, Laos, Myanmar… with large quantities. However, there is no partner in the country to produce corrugated iron conveyor belts, the businesses have to import them from abroad for production and replacement. The importation has faced many difficulties due to the Covid-19 epidemic, slow progress and high cost, which greatly affecting to the production of enterprises.

Foam corrugated iron roller – Figure: Internet

Before that situation; 75 Rubber Company Limited (75 Rubber) has focused on successfully researching and developing corrugated iron conveyor belts of foam corrugated iron roller, replacing imported goods, actively meeting domestic and export demands.

       Producing foam corrugated iron roller conveyor belts at 75 Rubber

 After successfully manufacturing the rubber conveyor belt of the foam corrugated iron roller, the product is tested on the customer’s line. Highly appreciated by customers for the quality and design of products, it will be installed on the foam corrugated iron roller system to export to Thailand market. For that achievement, it is necessary to mention the determination of the company’s leaders, enthusiastic technical teams, skillful hands of the workers who have set a pioneering step in the country for foam corrugated iron roller rubber conveyor belt manufactured by 75 Rubber. It promises to continuously develop to make the product more and more perfect.

Technical employees of 75 Rubber Company inspected installation on customer’s line

      Products manufactured according to standards ISO 9001: 2015

      In the future, 75 Rubber will continue to develop many new types according to the requirements of domestic and export customers.

Some figures of rubber conveyor belts of foam corrugated iron roller manufactured by 75 Rubber