maarg final report

8/7/2019 MAARG FINAL REPORT

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Copyrights, MAARG Consultancy & Solutions

A

Consultancy Report to

“Camlin India Limited”

Submitted by,

MAARG CONSULTANCY AND SOLUTIONS




About Camlin:

With our 50,000 strong retailer network, prestigious foreign collaborations, large consumer

base, regular interaction with consumers by the sales force and participation in international

trade fairs like Paperworld in Frankfurt, Camlin is now a trusted household name all over

India. Camlin was the first company in India to adhere to Art & Creative Materials Institute’s

world standards in toxicity certifications. All India Camel Colour Contest too has been well-

received, holding the record of the highest entries ever and has been registered in the Limca

Book of World Records. Camlin has been encouraging and promoting fine art, which is why

Camlin Art Foundation was set up.

From a company manufacturing ink powders in 1931 to a company manufacturing over

2000 products, operating in diverse fields, Camlin has come a long way.

Ideal for painting or drawing quick sketches in colour. They are also for superimposing as

they spread evenly on paper without smudging or smearing. Painting done with Camel Oil

Pastels can be protected by Camel Pas-O-Fix, a special fixer for Oil Pastels. They are

available in various pack sizes and shades assortments upto 50 shadesShades are Set of 50 Assorted Colours (1004 - 50) RD 60mm length x 10mm dia, Set of 25

Assorted Colours (1004 - 25) RD 60mm length x 10mm dia, Set of 15 Assorted Colours

(1004 - 15) RD 60mm length x 10mm dia.

Set of 12 Assorted Colours (1004 - 12) RD 60mm length x 10mm dia.




1.2 Scope of the Study:

The Study included the Productivity Improvement for Oil Pastels Line in Camlin India at

Tarapur Plant, Thane District. The major focus area was the final stage of Oil Pastel line

as it had maximum number of problems causing decrease in the productivity.

The focus area of the study was the man and machine utilization at the final stage of oil

pastel line.

Study focused on the Oil Pastels Manufacturing Activities in the following areas:-

1) Three Stages are there for Manufacturing of the Oil Pastels which is the highest selling

Product of Camlin India. Detailed Study of Man, Machine and Inventory in Preliminary,

Tripple Rolling and Final Stage(Mixing) of Oil Pastels Line.

2) Multiple Activity Chart Plotting for Final Stage of Oil Pastels Line.

3) Overall Equipment Effectiveness

4) Design of Experiment by Taguchi’s Method to Improve Productivity of Oil Pastels

Line.

The Scope of the Work included the review of Systems and Procedures to achieve the

Maximum Productivity of Oil Pastels Line as per the Machine Standards.i.e upto 350kg

of o/p per shift and also to streamline the Processes to utilize the Man and Machine

efficiently.




1.3 Methodology:

The Study was conducted using the following methodology:

1) Review of Systems and Procedures followed in the Manufacturing of existing Oil

Pastels Line.

2) Detailed Study and Critical Analysis of Present Practices at each stage of man,

machine, inventory, quality and productivity.

3) Interaction with different in-house departments like Quality, Stores, Shop floor to get

the cross functional view of the problem. Quality Department was visited to study the

nature of colors and which constituents of the colors undergo quality check. Stores

department was visited to review whether the raw materials of the color pastels are

weighed according to the standards.

4) Identification of Productivity Problems in oil Pastel Line related to man and machine

utilization with the help of multiple activity chart plotting.

5) Identification of Standard Parameters affecting machine performance with the help of

design of experiment using Taguchi method.

6) Suitable recommendations were made along with operational improvement

opportunities. The recommendations were discussed with the senior management.

However, the actual implementation of the recommendation will be the

responsibility of Camlin India, Tarapur plant.




1.4 Consultancy Team:

The consultancy team included the members from “MAARG Consultancy and

Solutions”. The following members were involved in the project:

Paresh Gugale Ashif Tadvi

Abhinav Gupta Radha Krishna Mothadaka

Kasam Srinath Kiran Dhamapur k ar

D

k1.5 Scheme of Report

Chapter II deals with the study of the most critical stage of oil pastel line using Multiple

activity chart to identify the utilization of man, machine, time and inventory and

includes the recommendations to utilize the resources properly to increase productivity of

oil pastel line.

Chapter III Highlights the Overall equipment effectiveness of the machine

Chapter IV deals with the Design of Experiment (Taguchi Method) to identi

fy the

standard parameters affecting machine performance and suitable recommendations were

given using the above principles.

Summary of recommendations are presented in Chapter V




Chapter II:-Multiple activity chart

Introduction:

It is these charts which give the idle time and the utilization times of the machines and

workers.

A Multiple activity chart is a chart on which the activities of more than one subject

(worker, machine or item of equipment) are each recorded on a common time scale to

show their interrelationship.

By using separate vertical columns or bars to represent the activities of different

operatives or machines against a common time scale, the chart would clearly showidleness on the machines of oil pastels.

The Multiple activity charts is useful in organizing teams of operatives on the mass-

production work i.e. Oil-pastels work and also on maintenance work as it is not

feasible to remain idle longer than the necessity.

In making the chart, the activities of the machines and the operators are being recorded

in terms of working time and the idle time. These times are being recorded by ordinarywrist-watch or a stop-watch.

Methodology adopted:

RECORD:

In this stage all the desired inputs of the workers (worker 1 and worker 2), machines

(rotating table) are being noted and then once in 20 minutes the operations of the

workers, machines are being recorded and is shown in the tabulated form as below for

the 3 different Oil-Pastel machines with different colors to get the more accurate results

so as to address more discrepancies.




EXAMINE CRITICALLY

All the critical activities are being noted from time to time with the change of

operations, with the change of the speed, with the effect of the external parameters like

chilling, the temperature of the rotating table and its speed, the movements of the

workers, the location and flow of the input material and all the activities are being noted

in the chart for the calculation of the Utilization and the Idle times of the Oil-Pastel

machine.

DEVELOP THE METHOD

After the total observations are being recorded and then critically examined for the Oil-

Pastel machines and the workers operating, this stage is the final stage involving the

development of the multiple activity chart with the inputs being recorded with the

IDLE TIME being shown as the RED COLOR and the WORKING TIME being

shown as the YELLOW COLOR in the experiments being carried out and is being

shown below.

Once the RED ZONE and the YELLOW ZONES are obtained it is quite easy to note

the working time i.e. UTILIZATION TIME and then the IDLE TIME of both the

workers and also the machines.

The UTILIZATION TIME and IDLE TIMES would help in addressing many issues

discussed after the experiment section.




EXPERIMENT NO: 1

MAARG CONSULTANCY & SOLUTIONS

MAN MACHINE CHART - OIL PASTEL LINE FINAL STAGE

Date:6thAugust 2008

Method:

Present/Proposed

MANMACHI

NE

Shift:Second

Shift

Idle

Time% 0.4516 0.225806

Analyst:Ashif Tadvi Utilizatio

n % 0.5484 0.774194

Remarks

Time W1 W2 W1 W2 S1 S2 RT

4:10 Counting & stacking Idle


4:30

Counting & stacking Adjustingstroke

4:40

Idle Manualstroking

4:50

Idle Manualstroking

5:00 Idle Adjustingstroke

5:10 Idle Idle

5:20 Idle Idle


5:40

Counting & stacking Gone for rawmaterial

5:50

Counting & stacking Gone for raw

material

6:00

Counting & stacking Gone for

rawmaterial

6:10

Idle Gone for rawmaterial


6:30 Idle Idle

6:40 Counting & stacking Inspecting




EXPERIMENT NO: 2



MAN MACHINE

Date: 6th

august 2008

Method:

Present/ProposedW1 W2

S1 s2

Shift:First shift Idle Time 0.14 0.62 0.29 0.29

Analyst: Kasam

Srinath Utilization % 0.86 0.38 0.71 0.71

NOTE: Continued work from the previous Shift of white color

Remarks


7.00IDLE FOR CHALKS

Adjustingstroke

7.10

Counting &stacking

Gone for rawmaterial

7.20Counting &stacking

Idle


Idle


Idle

7.50 Counting &stacking

Materialpouring

8.00

Make ready

next box Inspecting


Handlingscrap

8.20

Counting &stacking

Gone for raw

material


Idle


Idle

8.50

Counting &

stacking

Idle

9.00

Break for Break-Fast9.10

9.20

9.30

9.40 IdleAdjustingstroke

9.50Idle to getCHALKS

MakingStable

10.00 Counting & Idle




stacking

10.10Counting &stacking Idle


10.30

Counting &

stacking Idle


10.50Counting &stacking Inspection

11.00

Counting &

stacking

Material

pouring

11.10

Counting &

stacking Idle

11.20

Counting &

stacking Idle

11.30

Counting &

stacking Idle



12.00

Chilling Stopped12.10

12.20

12.30

12.40

LUNCH BREAK

12.50

1.001.10

1.20

CHILLING STOPPED1.30

1.40 Idle

Adjusting

stroke

1.50

Counting &

stacking Idle


2.10

TEA BREAK

2.20

2.302.40 STOPPED WORKING AND STARTED

CALCULATIONS OF THE SHIFT2.50

3.00




comments:

1 Between 12.00 to 3.00 only 40 minutes was being output and worked

2 Chilling Problem is a prime Concern as it stopped one-third of the work per shift

3 Adjusting the rotating speed and putting down the chalks produced as scrapeats away 1 hour time as they do it for 4 times.

It is a form of Reworking -- waste of labour hours, machine hours of time as well.




EXPERIMENT-3



Date: 06

/ 08 / 08

Method:

Present/Pro

posed

MAN

MACHINE

Shift:

2nd Shift Idle Time

Analyst:

Radha K Mothada

ka

Utilizatio

n %

Remarks


3:10 Bring Material Bring Material

3:20 Bring Material Bring Material

3:30Wait for mixing Wait for

mixing

3:40Wait for mixing Wait for

mixing

3:50 Doing Collection Removingscrap4:00 Doing Collection Helping to W1

4:10 Doing Collection Helping to W1


4:30 Doing CollectionMaintenanceWork



5:00

TEA BRAKE5:10



5:40 Doing Collection Not available






6:10 Doing Collection Not available6:20

Doing CollectionMaintenanceWork

6:30 Doing Collection

Maintenance

Work




Maintenance

Work


Maintenance

Work


Maintenance

Work 7:30

Doing Collection

Maintenance

Work


7:50

DINNER / LUNCH

TIME

8:00

8:10

8:20

8:308:40 Doing Collection Helping to W1



9:10 Doing Collection Helping to W19:20 Doing Collection Helping to W1






REMARKS

Mix problem , Viscousity problem

Worker 2 is in maintenace work most of the time because of mixture

problem

The Output lot is almost defective

Chilling failure and improper liquid temp problems




5. From the entire 3 experiments one can infer an observation that the idle time of the

worker 2 (Maintenance worker) is having or spending most of the time idle

ranging from 45 -65%.

Worker 1 who is allocated the work of counting sticks is doing his activity withjust 10-`15% of idle time (as the sticks have to get accumulated in order to start

his operation).

6. It is one of the feasible and advisable to allocate 2 machines to operate for the

worker 2 which helps in the reduction of one worker.

7. The allowance time that the company has allotted and the times the workers are

really taking for allowance has a difference of 20 minutes per shift(1 hour per 3

shifts --- loss of close to 40 kg output)




Chapter III:-

Overall Equipment Effectiveness (OEE)

Introduction:

Overall Equipment Effectiveness (OEE) is a total measure of performance that relates the

availability of the process to the productivity and quality. The OEE measure shows how

well the company is utilizing resources, which include the equipment, the labor and the

ability to satisfy the customer in terms of delivering the quality specified by the customer.

This approach provides focus and simplicity to decision making with respect to

controlling unplanned downtime, the cycle time of the process and the quality rate.

OEE is directly related to the six big losses, which are as follows: -

Breakdown and Changeover form the Availability measure.

Minor stoppages and reduced speed form the productivity/performance measure.

Non-Conforming items and changeover scrap form the quality measure.

Where appropriate

OEE measure is suitable for any process within a manufacturing environment and

provides a means of prioritizing improvements.

Requirements when implementing




When undertaking an OEE on a process the following issues need to be addressed: -

Availability of the process

The productivity/performance of the process

The quality of the process

The Overall Equipment Effectiveness is now calculated by taking all three factors into

consideration using the metric listed below: -

In world-class terms an OEE of 85% is a good performance and maybe used as a

benchmark.




OEE Calculation SHEET

(Example is given)

Maximizing Equipment Effectiveness

Breakdowns and minor stoppages impede automation

Stop accelerating the deterioration of equipment

Preventive maintenance alone cannot eliminate breakdowns




IN CAMLIN:

The project work is carried out in Oil Pastels production line of Tarapur plant. The

production process is analyzed and it is identified that the final stage viz. the mixing &

molding stage is very critical for the line efficiency as well as productivity.

A brief about the Mixing Stage:

The necessary quantities of raw materials are taken as prescribed by the R & D dept. and

are used in lots to load in to the machines. The Mixing machine has two tanks, one is

main tank in which the raw materials are mixed thoroughly and the other tank is in which

the ready to mold liquid is available. From this second tank, the hot liquid is circulated in




to a molding table which rotates at a certain adjusted speed. The liquid is mad cool to

solidify while the table is rotating, by passing a child water circulation. Once the liquid is

solidified in the molds of the table, a set of plunging sticks will eject the sticks finishing

the process of production.

Sticks are collected in trays and sent for labeling and then for packaging.

OEE of the machines in Mixing Stage:

As per the above description of the machine, the different chances / causes that can affect

the OEE of the Mixing machine are:

• Molding table speed (has affect on productivity).

• Plunger sticks action (has affect on productivity).

• Viscosity of the liquid (has affect on quality).

• Hot & Cold temps (has affect on quality).

• Machine running time (has affect on availability).

• Color changing time (has affect on availability).

OEE Improvement Measures:

• Experiments are conducted on the machine at different table speeds to increase the

output which can increase the production efficiency of the machine. An optimal

machine setting parameters are found for max. Output.

Machine Setting parameters include:

1. Molding table speed.

2. Valve angle.

3. Hot & Cold Temps.

• Proper mixing of raw materials to maintain the necessary viscosity of the liquid is

suggested as per the R & D dept. recommendations. Proper viscosity ensures the




better quality of the pastel sticks. Similarly, Hot and Cold temps. are properly

regulated to maintain the proper viscosity of the liquid for better quality output.

• To increase the machine availability, Man machine charts are drawn and analyzed.

Measures to reduce the worker idle time and machine time are suggested. Color changing time is very considerable and has a greater affect on machine

availability. Hence, a proper color changing sequence is suggested to minimize the

color changing time.

All the above measures, address to increase the OEE of the machine.

COLOR

Production

PerformanceAvailability Quality OEE

RED 86.28% 85% 92.78% 68.0%

YELLOW 90.75% 85% 92.69% 71.5%

PURPLE96.38% 85% 91.66% 75.0%

NOTE:

• Availability is taken as 85% only because of the worker behavior and additional

allowances he is taking in the shift time.

• Production performance is calculated based on the assumptions that max. output

per shift (i.e. planned run time) is 350Kg.

Increase in Availability can directly increase the OEE of the machine




Chapter IV:-

Design of experiment

What is it?

DOE is a systematic approach to investigation of a system or process. A series of

structured tests are designed in which planned changes ar e made to the input variables of

a process or system. The effects of these changes on a pre-defined output are then

assessed.

Why is it important?

DOE is important as a formal way of maximizing information gained while resources

required. It has more to offer than 'one change at a time' experimental methods ,

because it allows a judgment on the significance to the output of input variables acting

alone, as well input variables acting in combination with one another.

'One change at a time' testing always carries the risk that the experimenter may find one

input variable to have a significant effect on the response (output) while failing to

discover that changing another variable may alter the effect of the first (i.e. some kind of

dependency or interaction). This is because the temptation is to stop the test when this

first significant effect has been found. In order to reveal an interaction or dependency,

'one change at a time' testing relies on the experimenter carrying the tests in the

appropriate direction. However, DOE plans for all possible dependencies in the first

place, and then prescribes exactly what data are needed to assess them i.e. whether input

variables change the response on their own, when combined, or not at all. In terms of

resource the exact length and size of the experiment are set by the design (i.e. before

testing begins).




When to use it?

DOE can be used to find answers in situations such as "what is the main contributing

factor to a problem?", "how well does the system/process perform in the presence of

noise?", "what is the best configuration of factor values to minimize variation in a

response?" etc. In each case, DOE is used to find the answer , the only thing that marks

them different is which factors would be used in the experiment.

How to use it?

The order of tasks to using this tool starts with identifying the input variables and the

response (output) that is to be measured. For each input variable, a number of levels are

defined that represent the range for which the effect of that variable is desired to beknown. An experimental plan is produced which tells the experimenter where to set each

test parameter for each run of the test. The response is then measured for each run. The

method of analysis is to look for differences between response (output) readings for

different groups of the input changes. These differences are then attributed to the input

variables acting alone (called a single effect) or in combination with another input

variable (called an interaction).

DOE is team oriented and variety backgrounds (e.g. design, manufacturing, statistics etc.)

should be involved. Moreover, as this tool is used to answer specific questions, the team

should have a clear understanding of the difference between control and noise factors.

In order to draw the maximum amount of information a full matrix is needed which

contains all possible combinations of factors and levels. If this requires too many

experimental runs to be practical, fractions of the matrix can be taken dependent onwhich effects are of particular interest. The fewer the runs in the experiment the less

information is available.

Design of experiment at Camlin




We have identified following process parameters at oil pastel line:

1. Table speed

2. Valve opening

3. Boiling temperature

4. Chilling temperature

The design of experiment at camlin has been performed in two stages

In the first stage we have changed only one parameter at one time called “a single

effect”. Here the change of table speed and valve opening has been observed

while keeping other process parameters (Boiling temperature & Chilling

temperature) constant. The rationale behind doing so is that we were not in a

position to change the chilling temperature because only one chilling unit is used

to supply chilling water to whole unit. Same is the case with boiling temperature

(same unit supplies water to all oil pastel line).

In the second stage we have changed more than one

parameter at a single time. It is called “an interaction effect”. Here the valve

setting and table speed both have been changed and the result was investigated.

“A single effect design of experiment”

The experiment was done for three oil pastel lines. Here we have changed the

table speed keeping all parameters constant. Following graphs illustrates the effect

of table speed on the output.




Table

Speed

(volts)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)

Accepted/RejectedShift

Prod(Kg)

18 9.65 0.75 82 8.8 12.87 257.33

At the moment when maximum output was reported the process parameters are shown

in the above table.

Conclusion:- The Optimal Condition for Red Color is –Table Speed is 18 and the

Output Obtained is 257 kg/shift.





in the above table.

Conclusion:- The Optimal Condition for Pale Yellow Color is –Table Speed is 19.2

and the Output Obtained is 270 kg/shift.

Table

Speed

(volts)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)


Prod(Kg)

19.2 10.15 0.8 82 8 12.69 270.67




Table

Speed

(volts)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)


Prod(Kg)

10 12.65 1.15 76 9.8 11.00 337.33


in the above table.

Conclusion:- The Optimal Condition for Purple Color is –Table Speed is 10 and the

Output Obtained is 337 kg/shift.




“An interaction effect design of experiment”

In the second stage we have changed more than one parameter at a single time. It is called

“an interaction effect”. Here the valve setting and table speed both have been changed

and the result was investigated


in the above table.

Conclusion:- The Optimal Condition for Pale Yellow Color is –Table Speed is

19.2,Coolant Opening is 90 degees and the Output Obtained is 270 kg/shift.

Table

Speed

(volts)

Flow

in

Angle

(Deg)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)


Prod(Kg)

19.2 90 10.15 0.8 82 8 12.69 270.67





in the above table.

Conclusion:- The Optimal Condition for Red Color is –Table Speed is 18,Coolant

Opening is 85 degees and the Output Obtained is 257.33 kg/shift.

Table

Speed

(volts)

Flow

in

Angle

(Deg)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)


Prod(Kg)

18 90 9.65 0.75 82 8.8 12.87 257.33





in the above table.

Conclusion:- The Optimal Condition for Purple Colour is –Table Speed is 10,Coolant

Opening is 90 degees and the Output Obtained is 337.33 kg/shift.

Table

Speed

(volts)

Flow

in

Angle

(Deg)

Sticks

Accepted

(Kg)

Sticks

Rejected

(Kg)

Boiling

Temp

(Deg

C)

Chilling

Temp

(Deg C)


Prod(Kg)

10 90 12.65 1.15 76 9.8 11.00 337.33




Chapter IV

Summary of MAARG Recommendations to Camlin India Limited:

For Manpower:

1. Strict following of Scheduled breaks by labour by improving discipline among

workers. It was observed that there was little following of scheduled break timings

by workers.

2. Tea and snacks can be brought to the workstations instead of workers going to

canteen which adds to the non-productive time due to delays. This would make the

worker stay at the workplace for maximum time and the tolerances provided for

walking to the canteen and back can be eliminated.

3. Siren or Bell can be blown for all breaks to intimate the shift workers about all the

breaks. This would standardize the time of the breaks for all workers so that they

all follow the same breaks.

4. Shop floor should have a big display board showing the shift output for the week,

output given by different workers and other similar details. This will help in

developing healthy internal competition among the workers and also help in

segregating performers and under performers.

5. Performance Linked (e.g. according to kgs produced) can be started in the shop

with the help of matrix performance tables. This will give positive reinforcement

to the workers for their good performance.




6. In current situation it can be observed from the man machine chart that instead of

having 4 workers for 2 machines we can have 3 workers managing two machines.

7. Attitude of labour can be improved by making them aware about the actual gap in

demand and supply in the market and about future effect on the company due to

economic downturn in the market and corresponding layoffs by organizing

motivational workshops by top management.

8. Reward strategy can be used for workers and supervisors in the form of “Camlin

Man of the Plant” Award and bonus system based on monthly performance the

sample calculation of which is shown below:

Average performance per day = 180 kgs/shift (assumed)

After introducing bonus system suppose it is raised to 250 kgs/shift

Then improvement = 70kgs X 25 days = 1750 kgs and similarly increment in other

workers output due to internal competition.

For Machines:

1. Machine should be fully controlled by maintenance people and not by

production people. Giving controls to production people only gives them a

chance of manipulation.

2. All machine control parameters like table speed, valve opening, chilling

temperature, boiling temperature, etc. should be under the control of

maintenance people through locked machine panels.

3. The boiling temperature should be greater than 75 deg Celsius and chilling

temperature should be between 8 and 10 deg Celsius.




4. Pneumatic Circuits can be used to control the speed of the table and flow rate

of liquid pastel independently and not by the same mechanical linkages as seen

in the present situation.

5.

Separate hot water and cold water system should be used for all machinesbecause there is loss of heat if the same pipe is used for circulation to all

machines.

6. The stick holding unit should be fabricated with as close tolerances as the

circular table because if it is not so the sticks break and there is loss of time in

fixing this problem.

7. TPM ( Total Productive Maintenance) can be employed in a phased manner by

starting off with a pilot machine.

For Methods:

1. Methods at all stages should be standardized using work station standardization

methods like method study and time study.

2. Standardized operation sheets should be displayed at all stages.



Future Projects For Camlin India Limited

1)ISO Implementation in the Tarapur Plant.

2)TPM Implementation in the Tarapur Plant.

3)Development of Excel –Based Softwares for Inventory Management, Forecasting

Techniques etc.

4)Implementation of Six Sigma.

5)5 S Implementation in the Plant.

6)Training on various topics like “JIT,Poka Yoke,Kaizen,PMTS etc.

maarg final report

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