case study on newsprint waste reduction · web viewinitially, after identification of the problem,...

Jagran Prakashan Limited

Case Study on

Newsprint Waste reductionSubmitted to D L Shah Quality Award Competition - 2015

Dainik Jagran - NoidaD : 210 – 211, Sector – 63, Noida (UP)

CONTENTS

CONTACT DETAILS 2

EXECUTIVE SUMMARY 3

BRIEF HISTORY 5

WORK FLOW 7

PROJECT CHARTER 8

PLAN (IDENTIFICATION OF PROBLEM & ROOT CAUSES) 9

DO & CHECK (IMPLEMENTATION and CHECK RESULTS) 15

FINANCIAL BENEFITS 29

INTANGIBLE GAINS 30

STANDARDIZATION 31

IMPROVEMENTS 32

TOOLS USED 35

Dainik Jagran PROJECT - NEWSPRINT WASTE REDUCTION Page 1 of 35

CONTACT DETAILS

Chief Executive:

Mr. Sandeep Gupta

Coordinator:

Mr. Satish Chandra Mishra, Mr. S K Singh & Mr. Neetendra Srivastava

Project Leader:

Mr. Beer Bahadur Singh

Mobile: 09560798140

[email protected]

Team members:

Mr. Anil Kandhol

Mr. Durga Prasad

Mr. Pramod Sharma

Company Address:

Jagran Prakashan Limited

D : 210 -211, Sector – 63,

Noida (UP)


mailto:[email protected]

EXECUTIVE SUMMARY

Newsprint is the major cost contributor among all consumables in the Newspaper

printing process. We are using 85% indigenous newsprint.

Initially, after identification of the problem, a Continuous Improvement Group –

Newsprint (NP) was formed. The group works for improvement of processes in the

organization and the project scope covers waste reduction in all Newsprint categories –

Print, Reel-end, Tear- off and Sweep waste. The team used the PDCA cycle to identify

opportunities for improvement.

Data analysis was carried out with the help of different statistical tools. After Pareto

analysis, it was found that Print, Reel-end and Tear-off wastes are the major

contributors of Newsprint waste. To know different causes leading to Print waste, a

Cause and effect diagram was prepared. Similarly, 5 Why analysis helped determine

the root causes for Reel-end waste and Tear-off waste.

Ideas were generated to improve the process and reduce the newsprint waste in all

categories. Acceptable ideas were implemented by the CIG - Newsprint team with the

help of other departments and senior management.

Control charts were used to monitor the progress and the team tried to eliminate all

assignable causes. Finally the values were monitored with I-MR charts to see whether

the process lies between specified limits.


After implementing all the acceptable ideas, the result (Newsprint waste %) was

compared with the base data (4.97%).

This case study would trace the journey in reduction of newsprint waste from 4.97 % to

4.28%.

The team achieved improvement of 13.88% compared to the target of 10% reduction.

Now efforts are made to monitor the process by using different tools to improve &

sustain it.


Dainik Jagran

Brief information about the organization:

Dainik Jagran is professionally organized company and printed the newspapers in

many languages like Hindi, Punjabi, Urdu, English as well as Sakhi and Josh

magazine also published from here. As of now 32 branches we have in various states

of the India.

MID DAY and NAI DUNIA is also integral part of the Dainik Jagran.


Noida Plant:

The Noida plant started operating from its present location of Sector – 63, Noida UP.

Now this year is going to celebrate the silver jubilee after successfully completing of 25

Years. Over the years, the operations increased manifold to make it one of the biggest

newspaper printing plants in India. At present, the editions being printed at the plant

include Jagran, Jagran National, Nai Dunia, Inqulab,

The Vision statement of Production Department is:

“Creating an entrepreneurial culture of innovation and

empowerment to achieve sustainable technology leadership

in print and beyond”


WORKFLOW OF THE PRODUCTION DEPARTMENT


Editorial department releases the pages via leased lines to the Plate making department

which prepares the plates for mounting on machine. In production department printing is done

on paper and delivered to the mail room department. Finally dispatch department distributes

newspaper to the customer.

PROJECT CHARTER

Project Name:Newsprint waste reduction at Dainik Jagran – Noida (UP)

Business CaseNewsprint is the largest cost component among variable cost. Newsprint waste % figures for FY 12 – 13 is 4.97% which needs to be improved.

Project ObjectivesTo reduce Newsprint waste by 10% from 4.97 % to 4.48 % by March 2014. Also reduced from 4.47% to 4.28% till Dec, 14.

Expected Savings 10% waste reduction translating to Rupees 38.89 Lac for 2013-14 and also rupees 15.55 Lac. till date Dec,14

Project ScopeNewsprint waste reduction savings shall include savings due to waste reduction in all categories of the Newsprint.

Project Schedule Team Members and other resources


Project Identification 01/04/2012Champion Mr. Sandeep

Gupta

Plan 02/04/2012 Team Leader Mr. Beer Bahadur Singh

Do 15/04/2012Team Members:

Mr. Anil Kandhol

Mr. Durga Prasad

Mr. Pramod Sharma

Mr. M P Singh

Check 15/09/2013

Act01/12/2013

Close 31/03/2015

Signature Champion:

Mr. Sandeep GuptaOther Resources

MIS reports.

Production Report

IDENTIFICATION OF THE PROBLEM


The Newsprint is the printing paper which is used to produce a newspaper. The paper

is supplied by the papermaking mills in the form of reels. These reels have different

specifications such as different sizes, color, GSM, pulp quality etc.

After manufacturing, the reels are loaded in containers and delivered through ships by

the papermaking mills. The containers are offloaded at destination seaports, brought to

warehouse via trains, stored, before being ultimately delivered to the printing sites with

the help of trucks and forklifts.

DVC: Other than the newsprint several materials such as ink, plates, chemicals,

electricity, water etc. are required in the production of a newspaper.

There are certain wastages occurring in the process of producing newspaper as shown

in the structure below.


Newsprint Waste Generation

Press Operation Newsprint HandlingProject focus

Project focus

Newsprint waste generation chart

Jagran Noida plant consumed 15581 MT of newsprint in 2012-13 with newsprint waste

percentage of 4.97 %. Since newsprint is the major contributor to the consumable cost,

even slight reduction of newsprint waste would lead to huge savings and improve the

operational and financial efficiency of the printing plant. Therefore, efforts were done to

reduce the newsprint wastage through continuous process improvement.

Keeping in view the scope of above stated reduction, it was decided to form a

Continuous Improvement Group (CIG) for Newsprint waste reduction with an objective

to reduce newsprint waste by 15% from the baseline figure 4.97 % of FY 12 – 13 to

10% in next FY is 4.47 %.


Printed waste

Reel –end waste

Tear off waste

Transit waste Forklift operation

Sweep waste

Tear-off

Waste during run

Start- up waste Auto splice waste

White waste

Register out

Late copy clearing

DEFINITIONS OF NEWSPRINT WASTE CATEGORIES

TEAR-OFF WASTE

SWEEP WASTE


Tear -off due to transit damage

A newsprint reel brought to the shop

floor is loaded on the reel stand of

the press where the wrapper is

removed.

The top most layers (which are

damaged due to transit) are sliced

off. This is called “Tear- Off” waste.

The waste of top 2.5% of reel

diameter is equal to 9.85% of total

reel weight.

The paper is then threaded through

the press due to which some amount

of it is wasted. This is called “Sweep”

waste.

PRINTED WASTE

REEL- END WASTE


The copies that get wasted to

get the saleable copy (i.e. gross

counter minus net counter)

amounts to “Printed” waste.

The butt end of the newsprint reel that

is left behind after splice is called “Reel-

end” waste.

BASE DATA

The base data was taken for the period April-08 to Mar-10 as shown in

the table below.

FY 2012 - 13

Months Consumption (Kg)Waste %

April,12 1465835 4.76May,12 1480760 5.04June,12 1427770 5.37July,12 1514297 5.56Aug,12 1357963 5.25Sep,12 1339418 4.74Oct,12 1478550 4.96Nov,12 1399658 4.86Dec,12 1359095 4.96Jan,13 1429518 4.93Feb,13 1328578 4.45March,13 1421252 4.70Average 1416891 4.97


DIAGNOSTIC APPROACH FOR PROBLEM SOLVING

The CIG Newsprint team adopted PDCA methodology for the continual

improvement in the Newsprint waste reduction area.


STEP 1 :- Plan for a change

STEP 4 :- Redefine the change as necessary

STEP 3 :- Observe the results

STEP 2 :- Try plan on a small scale

After collection of data, a pareto analysis was done to determine the vital few causes

leading to Newsprint waste.

86% of the waste is due to Print waste, Packing and Tear-off.

Print waste, Reel-ends and Tear-off are in the priority list to reduce Newsprint

waste.

After discussions within CIG- NP team, it was decided to use below mentioned tools for

analysis of root causes:

Causes Tools used

Print waste Cause & effect diagram

Reel-end waste 5 Why analysis

Tear-off waste 5 Why analysis


CAUSE AND EFFECT DIAGRAM

Brainstorming was done to prepare a cause and effect diagram to determine various

causes leading to Print waste.


Man

Component malfunction

Compressor trip

Auto splice failure

PRINT WASTE

Improper diagnosis

Catch-up due to fluff

Moisture

Materials

Wrinkles due to dryness

Scum due to roller ageing

Improper Blanket cleaning

Machine

Method Environment

Dirty web eyes

Human error

Scum due to roller washing

Wrong plate mounting

Awareness regarding newsprint handling

Unskilled operator

Splice copies

Mis-registration during running

Folder jam

Incorrect electrical parameters

Incorrect tension values

Spray problem

Test run

Reel inspection method

Warehouse conditions

Reel turning brittle

Image wear-off

Mis-registration after brand change

Web wandering

Loose winding

Out of round reels

Mill joint failure

Inside sticky reelPoor slitting

Core slippageInside cut

Run sequence

Scum

No scientific procedures for reel unloading

Loose sheet after splice

Sensor activated

Predetermined by manufacturer Component malfunction

After determining probable causes leading to Print waste, significant causes were

chosen with consensus as shown below.


Man

Auto splice failure

PRINT WASTE

Improper diagnosis

Improper Blanket cleaning

Human errors

Wrong plate mounting

Awareness regarding newsprint handling

Unskilled operator

Scum

No scientific procedures for reel unloading

Wrong plate mountingInsignificant causeAwareness regarding newsprint handlingSignificant causeAuto splice failureInsignificant causeImproper diagnosisInsignificant causeImproper blanket cleaningInsignificant causeHuman errorsInsignificant causeUnskilled operatorInsignificant causeScumInsignificant cause



Compressor trip

PRINT WASTE

Machine

Splice copies

Mis-registration during running

Folder jam

Incorrect tension values Incorrect electrical parameters

Turbo problem

Loose sheet after splice

Sensor activated

Mis-registration during running Insignificant cause

Folder jam Insignificant cause

Component malfunction Insignificant cause

Compressor trip Insignificant cause

Incorrect tension values Insignificant cause

Incorrect electrical parameter Insignificant cause


PRINT WASTE

Method

Dirty web eyes

Scum due to roller washing

Test run

Reel inspection method

Run sequence

Predetermined by manufacturer

Scum due to roller washing Insignificant cause

Reel inspection method Insignificant cause

Dirty web eyes Insignificant cause

Test run Significant cause

Run sequence Significant cause

No fixed counter for copy checking

Predetermined by manufacturer



PRINT WASTE

Moisture

Wrinkles due to dryness

Environment

Warehouse conditions

Reel turning brittle

Warehouse conditions Insignificant cause

Moisture Insignificant cause

Wrinkles due to dryness Insignificant cause

Reel turning brittle Insignificant cause



PRINT WASTE

Catch-up due to fluff

Materials

Scum due to roller ageing

Image wear-off

Mis-registration after brand change

Web wandering

Loose winding

Out of round reels

Mill joint failure

Inside sticky reelPoor slitting

Core slippageInside cut

Slitter grinding required

Catch-up due to fluff Insignificant cause

Image wear-off Insignificant cause

Scum due to roller ageing Significant cause

Mis-registration after brand change Insignificant cause

Web wandering Insignificant cause

Loose winding Insignificant cause

Out of round reels Insignificant cause

Mill joint failure Insignificant cause

Inside sticky reels Insignificant cause

Core slippage Insignificant cause

Inside cut Insignificant cause


5 – Why Analysis to find out root-cause of Reel-end waste

ACTION PLAN

Optimize the reel-end cut diameter to the lowest possible value.


High reel-end waste

Leftover generated by the

machine

To avoid splice failure

Reduce cut dia required

Why? Why?

Why?

Solution

Some length required by flying autosplicer

5 – Why Analysis to find out root-cause of Tear - Off waste

ACTION PLAN

Regular inspection of forklift rubber pads.


High Tear-off waste

Due to transportation

damage

Poor condition of forklifts clamp

rubber pads and unskilled operators

Reduce handling damage by

Changing forklift clamp rubber pads

Dock leveler for unloading reels

Emami reels transportation by train

Why? Why?

Why?

Solution

Poor handling of reels during

loading/unloading at vehicles/ warehouse

Best Practices:

Idea & Best Practices Waste CategoryImparted training regarding newsprint handling and awareness

Tear – off & print waste

Regular inspection of forklift rubber pads. Tear - off

Run sequence modification Print wasteReduction of pasting failures Print waste

Reduction of web breaks Print waste

Reduction of Start up waste Print waste

Followed Preventive SOP Print waste

Acquire and note the press parameters like LR & CR.

Print waste

Proper followed the check points & settings

Print waste


Awareness regarding Newsprint Handling:

a) Providing reel cushions during unloading to prevent Out Of Roundness

(OOR)The reels are now dropped on a cushion made of foam to minimize the

impact if left directly on the floor.

Before After


b) Protecting left over reels to reduce Tear- Off waste

The leftover reels after printing are properly wrapped so as to avoid damage to

top layers by incision of foreign materials lying on the floor.

Inspection of Forklift pads to prevent side damage to the reels and

maintain clamp force to reduce out of roundness

Damaged forklift pad New forklift pad


Worn out Forklift pads causes cuts and damages to the newsprint while gripping.

Regular inspection is done to check its condition and to be replaced if required.

Clamp force to be set to an optimum level (15 KN for 1000 kg reel) to avoid Out of

Roundness at the time of gripping the reels.

Reel- end diameter reduction and improvements:


FINANCIAL BENEFITS & BUSINESS RESULTS

Saving Calculation details


INTANGIBLE GAINS


STANDARDIZATION

Standard Operating Procedures for different processes were made. Following are the

list of processes:

Reel Make-ready

Cushion for Reel Unloading

Ink & Water Curve check

Run sequence.

Reduction of web breaks & Pasting Failures.

Reduction of change over Time.

Control charts & Bar graphs:

Printed waste control charts are being used every month to monitor the variation.

Appropriate actions are taken for any variance reflected.

Following are the Bar graphs used to monitor the machine performance:

Newsprint waste

Newsprint yield

Web breaks

Startup waste

Average speed

Average downtime


SUSTAINABILITY

Training & Developments:


Improvements:

I-Chart of Newsprint Yield.

I-Chart of Newsprint Waste.


TOOLS USED FOR ANALYSIS


case study on newsprint waste reduction · web viewinitially, after identification of the problem,...

Documents