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National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry26th & 27th February 2016

ISA

B/F

&B

Sym

p/20

1602

26/S

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No.

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Balaji Hiremagalur,Mentor,Jack n Jill Lean Mfg.SolutionsBangalore-560098E-mail : balaji.jacknjill@gmail.comWebsite : www.jacknjillleanmfg.com

Developing Efficient Manufacturing Lines

Academic

Bachelor of Science from Mysore University

Worked : 40 years in the Packaged Food Industry.

Worked as Manager-Emerging Markets for the Global Engineering of Kellogg’s from March 2013 to Dec 31st 2014 based in Bangalore, India.

Worked as a Full time Consultant with Cadbury Kraft In India from 28th June 2010 to 28th Feb 2013. Installed, commissioned and successfully started the First “OREO” Line in India In Jan 2011.

Regional Head of Mfg. URC International from 2001 to 2010. The product categories of the company include, Biscuits, Cookies, Crackers, Wafers, Candies, Snacks, & Beverage. Responsible for Mfg.operations in the region comprising of Mfg.facilities in Thailand, Malaysia, Vietnam, Indonesia & China.

Vice President Operations With First Choice Food Corporation, Philippines from 1995 to 2001

Currently :

Working as “ Mentor” with Jack n Jill Lean Manufacturing Solutions based out of Bangalore, India. We are leading consultants to the Food Industry and have completed prestigious assignments in India, Asia and the Middle East. ( www.jacknjillleanmfg.com)

Balaji Hiremagalur

Integrated Work System (IWS)

Engineering & Developing Efficient Manufacturing Lines

It all started with “ this “

Sl # CHALLENGES IN DEVELOPING EFFICIENT MFG.LINES

1 CAPITAL EXPENDITURE & ROI

2RESISTANCE TO CHANGE FROM OLD TECHNOLOGY TO NEW

TECHNOLOGY

3 GETTING AWAY FROM A COMFORT ZONE

4 PEOPLE DEPENDENCY vs PROCESS DEPENDENCY

5 LINE BALANCING

6 PASSING ON THE BUCK AND PLAYING THE BLAME GAME

Resistance to Change

So, The only YANTRA to build Efficient Manufacturing Lines is to adapt LEAN MANUFACTURING PRINCIPLES

What Does ‘Lean’ Mean?

Lean gives the idea of skinny or slim. The word skinny has a negative connotation for a lot of people. There can also be a positive interpretation: ‘free of burden, healthy,

a lot of freedom of movement, muscles, etc.’ With this specific vision in mind, people went looking for techniques

that would allow a production system to function faster, cheaper,and better.

Lean Manufacturing is distinguished by: a minimum changeovertime, Just-In-Time (JIT) production, Kan Ban systems, a minimum ofsupplies and last but not least a "zero waste" attitude with eachemployee.

Lean priniciples

The Nature of Lean Manufacturing

The concept of Lean Manufacturing is a continuation of the mass productionsystem, known in the twenties as the ‘conveyor belt’ of automotivemanufacturer Ford.

Taiichi Ohno and Eiji Toyoda, two employees of the automotivemanufacturer Toyota in Japan, developed Lean Manufacturing after theSecond World War.

Lean Manufacturing became known worldwide thanks to the best seller "Themachine that changed the world", in which the aspects leading to thesuccess of the Toyota production system are described.

In the eighties Lean Manufacturing also got a base in America. This waspartly caused by the co-operation between Toyota and General Motors, whobuilt a factory together.

Lean Manufacturing

Lean Manufacturing Basics

• The Lean approach is based on finding efficiencies and removing wasteful steps that don't add value to the end product. There's no need to reduce quality with lean manufacturing – the cuts are a result of finding better, more efficient ways of accomplishing the same tasks.

• To find the efficiencies, lean manufacturing adopts a customer-value focus, asking "What is the customer willing to pay for?" Customers want value, and they'll pay only if you can meet their needs. They shouldn't pay for defects, or for the extra cost of having large inventories. In other words, they shouldn't pay for your waste.

• Waste is anything that doesn't add value to the end product.

The 8-wastes

The Supply Chain Flow

Tools for Lean Mfg.

5-S Principles

Tools for Lean Mfg.

Value Stream Mapping Tool

Tools for Lean Mfg.

OEE

Overall Equipment Effectiveness = Availability x Performance x Quality rate

% Quality rate =( total output- defectives ) x 100

( total Output+defectives)

% Performance = Actual output/ hr x 100

Standard output/hr

% Availability = (Shift time – downtime) X 100

Shift Time

OEE Principle

Availability x Performance x Quality rate = Overall Equipment Effectiveness

75 % X 85 % X 95.55 % = 60.91 %

% Quality rate =( 22000 - 500 ) x 100 = 95.55 %

( 22000 + 500)

% Performance = 850 x 100 = 85 %

1000

% Availability = (8 – 2) X 100 = 75%

8

OEE Example

OEE Reports

Breakdown Analysis

Case Study before Lean Mfg

Integrated Work System (IWS)

Case Study after implementation of Lean Mfg

The Ultimate Factory

Thank You