Bikram DahalThapathali Campus

PMD

OJT AT SURYA NEPAL

SupervisorAyush Raj Aryal

I/C PMD

Projects

• Admoist protocol

• Increase filling value of Surya

Main projects

• Spillage reduction in CTS bin

• GFP feed maintenance at CRS Cutter

• Cp & Cpk of CRS Dryer

• Optimization of blend change time (CRS line)

Side Project

• Design of pan for Sampling at HT and stand for Serrico TrapDesign

ObjectiveIncrease productivity, quality and profitability through keen data analysis and process design; significantly improve operations and provide efficient resolution of process issues.

OJT at Surya Nepal

Methodology

Asking question (understanding problem)

Labeling patterns in data

Modeling conceptually

Decomposing

Experimenting

implementation

Continual monitoring and communicating

1

2

4

5

6

7

3

OJT at Surya Nepal

Moisture Content

variation in cutter above

0.5

Raw material Method Mother Nature

Size distribution

Intrinsic Property

Moisture Content

Type

(cold or Hot)

Bulking time

Temperature

Power failure

Humidity

Hand feel

Moisture

Measuring Instrument Least count Setting of machine

Uniformity of filling

Uniformity of water, raw material

and steam flow

MachineMan

Finding

Fig 1: Fish bone Diagram of causes for moisture variation

Admoist protocol and Data Analysis

Result and Discussion

35.50

36.00

36.50

37.00

37.50

38.00

38.50

39.00

39.50

40.00

0 5 10 15 20 25 30 35

Moisture Mean Ex-cutter

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0 5 10 15 20 25 30 35

S.D Chart

Admoist protocol and Data Analysis

Result and Discussion

• Weight deviation

for HVM/VSN5

stem is high

because stem of

this Grade are

longer and have

non-uniform

thickness

Admoist protocol and Data Analysis

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

0 5 10 15 20 25 30

Coefficient of Variation of weight

• Failure of PRV to maintain set pressure of 0.3-0.4 bar. Line pressure was changing as per main pressure variation.

• Main line pressure was decrease to 5bar from maximum pressure of boiler i.e. 7- 8 bar.

Cause Solution Result• Temperature of 3 samples

of 3 operation was tracked average value was found 71 C

Due to low filling value of CRS from regular interval in QUAS daily report after 17 aswin.

Temperature of product at 1 meter distance from outlet of admoist was checked. It was

found that temperature was above SOP i.e. 76.

Further Step

Admoist protocol and Data Analysis

Finding (Research)

• Virginia Tobacco have less filling Value due to high sugar Content

• Lamina Cutter is optimum at 32CPI other argue its best at 25 CPI

• F.V varies among different part of same leaf, between different year crops

• FV is very sensitive to moisture

• Main control able factor effecting filling value

• HT steam pressure

• CPI of cutter

• Storage time and temperature

• Cheese pressure of cutter

• Type of dryer

Increasing filling Value of Surya

Finding(Data analysis)

• F.V after Ex-cutter was below average

• Expansion from cutter to H.T of both

lamina and CRS was with in speciation limit

• CPI of Cutter was below average and

not uniform

• Steam pressure of CRS H.T could be increase

• Order of operation had no effect on

filling value

Increasing filling Value of Surya

13.62

8.11

0%

2%

4%

6%

8%

10%

12%

14%

16%

Ex-cutter to Ex-bin Ex-cutter to Ex-Dryer

CRS Lamina

• Filling value jump from ex-

cutter and ex-dryer

Step taken to improve F.V

• Maintenance and Calibration of Cutter was carried out

• Steam pressure of CRS H.T was increased from 4bar to 5bar

• Cheese pressure of lamina cutter was reduce for NG to 15KN

• Temperature of lamina dryer was reduced from 66 C to 62 C

Increasing filling Value of Surya

Increasing filling Value of Surya

CPI of Cutter Result

139

166

0

20

40

60

80

100

120

140

160

180

Before After

CP

I0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0 10 20 30 40 50

Wax Thickness (before)

0

0.05

0.1

0.15

0.2

0.25

0 10 20 30 40 50

Wax Thickness (after)

Result

Increasing filling Value of Surya

47.78

49.15

47.00

47.50

48.00

48.50

49.00

49.50

Before After

Filling Value Cut Tobacco

* FV value for before batch (NG1-42) and after (NG-43-78) was taken form QUAS daily report

After Before

Mean 49.16 47.78Observations 32 36p-value 2.91E-06

• Continuous

monitoring was

carried till end of

project

Scope of Further Improvement

• Increase tobacco and steam ratio to find optimum ratio in H.T

• Changing rate and temperature of airflow in dryer

• Experimenting with CPI of both cutter under control environment

Increasing filling Value of Surya

Result

0

0.5

1

1.5

2

2.5

3

3.5

1 2 3 4 5 6 7 8 9 10

Old Boiler | | New boiler

Cp and Cpk of CRS dryer

Cpk

Cp

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 1 2 3 4 5 6 7 8 9 10Old Boiler | | New Boiler

SD chart of Steam pressure at HT

Cp and Cpk of CRS Dryer

• Large tart time difference between VOV(2) and bin belt conveyer(1) i.e. 5 sec

• High speed of Belt conveyer(6)

• Start time difference between 2 and 1 was reduce to 1 sec

• Speed of 6 was reduce to 12+0.5 all other blend except VSY from which it was reduce to 15+ 0.5

Cause Solution Result• No single gap between

stem in conveyer from bin to cutter

• Product at GFP was visible most of the time

In order to maintain uniform flow of product at CRS cutter, product level at GFP should always

be visible. But some of the time, product at GFP of CRS cutter is empty.

Introduction

Feed maintenance at CRS cutter GFP

Feed maintenance at CRS cutter GFP

Spillage reduction CTS Area

• Inter-

operational

time 8 minutes

• 90sec gap

• 390sec time

difference

between start

and finish

Stem Conditioning

WEIGHCON

SC

ADMOIST

AIR LIFT

Optimization of Blend Change Time

40 sec 65 sec 165sec

45 sec 510 sec

sec

60 sec

30 sec

35 sec

OP 1 390 sec 90 Sec OP 2

Inter-operational time

Start:

Finish:

GapDiff. start to finish

HT• Speed cylinder

rpm at tail out was increase from 16 to 18

• Decrease In 1 minutes tail out time

• Inter-operation time is 360sec after sensor in GFP Detects no Tobacco

CRS Dryer

VC

WEYCON

KLS

Optimization of Blend Change Time

55 sec 70 sec 390 sec 45 sec

705 sec90 secVariable 40 -240 sec 50 sec

Start:

Finish:

secOP 1 280 sec 80 Sec OP 2

Inter-operational time

GapDiff. start to finish

Design

Design of Pan for Sampling at HT

Summary

• Admoist protocol was passed

• Filling value of NG was increased by 3% on average

• Cp and Cpk of CRS dryer were calculated

• Spillage of CTS was reduce by 5-8 kg/day

• Uniform feed at CRS cutter was maintained

• Pan and stand were designed

• Standard blend change time was established for CRS conditioning and CRS

Dryer line. Along with decrease in tail out time of CRS dryer.

OJT at Surya Nepal