fmcg ojt presentation, uniliver nepal limited

“On the Job Training”at

Hetauda, Makwanpur

(29 May to 29 August, 2012)

Pratap Jung Rai

Institute of Engineering, Thapathali Campus

Assigned Projects by Unilever Nepal Limited

1. Shampoo Production Process

2. Develop Preventive Maintenance Check list

3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for

Techeff Losses in case of sachet laminates and SLES

4. Assist in Designing - Capping Unit Installation

5. Assist to prepare FWS document for upcoming FWS audit

Extra Activities

• Ganga Soap & Chemical Ind. Is 3P Company of UNL

• Established in 2005 A.D.

• Total Area = 1500 squa. ft

• Plant Area = 1200 squa. Ft

• Administrative Employees = 8

• Workers = 51

Thick and Long

Jasmine

Black

Sunsilk

(3.5 ml)Sunsilk

Sunsilk Black

100 ml

350 ml

Sunsilk Pink

180 ml

350 ml

Sunsilk Hair fall solution

350 ml

Clinic Plus

100 ml 180 ml 425 ml

Hair Care Product produced by Ganga 3P

Unilever Nepal LimitedAbout Ganga Soap & Chemical Industries Pvt. Ltd




3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff

Losses in case of sachet laminates and SLES



Extra Activities

RO Plant

Water tank

DM water heater

Hot water Tank

Carbopol charger

SLES Charger

Side pot agitator Emulsion

pump

Mixer

Silverson pump

Transfer Pump

Holding Tank

Hopper

FFS M/C

CLD Packing

Filling M/C

Printing M/C

CLD Packing

Transfer Pump


Shampoo Production Process

Cont….

Shampoo Attributes/ComponentsShampoos generally comprise of an aqueous mixture of ingredientsa) CleansingPrincipal function of the shampoo is cleaning; the removal of sebum and environmental dirt from the hair and scalp. b) ConditioningTypical conditioning agents are cationic polymers and silicone emulsions. c) Functional AdditivesFunctional additive includes ingredients that are added to adjust the pH and viscosity of the shampoo. Acidic or alkali solution for pH and Salt for viscosity.d) PreservativesShampoo is high water content and high risk products for the growth of mould, yeast and bacteria. This could result in decomposition of the product and/or a potential health risk to the consumere) FragranceThe addition of a fragrance in shampoo production appears to be a trivial task f) Anti-OxidantsAnti-oxidants are used in shampoo formulations to prevent the formation of nitrosamines and to prevent problems caused by the oxidation of certain raw materials such as perfume.

Water Treatment

System

Ingredient Charging System

Manufacturing and Packing

System

Mixer

Product Holding Tank

Bottle filling

machine Form fill seal

Machine

CLD

packaging

Printing

Machine

CLD

packaging

Ware House

Opaque

Storage

RO Plant

Water Storage

DM Water Heater

Hot Water Storage Tank

SLES

Charger

Carbopol

Charger

Packing lines 3.5ml Sachet line – Two 8- Track M/Cs 7ml Sachet line – Two 5- Track M/Cs Bottle line – Filling and Packaging M/C

Shampoo Batch

Finished Products

Sachet shampooBottle shampoo

Ingredients Water + Preservative

Heating in jacketed tank(80-90 deg. C)

Mixing

Cooling(<40 deg. C)

Mixing (approx. 3 hr)

PreservativesPerfume

Shampoo Production Process Flow DiagramScametic diagram of Shampoo Production Process1. Shampoo Production Process

Name of Machine

Amount/Sachet

(ml)N0. of

Stroke/minuteNo. of Nozzle No. of shift

Total Sachetproduction/Track

(Ton)

Total Packing Capacity (Sachet + Bottle) (Ton/day)

5 track, 01 Machine 7 61 5 2 3.07445 Track, 02 Machine 7 60 5 2 3.0248 Track, 02 Machine 3.5 63 8 2 2.540168 Track, 03 Machine 3.5 65 8 2 2.6208

Total Production 11.25936

Filling and Packaging M/C 100 6 5 2 4.32 15.57936




Packing Capacity

Manufacturing Capacity….Mixer Capacity: 13.2 tons/dayHolding Capacity: 20 tons/day

Packing Capacity: 17.48 Tons /day (middle bottle + Sachet)

Shortfall = 4.28 tons/day

Bottleneck between Batch Making Capacity and Packing Capacity

Capacity is given in 100%









Extra Activities

2. Assist to prepare Preventive Maintenance Check listBackground study for maintenance practices for Ganga 3P

• Study part replacement history of all Form Fill Seal machine of 9 months

Cont….

Subsequently, developed CLIT checklist and Preventive Maintenance checklist (which is also provided in Local Language)

Clutch brake, 1 Cup

washer , 1

horizontal heater, 5

perforation blade, 4

Rod end bearing, 1

vertical heater, 2

5 Track 01 M/C(14/09/2011-26/06/2012)

Cup washer , 1 Horizontal heater, 2


SSR , 1Thermocouple, 1

Vertical heater, 6

5 Track 02 M/C(13/05/2012-28/06/21012)

Bearing , 2Cup washer

12D, 1

hinge with

harden pin, 1

Horizontal sealer, 2

One way clutch, 2

pencil heater, 4


pull roller , 2Rotary

cutter, 5

8 Track 01 M/C(28/09/2011-26/06/2012)

Bearing, 3 Horizontal heater, 2

one way clutch, 3


piston seal, 2

PLC, 1

Pneumatic cylinder , 2

pull roller, 1

Rotary cutter , 3

spool , 3

switch, 1 Thermocouple, 1

8 TRACK 02 M/C(28/09/2011-26/06/2012)

Know how about MTBF and MTBR

CLIT Maintenance ChecklistDaily CLIT Maintenance @ 11:00 am for 15 minute

C= CleanL=LubricationI= InspectionT =Tightening

Weekly Preventive Maintenance, Friday @ 11:00 am for 30 minute

Daily CLIT Checklist

Month: Time: 15 minuteBottle Filling Machine

Date: 11:00 AM

S.N. Where to check what to check solution Status

1

Piston - Cylinder, M/C Body, Conveyer Belt, Nozzle, Switch Panel, Printing M/C body

dirt/drops of shampoo

clean by clean cloth

2

Piston-Cylinder Hanger block with Bush dryness keep oil

Speed Breaker sleepinessclean by clean cloth

Weight Adjustment Block dryness keep oil

Drive Chain and sprocket of main drive and printing conveyer

drynesskeep new grease

3 Jugli Clamp, Union loose tighten

shift supervisorMachine operator

Daily CLIT checklist

Month Time: 15 minute FFS M/C No.

DateS.N Where to check what to check Solution Status

1

Hopper, Drive Area, Spool, Cylinder piston, Transparent Guards, Main motor Dirt/drops of shampoo clean with clean cloth

2

Sealer Assembly- Horizontal Sealerclean sealer weather laminate stick or not clean by wire brush

Filling and Drive Assembly dryness1. Rod End Bearing of Spool Drive keep oil2. Rod End Bearing of Main Drive keep oil3. Rod End Bearing of Filling Cam keep oil

3 Rotary Cutter Set dryness keep oil

4

Main Drive Chain/ Rotary Cutter Drive chain loose tighten if loose

5Weight Adjustment Block Dryness keep oil

6Collating Conveyer and bearing dryness, drops of shampoo

keep grease/ clean by white cloth

shift supervisor Machine operator

Cont….2. Assist to prepare Preventive Maintenance Check list

Previous Weekly Preventive Maintenance Checklist

Weekly Preventive Maintenance-ChecklistFFS Machine

Month:Time:

11:00 am

Date: Friday

S.N. where to check what to check what to do Remark Status

1Turnbar Assembly-All rollers Dirt, Shampoo Drops, Remove laminate, Clean with wet cloth

2Filling/Sealing Assembly Dirt, shampoo metallic dust clean the previous grease with brush white cloth and apply new grease

Filling guide shaft

Vibration, loose check nuts tighten it

All bevel gearsRack and Pinion Assembly

Main Drive ChainMain Drive Cham

Rotary Cutter Drive Chain

Horizontal Sealer Shaft

H Block Shaft

U Hinge and Harden pin

3Rod Heaters(to be done by electrician) Current Consumption Replace if damage

4Pneumatic line Air Pressure (6-8) psi clean pipes if blocked6Main Motor V belt Slag and tight adjust, tighten or replace

7Clamp of billet (laminate cutter) orientation, loose tighten, change billet

Modified Weekly Preventive Maintenance-ChecklistMonth: Foam Fill Seal Machine Time: 11:00 amDate: Friday

S.N. Sub s.n. Where (Location) What to check What to do Remarks Status

1

FillingI Guide bar shaft dirt in LM bearing, alignment or play clean LM bearing, replace if damageII Piston leakage carbon "O" ring and "U" seal leakage adjust or change if damageIII Rod end bearing Play, dryness keep oil, adjust or change bearing if damageIV Hinge with coupling drive play, loose bolt, key broken tighten bolt or change key if brokenV Bevel gear play, teeth, loose bolt, dryness tighten bolt, keep greaseVI Dog clutch with clutch sprocket chain play, bearing, teeth of sprocket tighten, keep oil or change clutch if damageVII Driven hinge with coupling loose bolt, oscillate rotation, key way tighten bolt, coupling or change if damage

2

SealingI Rod end bearing Play, dryness tighten, keep oilII Main drive chain play, dryness tighten, keep grease

III Horizontal sealer loose bolt, LM bearing, compression spring, dirtclean sealer and keep maintenance as per requirement

IV Heater (vertical and horizontal)loose connection, open circuit, shut circuit, current consumption

replace if damage

3

CuttingI One way clutch bearing check one way rotation, loose tighten or replace if oscillateII Rotary cutter bearing, cutting profile, dryness keep oil, change cutter if damageIII Idler chain with sprocket Play, teeth profile, dryness keep grease, replace if damageIV Perforation blade tie, loose bolt, broken tighten bolt or replace blade if damage

4

PullingI Pull roller cutter profile, dirt clean with dry white clothII Magnetic brake Gap clearance, coil test, current consumption tighten bolt, replace if damageIII Magnetic clutch Gap clearance, coil test tighten bolt, clean and replace if damageIV Spur gear teeth profile, play, dryness clean with dry white cloth and keep greaseV Rack and pinion teeth profile, dryness keep greaseVI Bevel gears teeth profile, play, dryness greasing, replace if damage

5

UnwindingI All roller Dirt/drops of shampoos clean by clean cloth

II Spring Check tension replace if damage

III Adjustment valve with thread Thread profile keep oil6 Pneumatic line Air pressure (6-8 psi) clean pipe if block








Extra Activities

Laminate(83.106 kg/ton)

Wrapper Adjustment

(0.303Kg)

GSM(57.35)(0.539Kg)

Changeover(0.055Kg)

Leakage(1.889Kg)

Others

Wrapper Change Wrapper Breakage

Equipment Problem

SSR fault

Set up & Adjustment

Weight Problem Electrical Problem

Level sensor V/H heater

Perforation blade

Pull roller Rotary cutter

QC storage

Weight adj. cylinder

Weight adj. blockPneumatic cylinder

Loss tree of Laminate based on (3.5ml)

Wastage given in per ton


Techeff Losses in case of sachet laminates and SLESCont….

Wrapper Adjustment

(0.303Kg)

GSM(57.35)

(0.539Kg)

Changeover

(0.055Kg)Leakage

(1.889Kg)




Laminate(90.353kg/ton)

Wrapper Adjustment(0.506Kg)

GSM(73.51)(0.631Kg)

Changeover(0.083Kg)

Leakage(0.548Kg)

Others

Wrapper Change Wrapper Breakage

Equipment Problem

SSR fault

Set up & Adjustment

Weight Problem Electrical Problem

V/H heater

Perforation blade

Pull roller Rotary cutter

QC storage

Weight adj. cylinder

Weight adj. blockPneumatic cylinder

Loss tree of Laminate(7ml)

Wastage given per ton

Cont….3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for


Total Losses

(1.768Kg)

Changeover

(0.083Kg)

Wrapper adjustment

(0.506Kg)

Leakage/Over or Under wt.

(0.548Kg)

GSM

(0.631Kg)




SLES(200Kg)

Leakage(1 Kg)

Packing give away

(1.78 Kg)

SLES Loading(1.5Kg)

Sanitization(4.2Kg)

Others

Gland Pipe line

Circulation pipePump

QC storage

PCRO RuleWeight adj. block

Piston

Loss tree of Sodium lauryl ether sulfate (SLES)

wastage given in per ton

Cont….



SLES Loading(1.5Kg)

Sanitization(4.2Kg)

Leakage(1 Kg)

Packing give away

(1.78Kg)

Total Losses(7.98 Kg)


Cont….










Extra Activities

Initial proposed Capping unit installation

Cont….

Problems encountered in initial design Bridging between two conveyors

Maintain gap between flowing bottles

Difficult to change orientation of Bottle

So After discussion, Modified design

Back View

Top View

Side View Front

View

Filling m/c

Printing Bench

Domino printer

Stamper

Pneumatic cylinder

Belt conveyer

Metal Belt conveyer

4. Assist in Designing , Capping Unit Installation

Criteria for Capping unit installation Maintain gap between two bottle is 30-40 mm

Change the orientation of flowing bottle

Initial Design, Advantages of Initial Design1. No disturbance to Domino printing unit

2. Buffer better easy for packer

Objective of Capping Unit Installation Eliminate Ergonomic hazard in palm Man power Elimination

Filling m/c

Metal Belt conveyer

Domino Printer

Stamper

Belt conveyer

Opaque flowing Direction

Pneumatic cylinder

Advantages of Modified

Capping Unit Installation Address all above Criteria

No extra electricity consumption

Reduce space consumption

Required less maintenance

Modified view of Capping Unit

4. Assist in Designing , Capping Unit Installation








Extra Activities

5. Assist to prepare FWS documents for upcoming FWS auditCont….

Following of the documents were missing at Ganga 3P

• Listing of Inventory of Tasks

• Prepared Critical Task Inventory (CTI)

• Prepared Task Hazard Analysis (THA)

SOP has been updated.

Prepared Standard Operating Procedure (SOP) of Ganga 3P. (in Local

Language)

3224

32

16

3224 24 24 24

16 1624

32

20

05

101520253035

Severity Ranking of THA Candidate Operation

S. No. Location Tasks

1 Production Hall FFS operator

2 Production Hall Bottle Filling operator

3 Production Hall Changeover Process in FFS machine

4 Production Hall Changeover process in Bottle Machine

5 Batch Mixer Area Batch Maker

6 Batch Mixer Area Batch Changeover

7 Batch Charging Area SLES and Carbopol Charging

8 Batch Charging Area Squeezing

10 Minor Wightman Room Minor Weightiest

11 Engineering Store Engineering Store

12 Cooling Tower operation

13 Compressor operator

14 Entire factory GHK

15 RO plant RO operation

16 DM plant DM water Heater operation

17 DG Room DG operator

18 RM/PM Area RM/PM handler

19 PCC Room PCC operator

20 Canteen Caterer

21 Grinding

5. Assist to prepare FWS documents for upcoming FWS audit

Inventories of Tasks

Risk = Consequence×Probability

Task : Bottle Filling Operator Ref : 2

Assessed By : Date :

S.No.SEQUENCE OF

BASIC STEPSHAZARDS & PERSONS AT RISK

POTENTIAL

HARM

EXISTING CONTROLS & SAFE

PROCEDURES

Evaluation of riskACTION & ADDITIONAL

CONTROLSS L R

1 Bottle placing MSD (Musculoskeletal Disorder) Minor Injury Shoes, Ergonomic Chair 2 2 4

2Operating filling

Nozzle

shampoo splashes may enter into eye, Hand in Machine

Major Injury 6 4 24Goggles, nozzle should be covered by Transparent plastic cover

3Conveyer motor

operationElectric shock Single Death

ELCB, VFD, Double earthing have been provided

8 2 16timely check the condition of ELCB and Earthing

4 Weight adjustmentHand may damage if spanner broken, shampoo splashes may enter into eye

LTA 4 2 8Goggles, adjust weight of shampoo by stopping machine

5 Domino operation Electric shock Single Death Double Earthing, ELCB, Safety shoes 8 2 16timely check the condition of ELCB and Earthing

6 CLD packaging hand may cut, CLD may fall from the stack Minor InjurySafety shoes, Safe stacking procedure exist

4 2 8

Occupationor Job Title : Bottle Filling operator

Completed by :

Reviewed by:

Reviewed on:

Approved by:

Tasks Loss Exposures Risk Evaluation Programme Needs

S.N.

List all tasks or activities normally done or that

might be done by a person in this occupation Safe

ty

Health

Fire /

Ele

Ris

k

Equip

me

nt

Environ

ment

Severity

Pro

babili

t

y

Ris

k

Pro

cedur

es

Skill

Tra

inin

g

Specia

l

Rule

s /

Perm

its

PP

E

1 Bottle placing Yes No No No No 2 2 4 No No No Yes

2 Operating filling Nozzle Yes No No Yes No 6 4 24 No No No Yes

3 conveyer motor operation Yes No Yes Yes No 8 2 16 No No No Yes

4 Weight adjustment Yes No No No No 4 2 8 Yes No No Yes

5 Domino operation Yes No Yes Yes Yes 8 2 16 Yes Yes Yes Yes

6 CLD packaging Yes No No No No 4 2 8 No No No Yes

Sample of CTI and THA

5. Assist to prepare FWS documents for upcoming FWS audit Cont….








Extra Activities

Extra activities done

• Design a pictorial information of From Fill Seal Machine parts (so that operators could easily identify the parts and it’s name and accordingly carry out maintenance job)

• Leakage Trouble shooting of FFS machine

• Prepared Electrical diagram of Ganga 3P

(Leakage was found the major problem in FFS line so made “Trouble Shooting Guide to Leakage”.)

Posters of 5 and 8 track Machine Parts Name

Any Quarries?????

THANK YOU !!!