arjun_lam. wastage-nhc-april-2014 (5)

Parsons Nutritionals Pvt Ltd- Sahibabad

Parsons Nutritionals Pvt Ltd-Sahibabad 1

Team Arjun


SN Team Name of Quality circle team

1 Virender Singh Section Incharge Production-NHC

2 Amar Supervisior Production-NHC

3 Sumit Singh IPQI Production-NHC

4 Amit Kumar Lab attendent Laminate sampling

5 Vinod Singh Foreman Production-NHC

6 Vinod Kumar Operator Production-NHC

7 Pankaj Chaubey Operator Production-NHC

8 Ram Dayal Operator Production-NHC

9 Bablu Helper Production-NHC

10 Gudiya Helper Production-NHC

11 Farha Helper Weightment

12 Tara Wati Helper Production-NHC

13 Pradeep Devidi Helper Production-NHC

Introduction to Quality Circle-

Name of the Quality Circle : Arjuna

Department : Manufacturing

Circle Starting Date : April’ 2014

Meeting day : Every Monday

Meetings : 13

Average Attendance : 90%


4

1. Problem

Identification

2. Selection of problem

3. Define of problem

4. Analysis of the problem

5. Identification of cause

6. Find the root cause

8. Development of

solution

7. Data analysis

9.Foreseeing probable

resistance

10. Trail implementation

11. Regular

implementation

12. Review

DR. JURAN

12 Step Problem Solving Method-

Parsons Nutritionals Pvt Ltd-Sahibabad

Step 1

String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage test. Paper Shifting On Each Machine. Increased Laminate Wastage Due To Delimitation Of Roll From Inside. Increased Laminate Wastage Due To Damaged Core Of The Roll. Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting Of The Roll. Increased Laminate Wastage At The Time Of Roll Change Time. Increased Laminate Wastage Machine Setting. Increased Laminate Wastage After Change Over/ Wet Cleaning. Noise Of Vibrators. Increased Laminate Wastage Seal Powder, Leakage. Unclosed Cover Of Wraptech Machine. Holes In A.C Duct. Open Hole On The Wraptech Machine. Required Stands For The Tray. Unproper Wiring Of The Panel. Spillded Ink On The Nichrome Machine. Cover On The Wraptech Machine Wiring Tray.

Water Leakage From The Air cylinder Of The Wraptech Machine. Need To repaire The fioor of taping room. Uncontrolled Oven Temperature. Required Tube Light In QA Lab. Display Board Have To Be Repaired. Insided Transformer Of The Nichrome Machine Should Be Coverd. Required Door Mat At The Entrance Of Sechet Section & Filling Room. Adjoining Wire Of The Packing Table & Conveyer Should Be Covered. Flat Body Of The Metal Detector. Stopped Working Of The Emergency Stop OF The Wraptech Machine. Even In The Low Air Pressure Machine Don’t Stop Working. Wraptech Machine’s Farmer 'hole Have To Be Closed. Broken Light Cover Of The Sechet Packing Hall. Intercom Wire Should Be Placed In Pipe. Broken Light Cover Of The Filling Room & Taping Machine Room. The Problem Of Torned Laminate Roll In Running Machine. Untidy Cleaning Bay. Increased Laminate Wastage Due To Printing Cutting. Due To The Wrinkle At The Corner Of The Laminate Roll the Machine’s Photo Sensor Can’t Work That’s Why Increased Laminate Wastage. Need To Repair The Refrigerator Of Micro Lab. Broken Water Tap Pipe In Lab.

Step 2 Step 1

A B C

Involvement Of Team Member

Involvement Of Other Departments

Involvement Of Higher Management

SELECTION OF PROBLEMS ( A,B,C CATEGORY)

S.NO Problem Category 1 String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage test.

C

2 Paper Shifting On Each Machine A 3 Increased Laminate Wastage Due To Delamination Of Roll From Inside.

B

4 Increased Laminate Wastage Due To Damaged Core Of The Roll.

B

5 Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting Of The Roll.

B

6 Increased Laminate Wastage At The Time Of Roll Change Time.

A

7 Increased Laminate Wastage At The Time Of Machine Setting.

A

8 Increased Laminate Wastage After Change Over/ Wet Cleaning. A 9 Noise Of Vibrators.

C

10 .Increased Laminate Wastage Seal Powder, Leakage. A

S.NO PROBLEM CATAGORY

11 .Unclosed Cover Of Wraptech Machine.

B

12 .Holes In A.C Duct.

B

13 Open Hole On The Wraptech Machine.

B

14 Unproper Wiring Of The Panel.

B

15 Required Stands For The Tray. C

16 Spillded Ink On The Nichrome Machine.

A

17 Cover On The Wraptech Machine Wiring Tray.

B

18 Water Leakage From The Air cylinder Of The Wraptech Machine. A

19 Need To Prepare The Humidity Chamber In Lab.

B

20 Uncontrolled Oven Temperature Of Lab B


S.NO

PROBLEM

CATAGORY

21 .Required Tube Light In QA Lab.

B

22 Display Board Have To Be Repaired In Packing Hall Of Sechet Section. B

23 .Inside Transformer Of The Nichrome Machine Should Be Coverd.

B

24 Required Door Mat At The Entrance Of Sechet Section & Filling Room.

B

25 Adjoining Wire Of The Packing Table & Conveyer Should Be Covered. B

26 Flat Body Of The Metal Detector.

C

27 Stopped Working Of The Emergency Stop OF The Wraptech Machine. A

28 Even In The Low Air Pressure Machine Don’t Stop Working. B

29 Wraptech Machine’s Farmer 'hole Have To Be Closed. B

30 Broken Light Cover Of The Sechet Packing Hall. B


S.NO PROBLEM CATAGORY

31 Intercom Wire Should Be Placed In Pipe. C

32 Broken Light Cover Of The Filling Room & Taping Machine Room.

B

33 The Problem Of Torned Laminate Roll In Running Machine. A

34 Untidy Cleaning Bay. A

35 Increased Laminate Wastage Due To Printing Cutting. A

36 Due To The Wrinkle At The Corner Of The Laminate Roll the Machine’s Photo Sensor Can’t Work

B

37 Need To Repair The Refrigerator Of Micro Lab. C

38 Broken Water Tap Pipe In Lab.

B


A B C ANALYSIS

A B C

Involvement of team member

Involvement of Other Department’s

Involvement of Higher Management

12 21 06

SELECTION OF PROBLEMS ( A,B,C CATEGORY

31%

54%

15%

A -Involvement of team member

B -Involvement of Other Department’s

C -Involvement of Higher Management

Status of Problems

Problems Identified Problems Solved Problems Pending

NO OF PROBLEMS NO OF PROBLEMS NO OF PROBLEMS

38 20 18

SELECTION OF PROBLEM PROBLEM SELECTION FROM “A” CATEGORY

S.NO

PROBLEM IMPORTENCE

1 Paper Shifting On Each Machine

M I

2 Increased Laminate Wastage At The Time Of Roll Change Time.

M I

3 Increased Laminate Wastage At The Time Of Machine Setting.

I

4 Increased Laminate Wastage After Change Over/ Wet Cleaning.

I

5 .Increased Laminate Wastage Seal Powder, Leakage.

I

6 Spillded Ink On The Nichrome Machine.

LI

7 Water Leakage From The Air cylinder Of The Wraptech Machine. LI 8 . Stopped Working Of The Emergency Stop OF The Wraptech Machine.

M I

9 The Problem Of Torned Laminate Roll In Running Machine. I 10 Untidy Cleaning Bay I 11 Increased Laminate Wastage Due To Printing Cutting M I

SELECTION OF PROBLEM PROBLEM SELECTION FROM “A” CATEGORY

1 Increased Laminate Wastage Due To Printing Cutting..

2. Stopped Working Of The Emergency Stop OF The Wraptec Machine. 3. Paper Shifting On Each Machine . 4. Increased Laminate Wastage At The Time Of Roll Change.

SELECTION OF PROBLEM

DATA BASE ANALYSIS S.NO PROBLEM Amar sumit vinod gudiya Pankaj TOTAL

1. 1. Paper Shifting On Each Machine .

12 12 11 10 12 57

2. . Increased Laminate Wastage At The Time Of Roll Change.

11 9 10 12 10 52

3. Stopped Working Of The Emergency Stop OF The Wrapetech Machine .

10 11 9 9 11 49

4. . Increased Laminate Wastage Due To Printing Cutting

4 7 12 11 9 43

SELECTION OF PROBLEM SELECTION OF MAJOR PROBLEM

(Pareto Analysis)

0

50

100

150

200

250

0

10

20

30

40

50

60

4. Increased Laminate Wastage Due To Printing

Cutting

3. Stopped Working Of The Emergency Stop OF The

Wrapetec Mavchine

2.Increased Laminate Wastage At The Time Of Roll

change 1. Paper Shifting On Each

Machine

Total No

Percentage

cumilative No

28%

55%

79%

100%

Step 1

Step 2

Step 3

DEFINE THE PROBLEM

STEP 3

OBSERVATION PROCESS FLOW DIAGRAM

UN-PROPER SETTING OF ROLL

CODING OUT

PHOTO CELL OUT

ROLL CHANGE

CODING+LENGTH-OUT +OUT-CUTTING POUCH

DEFINE THE PROBLEM Increased Laminate Wastage At The Time Of Roll Change Due To Paper Shifting

IMPACTS OF THE PROBLEM:- Degradation of Pouch Quality

Dissatisfaction of customer.

High Laminate and Insert losses.

Wastage of time in repeated adjustments

DEFINE THE PROBLEM OBJECTIVES

To Eliminate The Losses. To Improve Product Quality. To Improve Packing Quality. Ensure Customer Satisfaction. To Improve Working Environment.

Step .3

Mile Stone Chart Mile Stone Chart

Sl.No Activity April.14 May.14 June.14 July.14 Aug-14

Week-1

Week-2

Week-3

Week-4

Week-5

Week-1

Week-2

Week-3

Week-4

Week-1

Week-2

Week-3

Week-4

Week-1

Week-2

Week-3

Week-4

Week-5

Week-1

Week-2

1 Identify problem

2 Selection of Problem

3 Define the Problem

4 Analysis of Problem

5 Identify Causes

6 Identify Root Causes

7 Data Analysis

8 Development Solution

9 Forseen Resistance

10 Trail Implement

11 Regular Implement

12 Followup and Review

Continuous Process

Analyze The Problem

Step 1

Step 2

Step 3

Step 4

STEP 4

4W & 1H ANALYSIS

Laminate wastage

WHERE PACKING MACHINE

WHEN

WHAT

WHEN

AT THE TIME OF ROLL CHANGE

WHO

OPERATOR,FOREMAN

HOW

UNPROPER SETTING OF ROLL / PAPER SHIFFTING ON MACHINE

Step 1

Step 2

Step 3

Step 4

Step 5

IDENTIFICATION OF CAUSES

CAUSE & EFFECT DIAGRAM

LAMINATE WASTAGE

MAN

MATERIAL

MAN

METHOD

MACHINE

PAPER SHIFFTING ON MACHINE

CODING OUT

PHOTO CELL OUT

STEP 5

Step 1

Step 2

Step 3

Step 4 Step 5

Step 6

STEP 6

S.No Cause Description Analysis Validation

1 IMPROPER SETTING OF THE LAMINATE ROLL

PHYSICALLY CHECKED LAMINATE ROLL WAS PROPERLY SET

2


PHYSICALLY CHECKED THAT ROLL WAS SHIFTING ON THE ROLLER CAUSE OF VIBRATION OF RUNNING MACHINE

3

CODING OUT ON THE MACHINE

PHYSICALLY CHECKED CODING WAS O.K ON THE POUCH

4

PHOTO CELL OUT ON THE MACHINE

PHYSICALLY CHECKED PHOTO CELL FOUND O.K .

5

WRONG CUTTING OF LAMINATE AT THE STARTING OF THE ROLL

PHYSICALLY CHECKED THAT OPRATOR WAS CUTTING THE ROLL IN WRONG MANNER AT THE STARTING

NOTE:- Gemba analysis done for validation of causes. Step 6

VALIDATION OF CAUSES ROOT CAUSE ANALYSIS

Step 5

Step 6

Step 7

DATA ANALYSIS OF THE CAUSES RANKING METHOD

S.R.NO Root causes SUDHIR

SUMIT VINOD I VINOD II PARDEEP TOTAL % age

1. PAPER SHIFFTING ON MACHINE 8 7 8 7

8

38

58%

2 WRONG CUTTING OF LAMINATE AT THE STARTING OF THE ROLL

6

5

6

5

6

28

42%

(Rating 10 being the Highest, 0 being the lowest

Step .7

DATA ANALYSIS OF THE CAUSES

42 42

42% 0

20

40

60

80

100

120

0

5

10

15

20

25

30

35

40

45

marks cumilative marks

cumilative %

§WRONG CUTTING OF LAMINATE AT THE STARTING OF THE ROLL


42%

SELECTION OF VITAL CAUSE (Pareto Analysis)

Step .7

DATA ANALYSIS OF THE CAUSES MOST VITAL CAUSE IDENTIFIED

From pareto analysis in last slide team members decided to eliminate all two root

causes

1 PAPER SHIFFTING ON MACHINE

ROOT CAUSE. 2 WRONG CUTTING OF LAMINATE AT THE STARTING OF THE ROLL

ROOT CAUSE.

Step 5 Step 6

Step 7 Step 8

Step. 8

Solutions from Team member

Two operators will Set the laminate roll On the machine

Proper cutting

of the

Laminate at the

starting

Of the roll after

the roll

change

To inform the vender For the wrinkle on the Side of the roll and for The core band

Roller mark must Be fixed on roll assembly

Roller mark must Be fixed on roll assembly

FORESEEN RESISTENCE

Step 4

Step 5

Step 6 Step 7

Step 8 Step 9

FORSEEN RESISTANCE FORSEEING PROBABLE RESISTANCE

S.No. RESISTANCE SOLUTION RESPONSIBILTY TARGET DATE

1 Oprator can do mistake to paste The taplone guide

Foremem & incharge will guide Operator to fix the taplone guide on farmer

Vinod Singh/ Pankaj Choubey

15.07.14

2 Two Operator will set the laminate roll on the machine

It will be scheduled properly to avoid the problems

Sechet incharge 15.07.14

3 Proper cutting of the Laminate at the starting Of the roll after the roll change

Operator will instruct before the starting of each roll

Supervisior/foremen

16.07.14

4 Roller mark must Be fixed on roll assembly

To check by the supervisior & foremen that roller mark is fixed properly

Amar Nath Singh/ Vinod Singh

16.07.14

5 To inform the vender For the wrinkle on the Side of the roll and for The core band

It is physically checked before fixing the laminate roll on machine

Vinod/Pankaj chouby

29.04.14

HENCE NO RESISTENCE TO IMPLEMENT THE SOLUTION STEP 9

Step 1

Step 2

Step 3

Step 4 Step 5

Step 6 Step 7

Step 8 Step 9

Step 10

TRIAL IMPLEMENTATION SOLUTION NUMBER-01

Tapelone Guide On Farmer Step 10


Proper cutting of the Laminate at the starting Of the roll after the roll change Step 10


Rollar Mark on Roll Assembly

Before

After

Step 10

TRIAL IMPLEMENTATION RESULT OF TRIAL IMPLEMENTATION

TRIAL RUN CONDUCTED BY MR. PANKAJ CHOUBY

1.20% 1.20% 1.20% 1.20% 1.20% 1.20% 1.20% 1.20% 1.20%

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

LAMINATE WASTAGE

18.JULY 19.JULU 20.JULY 21.JULY 22.JULY 23.JULY 24.JULY 25.JULY 26.JULY

Trial Successful Step 10

REGULAR IMPLEMENTATION

Step 2

Step 3

Step 4

Step 5 Step 6

Step 7

Step 8 Step 9

Step 10 Step 11

STEP 11

REGULAR IMPLEMENTATION TANGIBLE GAINS

Date SKU Daily Production Laminate Wastage

08.02.14 Bt0015s 581760 2.78

09.02.14 Bt0015s 584640 2.09

10.2.14 Bt0015s 391104 1.18 11.02.14 Bt0015s 570240 2.04

12.02.14 Bt0015s 587520 2.73

13.02.14 Bt0015s 587520 1.81

14.02.14 Bt0015s 587520 1.41

15.02.14 Bt0015s 587520 1.45

16.02.14 Bt0015s 588672 1.41

17.02.14 Bt0015s 587520 1.6

18.02.14 Bt0015s 587520 1.48

19.02.14 Bt0015s 587520 1.18

20.02.14 Bt0015s 524960 1.5

21.02.14 Bt0015s 302400 2.13

21.02.14 Bt0010s 331680 1.59

22.02.14 Bt0015s 691200 1.47

23.02.14 Bt0015s 685440 1.36

24.02.14 Bt0015s 685440 1.49

25.02.14 Bt0015s 685440 1.81

26.02.14 Bt0015s 685440 1.39

27.02.14 Bt0015s 345600 1.46

Date SKU Daily Production Laminate Wastage

02.05.14 Bt0015s 293760 2.75

03.05.14 Bt0015s 414720 1.28

04.05.14 Bt0015s 250560 1.2

05.05.14 Bt0015s 443520 1.2

06.05.14 Bt0015s 414720 1.25

07.05.14 Bt0015s 593280 1.04

08.05.14 Bt0015s 570240 0.91

09.05.14 Bt0015s 639360 1.01

10.05.14 Bt0010s 600000 1.55

11.05.14 Bt0010s 193440 1.01

11.05.14 Bt0015s 230400 0.93

12.05.14 Bt0015s 641664 0.99

13.05.14 Bt0015s 656640 1.04

14.05.14 Bt0015s 656640 1.02

15.05.14 Bt0015s 228240 0.54

21.05.14 SH18s 471600 1.46

22.05.14 SH18s 525600 1.1

23.05.14 SH18s 583200 1.3

24.05.14 SH18s 532800 1.29

25.05.14 SH18s 594400 1.11

26.05.14 SH18s 586800 1.07

27.05.14 SH18s 539280 1.22

28.05.14 Bt0015s 565200 1.32

Before Quality Circle Laminate Wastage After Quality Circle Laminate Wastage

REGULAR IMPLEMENTATION

TANGIBLE GAINS 1.50%

1.20% 1.20% 1.20%

0.00%

0.20%

0.40%

0.60%

0.80%

1.00%

1.20%

1.40%

1.60%

feb may june july

laminate wastage before quality

circle

laminate wastage after quality circle



Series1

Before Quality Circle in Feb 2014 Laminate Wastage Target = 1.51% r After Quality Circle in May 2014 Laminate Wastage = 1.21% After Quality Circle in jUNE 2014 Laminate Wastage = 0.99% After Quality Circle in jULY 2014 Laminate Wastage = 1.44% Approx Saving of Laminate Wastage per month = .29% Its Worth Near About = 1,40000

REGULAR IMPLENTATION INTANGIBLE GAINS

Money Saving Reduced Wastage Healthy Environment INCREASED STAFF CONFIDENCE

STEP 11

FOLLOW UP & REVIEW

Step 3

Step 4 Step 5

Step 6 Step 7

Step 8 Step 9

Step 10 Step 11

Step 12

STEP 12

PARSONS NUTRITIONALS PRIVATE LIMITED NO OF PROBLEMS SOLVED

S. No Problem

1 String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage test.

2 Increased Laminate Wastage Due To Delimitation Of Roll From Inside.

3 Increased Laminate Wastage Due To Damaged Core Of The Roll.

4 5.Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting Of The Roll

5 Unclosed Cover Of Wraptech Machine.

6 Holes In A.C Duct. 7 Opon Hole On The Wraptech Machine.

8 Unproper Wiring Of The Panel. 9 Spillded Ink On The Nichrome Machine.

10 Water Leakage From The Air cylinder Of The Wraptech Machine.

11 Need To repaire The fioor of taping room

12 Uncontrolled Oven Temperature.

13 Required Tube Light In QA Lab

14 Display Board Have To Be Repaired.

15 Insided Transformer Of The Nichrome Machine Should Be Coverd.

PARSONS NUTRITIONALS PRIVATE LIMITED NO OF PROBLEMS SOLVED

S. No Problem

16 .Required Door Mat At The Entrance Of Sechet Section & Filling Room

17 Adjoining Wire Of The Packing Table & Conveyer Should Be Covered

18 .Stopped Working Of The Emergency Stop OF The Wraptech Machine. Even In The Low Air Pressure

Machine Don’t Stop Working. 19 Wraptech Machine’S FarMer 'hole have to Be cloSeD 20 Untidy Cleaning Bay

21 even in the loW air preSSure Machine Don’t Stop Working. 22 Due to the Wrinkle at the corner oF the laMinate roll the Machine’S photo SenSor can’t Work that’S

Why Increased Laminate Wastage.

23 Broken Water Tap Pipe In Lab.

THE TOOLS AND TECNIQUES FOR PROBLEM SOLVING

Stratification

Cause And Effect Diagram

Pareto Chart

Pie Chart

Ranking Method

4 W & 1 H

Brainstorming

CONCLUSION

Lessons Learnt:-

• Innovations and working as a team towards achieving target.

•Systematic Problem Solving approach.

•Keep regular watch on key area after project implementation

arjun_lam. wastage-nhc-april-2014 (5)

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