sakc mission 26th april 2011-23rd april final

8/21/2019 SAKC Mission 26th April 2011-23rd April Final

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Theme: Capacity Creation of Ketchup Glass

Bottle through utilisation of ExistingMonogamy Line.

Migration

GlassMonogamy

D!E


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Selection ofSelection of

ThemeTheme

Capacity Creation for Glass Bottle

Setting up of a makeshift manual machine

Morale Very High.Safety.

Throughput 60TP.

!uality" Concern of

Hygiene.

#oreign Bo$y

Contamination.

%n$er %tili&ation of 'sset.

() *%P 's Bottle line +as not running.

CC#)T ,rop in Glass Bottle $ue to

Capacity Crunch.

*o+ Morale in (e+ #actor $ue to


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Data CollectionData Collection CC"OT Tren# $ Loss %nalysis

CC"OT& C'D

G

O

O

D

Mar(et Deman# tren# analysis

Glass

Bottle

'lastic

Bottle

G

OO

D

Deman# )s 'ro#uction Tren#G

O

OD


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Data AnalysisData Anal

ysis

Mar(et esearch

Glass Bottle Deman# )s CapacityDeman# )s Capacity "or 'lastic

Bottle

Mismatch Bet*een

!nstalle# capacity $

Mar(et #eman#

G

O

O

D

G

O

O

D
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OptionsO

ptions

Option +'urchase $ !nstall complete ne* line

Option ,

!ncrease 'ro#ucti-ity of manual line

Option

Con-ert i#le plastic /ottle line on glass /ottle

line.
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SWOTSWOTANALYSISANALYSIS

Capale / 1perience$ Manpo+er

2n3house Technical 1pertise an$ 1perience

Strong +ill to accept challenges / $eli4er

*ocal Ven$or Support

Staili&ation time can e 4ery high.

High Glass Bottle Breakage

Glass ottle Capping Prolem

Meeting Business 5euirement.

Capacity creation of Glass Bottle.

5e$uction of Con4ersion Cost..

2ncrease BB) an$ ).

Manpo+er Sa4ing.

5e$uction in Gi4e '+ay.

nhance$ Safety

Better Hygiene an$ 7iel$ Control.

Machine may fail to deliver results.

Switching back to Monogamy may be

difficult.

Weaknesses

Threats

Strengths

Opportunities


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OptionsOptions

Option +'urchase $ !nstall complete ne* line

Option ,

!ncrease 'ro#ucti-ity of manual line

Option

Con-ert i#le plastic /ottle line on glass /ottle

line.

Cost $

Time

Constraint

0afety $

1ygiene

!ssue


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Target SettingTarget Setting

Production (Ton/Week)

50%

Conversion Cost (Rs/Ton)

200%

%ctual

Targ

et


9/42

Team: ArroTeam: Arro

S 7a$a4

8 Singh

G SinghB Singh

# Singh

Team

, Sahar+al 8 Singh

G Singh Meher$een ,9 8ainS Singh, 9umar


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!aster "lan!aster "lan

ActualTarget

Policy

Plan

Do

Act & Review

Check

Continual

Improvement
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ChallengeChallenge

ss

Challenge + To con-ert inser Machine

Challenge , To con-ert "illing Machine

Challenge To #e-elop cro*ning

machine


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#rainstorming#rainstorming

Total #rain Storming I$easI$entifie$: %&

Cro*ning2

CT

,3 i#eas

#roppe#

,4 i#ea

implemente#through

55%

Directly

implemente

# i#eas & 4


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#ottle fee$ing to 'inser()illing#ottle fee$ing to 'inser()illing

!(c!(c

0tar *heel profile for

monogamy /ottles.

Mo#ifie# star *heel

profile for glass

/ottles.

BE"OE

%"TE

Hori&ontal replication on all star

+heels of 5inser / #illing machines.

Total 6 Star +heel Mo$ifie$.

516 & +

516 & ,

516 &

Chances of Bottle Breakage.

Profile of lass and Plastic Bottle is different.

!esign Problem" Star to be modified for lass Bottle Profile.

Challenge + $

,

55%&

+
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*limination of gripping*limination ofgripping

pro+lempro+lem

,Creati-e .ai/en0,Creati-e .ai/en0

"lexi/le 00gripper

*ith spring

tension.

igi# Teflon

gripper.

BE"OE

%"TE

516 & +

516 & ,

516 &

Bottle ri##ing issues can come.

!esign" $igid ri##er to be designed for heavier glass bottle.

Hori&ontal replication on all

Gripper of 5inser / filling machine

Total 6: Grippers Mo$ifie$

Challenge + $

,

ri##er Tension not ade%uate for heavier glass bottle.

55%&

,


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Bottle support "or Monogamy

/ottle

Mo#ifie# profile of glass /ottlesupport

BE"OE

%"TE

516 & +

516 & ,

516 &

Challenge ,

Bottle &olding 'ssues can come.

Smooth #ottle Tra-erse in )illingSmooth #ottle Tra-erse in )illing

!(c!(c

lass Bottle Profile different from Plastic Bottle.

Profile of Bottle Su##ort not suitable for lass Bottle.

516 &

!esign" Bottle Su##ort design to be modified for lass Bottle.

Hori&ontal replication on all

Bottle Support

Total ;: Supports Mo$ifie$

55%&


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;;0 mm

??< mm

Mo#ifie# Length

"illing 7o88le "or Monogamy

/ottle

;@< o-er 7o-+;.

'esult: !inor stoppage re$uce$ +y 6%7 o-er'esult: !inor stoppage re$uce$ +y 6%7 o-er

No- 89No- 89

Target
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35/42

(umer of 9ai&en implemente$ I :;

Total (umer of Mo$ifications inclu$ing Hori&ontal

5eplications"A6;D

Pro$ucti4ity " A:

!uality " 6

Cost "

sakc mission 26th april 2011-23rd april final

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