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THE PROCESS OF MAKING TIRE
MANAGERIAL ACCOUNTINGBy: SECOUND GROUP
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Tire manufacturing included intothe costing process. Because it has the followingcharacteristics:
Processcostingisusedwhenasingleproductisproducedonacontinuingbasisorforalongperiodoftime.
Processcostingsystemsaccumulatecostsbydepartment.
Processcostingsystemsusedepartmentproductionreportstoaccumulatecosts.
Processcostingsystemscomputeunitcostsbydepartment.
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CostCategoriesinProcess
Costing
Processcostingsystemsseparate
costsintocostcategoriesaccording
towhencostsareintroducedintothe
process
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DirectMaterial
ConversionCost
Department
1
DirectMaterial
ConversionCost
Department
2
DirectMaterial
ConversionCost
Department
3
DirectMaterial
ConversionCost
Department
6
DirectMaterial
ConversionCost
Department
4
DirectMaterial
ConversionCost
Department
5
DirectMaterial
ConversionCost
Department
7
ConversionCost
Department
8
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- ANY LOCATION IN AN ORGANIZATION WHEREMATERIALS, LABOR OR OVERHEAD ARE ADDED TOTHE PRODUCT.- THE ACTIVITIES PERFORMED IN A PROCESSINGDEPARTMENT ARE PERFORMED UNIFORMLY ON ALLUNITS OF PRODUCTION. FURTHERMORE, THE OUTPUTOF A PROCESSING DEPARTMENT MUST BEHOMOGENEOUS.
Processing Department
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Manufacturing Process Tire plants are traditionally dividedinto eight departments that perform
specialoperations.
These usually act as independentfactorieswithinafactory.
Large tire makers may set up
independent factories on a singlesite, or cluster the factories locally
acrossaregion.
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The Materials Naturalrubber
Styrene-
butadieneco-polymer(SBR)
Polybutadiene
Halobutyl
CarbonBlack
Silica
Sulphur
VulcanizingAccelerators
Activators
Antioxidants and antiozonants
Textilefabric
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How a Tire Is Made
SBRubbercompoundwiththesechemicalsformulations:
SBRubber100kg
carbon22050kg
zincoxide2.5kg
staticacid1.5kg
accelerator1.2kg
Oil3.5kg
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1. Mixing / Banbury (Compounding andMixing) Compoundingistheoperationofbringingtogetheralltheingredientsrequiredtomixabatchofrubbercompound
Mixingistheprocessofapplyingmechanicalworktotheingredientsinordertoblendthemintoahomogeneoussubstance
Aftermixing,therubberchargeisdroppedintoachuteandfedbyanextrudingscrewintoarollerdie
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2. Extruding Mixingthedoughwasmade intoatreadandsidewall.Theprocessisthe
injectionandextrudingtoforma
profile.Theendresultofthisphaseisthesidewall,treadandfiller
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3. Calendar Calendersareusedtoproducebodypliesandbelts.
Thecalendarisasetofmultiplelarge-diameterrollsthatsqueezerubbercompoundintoathin
sheet,usuallyoftheorderof2metreswide.
Fabriccalendersproduceanupperandlowerrubbersheetwithalayeroffabricinbetween.Steelcalendersdosowithsteelcords.
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4. Bead Whilethecalenderisrunning,onthe
othersidethereisthemanufactureofthebeadwirewithrubbercoatedsteelwire.
Thisprocessrunsautomaticallyandonceoutofthemachine,beadwireiscircularinaccordancewiththesizeoftherim.
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5. Cutting ThiscuttingprocessisanadvancedprocessofmachineCalender.TheendresultofthisprocessiscommonlycalledthePlyandCapPly
PlyisasheetmaterialconsistingofPolyester,NylonandthecompoundwhichhadbeenpreviouslyprocessedintheformoflongrollsCalendarmachinewhichisthencuttochangedirectionorangleoftheyarnfrom0to90
CapPlyisasheetmaterialconsistingofNylonandthecompoundwhichiscutintoseveralpartsintheengine
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6. Building Tirebuildingistheprocessofassemblingallthecomponentsontoatirebuildingdrum
Theassemblyprocessconsistsoftwostages.Firstlyweprocessthecarcass.Second,addasteelbelt,capplyandtreadintoGT
Thisstageisperformedbyusingamachineoperatedbyanoperatoreachphase
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7. Curing Curingistheprocessofapplyingpressuretothegreentireinamoldinordertogiveititsfinalshape,andapplyingheatenergytostimulatethechemicalreactionbetweentherubberand
othermaterials GTresultedfromtheassemblyprocesssenttotheareaCuringtobecooked
ThereGTwillbeplacedinthe
moldinaccordancewiththedesiredtemperaturefortheproduction
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8. Finishing / Quality Control ControlsareperformedwiththeexaminationofbalanceandusingX-Ray
Inthefinalstep,tiresareinspectedbyhumaneyesfornumerousvisualdefectssuchasincompletemoldfill,exposedcords,blisters,blemishes,andothers
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