A member of the Wire Association International, Inc. since 1972.                           A lifetime member since 2004.
Once a process is optimized and judged acceptable, repeatability becomes the key. This is achieved by a combination of process manuals , process recipes, effective employee training, and by verification with a good reporting system.
A Stranded Copper Conductor
Process manuals are multi-page, drawing and text booklets and are written for the machine operators. Each production machine generally has its own a process manual and each manual is stored at the operators' workstation. There are some exceptions. Each of the manuals covers the basic issues universal to each production machine and to all of the products manufactured on it or to all of the like-of-kind groups of products manufactured on it. The items covered in the process manual include but are not limited to: Controls and machine familiarization. Machine emergencies. How to set the machine up. How to start the machine. How to stop the machine. How to clean the machine at shut down. Complex slave machines such as high-speed ring markers or gravimetric mixers may have their own process manuals at the same operators' workstation. All process manuals appropriate to the machine are kept at each machine and are generally included in the ISO 9000 program so that your customers are confident that your machine procedures are fully under control. All copies of the process manuals are then tightly managed by the ISO 9000 system. Process manuals however do not guarantee repeatability by themselves but the addition of proper employee training programs, great reporting systems and effective process recipes do.
            Bare Copper Wire (Note the bad wind on one reel.)
Concentric Neutral Power Cable
Process recipes replace the operators' "personal survival guide" which is also known as the back pocket black book. These recipes are specific to each product and to each production machine. They are also about one page in length. Typically, the items included in process recipes are much like the following: Vacuum pressure Steam temperature and pressure Dielectric test settings (Sparkers) Screw types Screw cooling settings Screen packs Melt temperature Melt pressure Lay plate string-up diagrams Binder direction, actual pitch and RPM Binder closing die size Die sizes and other tooling parameters Gradient cooling temperature settings Linear capstan pressure settings  Although they are generally appended to the process manual and thus the ISO 9000 program, process recipes can be kept in many different forms such as  sheets in loose leaf books at the production machines, in memory in a PLC or on a CD-ROM in a computerized production machine. They can also be stored  in a department supervisory computer or in an overall plant management and scheduling computer. The only fundamental requirements are that the recipes  be easily and reliably accessed by the production machine operator and that they be securely backed up in the event of a serious system failure.    
  Product description   Information Date   Actual product dimensions   Line speed   Rotation speed   Actual measured pitch (Length of lay)   Direction of pitch (Left or right pitch or lay)   Annealing current and voltage   Preheater settings and wire temperature   Drive gears and gearbox positions   Plastic blending and mixing settings   Barrel temperature profiles   Other temperature profiles   Dry cure tube temperature profiles   Nitrogen pressure
It is essential that all employees understand at least the basic definitions and manufacturing technology of an electrical wire and cable plant. They must also clearly understand the reasons why process manuals and recipes are indeed crucial to the company's good health and long term survival. The pictures below are PowerPoint® slides taken from an actual Stewart-Hay Associates training seminar.
Stewart-Hay Associates promotes and teaches advanced reporting techniques using Microsoft PowerPoint®graphics software on your local area network, Intranet or Internet. This provides instant understanding, instant updating, and dramatically reveals progress or trending on any particular issue or parameter. These slides contain the full back up data and perhaps for the very first time, combine the efforts of the process engineers, the product engineers, the plant or manufacturing engineers and the quality control department on an ongoing basis. The reporting technique can can also be extended to all other plant, division or head office departments such as sales, marketing, purchasing, human resources and operations. We at Stewart-Hay Associates would be pleased to help you develop or rebuild your process engineering group, your process manuals and, your process recipe system or systems. We would also be pleased to present basic manufacturing training seminars to your staff and to set up advanced reporting systems for one or all of your departments. Please contact us to discuss your requirements in detail. All inquiries and transactions will be kept 100% confidential.  
Once we all are satisfied that the processes are stable, capable and repeatable we are halfway home on our journey to having fully optimized productivity. The second or sometimes parallel step is know as total machine control and we have have placed a short cut to those pages here.