hemas project final report-fr

PRODUCT WASTAGE ANALYSIS AND

MANAGEMENT

PROJECT REPORT

SAHAN NIPUNA

IN-PLANT TRAINEE (PRODUCTION) – PERSONAL CARE PLANT

HEMAS MANUFACTURING (PVT) LTD, DANKOTUWA, SRI LANKA

2

PROJECT SCOPE AND OBJECTIVES

SCOPE:

In order to recap on what the material usage variance is, what the material yield variance is and to analyze the difference

between how many actual materials we used for and how much we expected to use.

OBJECTIVES:

1. Identify material usage variances

Identify Overfilling/Under filling of each product

o Toothpaste / Mouthwash

o Cream / Lotion

o Shampoo / Hand wash

o Gel

o Oil

o Cologne

Cleaning wastes

Change over wastes

Other wastes

2. Identify material yield variances

The actual level of outputs vs. for given set of inputs

3. Process Mapping

For all process in mixing and packing

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INTRODUCTION

Personal Care Plant

In the Personal Care Plant six different types of products are manufactured. Mixing section is the first floor and after the

bulk is being manufactured there, it is pumped to the packing section which is the ground floor. There are six separate

mixing areas and six separate production lines. The main production categories are,

Colognes

Oil

Shampoo/Hand Wash

Hair Gel

Cream/Lotion

Toothpaste

There are several stock keeping units (SKUs) of those product categories which are given below.

1. Colognes

Type Size

Cologne

Baby Cheramy

Regular Cologne 50ml 100ml 200ml

Herbal 50ml 100ml 200ml

Floral 50ml 100ml

Bedtime Calming 50ml 100ml

BabyCheramy

Fun time

Lucky Ducky 50ml 100ml

Kitty Katty 50ml 100ml

Cuddly Bunny 50ml 100ml

Angel Fairy 50ml 100ml

Bien Aime Bien Aime 50ml 100ml 200ml

4

Gold

Black Jeans 50ml 100ml

Classic 50ml 100ml

Commando 100ml

Cool Splash 100ml

Hot Splash 100ml

Pro Sport

Extreme After Shave 90ml

Deep After Shave 90ml

Deep Cologne 100ml

Extreme Firm 100ml

Heat Seeker 100ml

Fresh Current 100ml

Chill Factor 100ml

Goya

Black Rose Cologne 35ml

Gardenia 35ml

Jasmine 35ml

Love Affair Body Spray 75ml

Secret Crush Body Spray 75ml

Mischief Maker Body Spray 75ml

Summer Kiss Body Spray 75ml

Paris

Floral 50ml

Jasmine 50ml

Capri

Capri Cologne 50ml

Shimmer Cologne 50ml

2. Oil

Oil Baby Cheramy

Regular 50ml 100ml 250ml

Herbal 50ml 100ml

Kumarika

Herbal 50ml 100ml 200ml 415ml

King Coconut & Rice

Split End Control 50ml 100ml 200ml

Anti-Dandruff 50ml 100ml 200ml

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3. Shampoo/Hand Wash

Shampoo Baby

Cheramy

Shampoo 100ml 200ml

Bedtime Head to Toe Wash 100ml 200ml

Dandex

Plus Shampoo 100ml 200ml

Family Shampoo 100ml 200ml

Plus Sachet 5.5ml

Family Sachet 5.5ml

Kumarika

100ml 200ml

100ml 200ml

100ml 200ml

100ml 200ml

100ml 200ml

Sachet 6.5ml

Velvet Hand Wash 250ml

Cheramy

Touch

Face Wash 100ml

Body Wash 250ml

4. Hair Gel

Gel Gold

Gold Gel 100ml

Gold Gel Sachet 4g

Pro Sport

Firm Hold Gel 120ml

Extreme Firm Hold Gel 120ml

Wet Shine Gel 120ml

Pro Sport Gel Sachet 4g

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5. Cream & Lotion

Cream

&

Lotion Baby

Cheramy

Regular Cream 50ml 100ml 200ml 400ml

Herbal Cream 50ml 100ml 200ml

Nappy Rash Cream 100ml

Regular Lotion 50ml 100ml

Bedtime Calming Lotion 50ml 100ml

Cheramy

Touch

Body Lotion-Lightening 100ml 200ml

Body Lotion-Hydrating 100ml 200ml

Face Cream 30g

Goya Body Lotion 100ml

Gold Hair Cream 100ml

Pro Sport Hair Cream 100ml

6. Toothpaste

Toothpaste

Clogard

Regular 40g 70g 120g 160g 200g

Fresh Mint 40g 70g

Non Fluoride 40g 70g 120g 160g 200g

Sachet 14g

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OVERFILLING / UNDER FILLING OF PRODUCTS

1) Overfilling/Under filling of Colognes

To determine the overfilling of cologne products individually, the following procedure was used.

Procedure:

First any cologne product was taken and its SKU’s were identified.

As most cologne products use glass bottles, a separate procedure was undertaken because of the variations in

the bottles.

Random samples of empty bottles of relevant cologne product were taken from several batches where the

production was online.

Sample size was 50 or 100.

They were numbered and weighed with the relevant insert or spray pump and noted.

Then they are filled with the cologne from the ongoing production line.

They are weighed again and the filling weight of each sample bottle was calculated.

The above procedure was repeated for several batches of the same product.

From those data ‘average filling weight per a bottle’ was calculated.

From that value overfilling/ under filling was calculated comparing with the lower value given in the relevant In-

Process sheet.

Reasons and solutions for overfilling / under filling issue were suggested.

Formula:

Overfilling/Under filling% = (Average Filling Weight per a Bottle/Tub – Lower Value of In-Process Sheet) *100

Lower Value of In-Process Sheet

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Type

Volume

Overfilling/

Under filling Amount

Per a Bottle (ml)

Overfilling/

Under filling %

Gold

Black Jeans 50ml -0.1 -0.2

100ml 0.3 0.3

Classic 50ml -0.1 -0.2

100ml 0.3 0.3

Commando 100ml 0.3 0.3

Cool Splash 100ml 1.3 1.3

Hot Splash 100ml 1.3 1.3

Bien Aime

50ml 0.6 1.1

100ml -1.8 -1.8

200ml -6.4 -3.2

Pro Sport

A/S Extreme 90ml -2.2 -2.5

A/S Deep 90ml -2.2 -2.5

Deep 100ml 2.0 2.0

Goya

Black Rose 35ml 0.5 1.3

Jasmine 35ml 0.5 1.3

Gardenia 35ml 0.5 1.3

Capri Cologne 50ml 1.4 2.8

Shimmer 50ml 1.4 2.8

Paris Jasmine 50ml 0.7 1.4

Floral 50ml 0.7 1.4

Baby

Cheramy

Regular/Herbal

50ml 1.2 2.4

100ml -0.8 -0.8

200ml -5.5 -2.7

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Type

Volume

Overfilling/


Per a Bottle (g)

Overfilling/

under filling %

Baby

Cheramy

Floral 50ml 2.0 4.4

100ml 0.8 0.9

Bedtime

Calming

50ml 2.0 4.4

100ml 0.8 0.9

Kitty Katty

50ml

1.1

2.4 Cuddly Bunny

Lucky Ducky

Angel Fairy

Kitty Katty

100ml

-0.9

-1.0 Cuddly Bunny

Lucky Ducky

Angel Fairy

Reasons for overfilling/under filling:

Colognes are filled by a level sensing vacuum filler and if there is a variation in the bottle volume, it will be filled

with a different volume of cologne other than the standard volume, as the level is same in both incidents. This

may lead to overfilling or under filling of cologne.

Some bottles have deeper bottoms and some have shallow bottoms. Hence the filling volume will be different as

the filling level is the same.

In Funtime cologne line the colognes are filled manually. Then the filling is not accurate. Filling will vary due to

the filling person’s accuracy and experience.

Also Funtime cologne empty bottles have more volume than its standard value due to manufacturing errors (mold

issues) as they are made of plastic material.

For some cologne products there is no exact level to fill.

Solutions:

Use volume wise filler or a weight wise filler other than level filler. Then the exact amount of volume can be filled

to each bottle.

Correct or reduce the variations in glass bottles.

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For Funtime cologne production line, it’s better to semi-automate the line by installing an automatic filler instead

of manual filling.

Update In-Process sheets to relevant filling volumes and give standard levels of filling for the production line.

2) Overfilling/Under filling of Shampoo

Since all the shampoo bottles are made out of plastic there will be no vast variations as glass bottles. So empty

bottles are weighed separately and an average value was calculated for empty bottles. Then the filled bottles

were weighed and noted. From these data ‘average filling weight per a shampoo bottle was calculated. The

calculation is the same as the sample calculation given in the previous category.

The relevant values are given below.

Type

Volume

Overfilling/

Under filling Per a

Bottle (g)

Overfilling/

Under filling %

Baby Cheramy Shampoo 100ml 0.6 0.6

200ml -0.2 -0.1

Dandex Plus 100ml 0.4 0.4

200ml 0.2 0.1

Dandex Family 100ml 0.4 0.4

200ml 0.3 0.1

Kumarika 100ml 0.4 0.4

200ml 0.7 0.3

BC Head to Toe Body

Wash

100ml 1.0 1.0

200ml 0.1 0.05

Velvet Liquid Hand Wash 250ml 0.1 0.04

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3) Overfilling/Under filling of Cream/Lotion

Cream and lotion bottles are also made of plastic and don’t give any significant amount of variations among bottles. So

the same procedure as shampoo was taken to determine the overfilling or under filling of cream and lotion bottles.

According to the tables given above it’s clear that the percentages of overfilling/under filling of creams, lotions

and shampoos are quite low when compared with other products. So there are no exact reasons to be checked,

but sometimes there will be some variations of the bottles. As they are filled according to the weight, the overfilling

or under filling amount depends on the worker who checks and adjusts the filling weight.

Furthermore there are some mechanical issues with the filling machine, so it’s better to replace the machine to

improve the efficiency.

Type

Volume

Overfilling/

Under filling

Amount Per a Bottle (g)

Overfilling/

Under filling %

Baby Cheramy Cream 50ml -0.4 -0.8

100ml 0.8 0.8

200ml 1.4 0.7

400ml 1.5 0.4

Baby Cheramy Lotion 50ml 0.4 0.8

100ml 0.6 0.6

Goya Body Lotion 100ml -0.2 -0.2

Nappy Rash Cream 100ml 1.1 1.1

BC Moisturizing Lotion 50ml 0.3 0.6

100ml 1.0 1.0

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4) Overfilling/Under filling of Toothpaste

When determining the overfilling/under filling amount in toothpaste tubes, each tube was tare by an empty tube and

weighed and results are noted, because there are hardly any variations can be seen on lami tubes. From those data

‘average filling weight per tube’ was calculated.

For mouthwash bottles the same procedure that used for shampoo bottles was used to determine the overfilling/under

filling amount.

Type

Size

Overfilling/Under filling


Overfilling/

Under filling %

Clogard Toothpaste

40g 0.69 1.75

70g 0.60 0.86

120g 0.56 0.47

160g 0.66 0.41

200g 0.65 0.33

Clogard Mouthwash 200ml 1.53 0.74

Reasons and Solutions:

There is no significant amount of overfilling among toothpaste tubes according to the data analysis. Since weight

is adjusted manually there may be little amount of overfilling or under filling until the worker sets machine’s

settings for the relevant weight.

But in mouthwash bottles the overfilling percentage is high. It’s mostly due to the variations of volume in the

bottles. And also the diameter of the bottle’s neck is larger and bottles are filled manually. While filling manually,

even if there is a slight change in the level, the volume will be varied much larger due its large diameter of the

neck of the bottle.

H H

V1 V2

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d D

D > d , V1 < V2

Same height, but the volumes are different. Slight change in the height can cause a much large effect on the

volume (V2).

5) Overfilling/Under filling of Oils

Some bottles of oil products have certain amount of variations. So that there may have significant amount of

overfilling or under filling for each bottle. Therefore for each product, samples of empty bottles and filled bottles

were weighed separately for several batches and calculated the ‘average filling weight per a bottle’ and

determined the overfilling or under filling percentage by comparing with the lower value of the In-Process sheet.

Type

Volume

Overfilling/


Per a Bottle (g)

Overfilling/

Under filling %

Baby Cheramy Baby oil 50ml 0.9 2.17

100ml 0.4 0.48

Kumarika

Split End Control

50ml 1.3 3.12

100ml 0.1 0.12

200ml 3.3 1.97

Herbal Oil

50ml 1.4 3.36

100ml 0.5 0.60

200ml 1.7 1.02

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Overfilling or under filling occurs in oil bottles mainly due to the variations in the volume of the bottles. In Kumarika

Hair Oil 200ml bottles, when the oil is filled to the required level, the volume exceeds about 2ml from the lower

value given in the In-Process sheet. It’s certain that volume of those bottles needs to be standardized again and

also the In-Process sheets have to be updated.

Since the oil lines of Kumarika 50ml and 200ml are manual, it’s impossible to maintain an exact filling level since

there will be human errors. According to the table the overfilling of 100ml bottles are low because it’s an automated

line. If a semi-automated line can be implemented for others as well, the overfilling percentage can be reduced.

A machine, filling according to the weight or volume wise can be implemented to the line and maintain a uniform

filling level.

6) Overfilling/Under filling of Hair Gel

Samples of hair gel tubs were weighed individually for each SKU and calculated the ‘average filling weight per a

tub’ and hence calculated the overfilling or under filling percentage.

Type

Volume

Overfilling/

Under filling

Amount Per a Tub (g)

Overfilling/

Under filling %

Pro

Sport

Extreme Firm Hold Gel 120ml 0.6 0.5

Firm Hold Gel 120ml 0.6 0.5

Wet Shine Gel 120ml 0.2 0.2

Gold Hair Gel 100ml 0.1 0.1


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Since the gel bulk is directly coming from the mixing vessel, there may be filling weight variations time to time

during the filling process. It has to be adjusted by checking manually. During the time which takes to correct the

weight, there will be overfilling or under filling in the tubs.

7) Overfilling/Under filling of Skin Care Products

The same procedure as cream/lotions was used for determining the overfilling or under filling amount of skin care

products.

Type

Volume

Overfilling/ Under filling


Overfilling/ Under filling

%

Cheramy

Touch

Milk Lotion-Lightening 100ml 0.39 0.4

200ml 0.86 0.4

Milk Lotion-Hydrating 100ml 0.79 0.8

200ml 0.38 0.2

Face Wash 100ml 0.59 0.6

Bottles are filled automatically according to the weight. When the vessel in the filling machine is completely filled

then the weight will vary. Again when the vessel is going to empty, there will be weight variances. Those are the

moments that mostly overfilling or under filling will occur. Time to time the filling weight has to be checked and

the machine has to be adjusted.

Sometimes there will be variations in the container bottles or tubs. Since the weight is checked including the bottle

or tub, the reading will not be accurate if the weight of the empty bottle or tub changes from one another. Then

there will be overfilling or under filling as the machine is adjusted to the inaccurate reading to be filled thereafter.

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CLEANING AND CHANGEOVER WASTAGES

After a batch is mixed there is remaining bulk in the mixer walls and propellers. They are washed with hot water or water

first. There is an exact washing procedure for each mixing process. So the leftovers of the bulk which are washed away

by the relevant washing method are wastage. It cannot be used for production.

Method used to calculate cleaning and changeover wastages:

To determine the amount of remaining bulk at the mixer after pumping for production, a known weight of water

was added to the mixer and cleaned the mixer from it. Then the remaining bulk was washed away with water. Finally the

weight of the water was weighed again.

Cleaning or changeover wastage = Weight of (water + remaining bulk) - Weight of water

1) Toothpaste

Size of a batch = 1500 kg

Average Total Filling Weight = 1200 kg

Overall Wastage = 300kg

Wastage due to Monthly Cleaning and Changeovers:

Remaining bulk in the mixer after pumping a batch = 178 kg

Remaining bulk in pump and pipe lines = 36 kg

Remaining bulk after cleaning = 35 kg

Remaining bulk at the filter = 4.1 kg

2) Hair Cream

Size of the batch = 100 kg


Overall wastage = 4 kg

Wastage due to cleaning of the mixer:

Remaining bulk in the mixer after pumping a batch = 1.2 kg

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Remaining bulk in buckets = 0.2 kg

3) Shampoo – Kumarika



Overall Wastage = 24 kg

Wastage due to Cleaning and Changeovers:


Remaining bulk in pump and pipe lines = 4.2 kg

4) Hair Gel



Overall Wastage = 12 kg

Wastage due to Cleaning and Changeovers:


Remaining bulk in pump and pipe lines = 7.2 kg

.

5) Lotion

Size of the batch = 400 kg

Average Total Filling Weight = 374.2 kg

Overall Wastage = 25.8 kg

Wastage due to Cleaning and Changeover:


Remaining bulk in the pump and pipe lines = 4.4 kg

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OTHER WASTAGES

There are some other wastages other than overfilling, cleaning and changeover wastages in manufacturing processes.

They were separately calculated for each manufacturing process in the Personal Care plant.

For a batch,

1) Toothpaste

Amount of CaCO3 removing from the siever = 0.6 kg

Amount of CaCO3 removing from the blower = 1.2 kg

Evaporation in the Gel Kettle (800C-650C) = 4.0 kg

Amount of bulk removing due to vacuum = 16 kg

2) Hair Cream

Evaporation in the pre-mixer (800C) = 0.05 kg

Amount of bulk removing due to vacuum = 2.90 kg

3) Hair Gel


4) Lotion


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Other possible ways of wastage in the production lines:

1) Cologne Production Line

Filling machine spillage and leakages.

During the checking of some SKUs of colognes. (When turning upside down to check whether there are

any dust particles or not)

During the pouring of cologne in rejected bottles to the vessel again.

Some amount of cologne is left with each rejected bottle.

Evaporation of cologne in every production step until the bottles are capped.

2) Funtime Cologne + Oil Manual Line

Spillage and leakage due to manual filling.

Due to mistakes done by labors.

A certain amount of oil is removed with rejected bottles.

Filling is done according to the naked eye level, which can be vary among labors according to their

experience and attitude towards the work.

3) Cream/Lotion/Shampoo Line

A certain amount of bulk removed during the process of removing trapped air in pump lines.

Filling weight variance is high during the starting period and ending period of a production.

Some amount of bulk is removed with the rejected bottles.

Spillage during the filling process.

4) Toothpaste Line

A certain amount bulk is removed with damaged tubes. (They are not used again due to microbial

issues.)

There may be some other ways of wastage in production lines, but they can be neglected since the amount of wastage

due to that particular reason is low or it may be a onetime incident.

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CONCLUSION

In a manufacturing process there are different ways of wastages. Basically in a production process, those wastages can

be divided into two types; wastages during the manufacturing process of bulk and wastages during bottling and packing

processes. In practically 0 % variance cannot be achieved in both ways. The only solution is to reduce it as far as possible.

Negligence of workers, poor manufacturing procedures, poor equipment or not enough equipment, poor raw material and

packing material and poor quality measures may lead to rise the variance for a certain high level. From this project I have

standardized the overfilling and under filling percentages for each product SKU in the Personal Care Plant. And I have

separately analyzed the other wastages including cleaning and changeover wastages during the production. I have also

given some suggestions to reduce the wastage in each production lines.

hemas project final report-fr

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