PROJECT AT GLANCE..

Focus : Improve productivity of Compression MachineProject ID : Six Sigma ProjectDate : Dec.2011Green Belt : Mr. Yogesh Tripathi

SUMMARY OF PROJECTProject Name : Improvement of OEE of compression by 10% Define | Project scope, team formation, project plan & charter. Measure | Use of C & E Diagram for route causes (Brainstorming conducted). OEE tool used. Analyze | Availability loss is mainly from changeovers & break down Performance loss is mainly due to machine setting and RPM Quality losses is mainly significant to individual neglianceImprove | Interpretation & action plan for Product c/o, breakdown , m/c setting & RPMControl | Skill matrix / ownership applied OEE comparison (Before:-44.11%,After:-56.81%) Project benefits & financial calculations Monitor action steps & form system

Chart1

46

56

OEE

Sheet1

OEE

Before46

After56

To resize chart data range, drag lower right corner of range.

Define

Charter1.2

Team Charter

Project :Reduce product length variation From 182-192 to 182-186

Business CaseOpportunity Statement

This project supports our Business objective of improving Plant performance thru' reducing length variability. From 182-192 to 182-186Current length range is 182-192 it is an opportunity to

reduce length variablity to 182-186

Low variablity in length will improve PHD loading performance and reduce RT

This project is towards material saveing by reducing length variation .Process sigma improvement for length from 1.5 to 2.5 sigma level.

Goal StatementProject Scope

Reduce length range from 182--192 to 182-186 (large & small)

Reduce length std. Dev. From 2.65 to 2.0

Process : Dipping

Financial benefit :Reduction in length variation leads to reduce productStart point : Glass former inventery

weight by 0.04 gms/PC for higher length condomGlass former assembly

which gives finincial benefit of 4.0 K $line conveyor fitting

End point : QC inspection

Project PlanTeam Members

Champion :RSWork's Director

Task/PhaseStart DateEnd DateActual EndBB :SRDSr.Mgr.Engg.

Form team19/09/0423/09/04Process Owner :R S TabadeDipping Incharge

Finalize Charter24/09/0430/09/04Green Belt :DineshOfficer QC/Lab

Gather data01/10/0420/10/2004Member :VGFinance Maneger

Analyse Data21/10/200430/10/2004Member :PallaviQA,Jr.Executive

Select Solution1/11/0410/11/04Member :SNQA,QC & TECH.Manager

Implementation11/11/0425/11/2004Member :DNKSup-QC

Verify solution26/11/200420/12/2004Member :YGDSup- Diping

Close and RecognitionMember :Bhagwat K.Worker Assembly

20/12/200430/12/2005Member :LPKTester QC

Reduce glass former variationfor all types.thrua) Review of glass former specification, b) Release criteria c) Including all dimenstions, d) New gauge GO/ NO GO & e) Method of measurement.

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schedule1.2

PROJECT PLAN

PHASEACTIVITYSEPT-04OCT-04Nov-04Dec-04

WK4WK1WK2WK3WK4WK1WK2WK3WK4WK1WK2WK3WK4

DEFINEIdentify buisness opportunity

Finalise project charter

Finincial benefit explanation

Charter Evaluation

Form team & gather data

Project schedule

Team Building

SIPOC

Top down charting

Process Flow Chart

VOC/VOB to CCR/CBR

Quick win Opportunity

MEASUREPlot & Analyse data

Mesurment system Analysis

Special cause

Determine sigma performance

Collect other base line performance data

ANALYSEValidate root cause

Source of variation

FMEA

Problem statement

Potential solutions

IMPROVESolutions

Process maps & documentation

Implementation mile stone

Improvement impacts & benefits

Story board

Change maps

CONTROLProcess control system

Standerds & procedure

Trainning

Team evalution

Change implementation plans

Potential problem analysis

Pilot & solution results

Success stories

Trained associates

Replication apportunities

Standerdization apportunities

Run chart1.1

Identify Buisness opportunity

180

Higher Length

box plot1.1

Hypothesis for normality of data :Ho : Data is normal,Ha : Data is not normal

Condition :P- value > 0.05 fail to reject Ho,P- value < 0.05 reject Ho

P- Value is 0.251 is moreP- Value is 0.587 is more

than 0.05 Fail to reject Hothan 0.05 Fail to reject Ho

Two-Sample T-Test and CI: Length-182, lenghth-192

Two-sample T for Length-182 vs lenghth-192

N Mean StDev SE Mean

Length-182 10 1.4142 0.0260 0.0082

lenghth-192 10 1.4513 0.0239 0.0076

Difference = mu (Length-182) - mu (lenghth-192)

Estimate for difference: -0.037100

95% CI for difference: (-0.060673, -0.013527)

T-Test of difference = 0 (vs not =): T-Value = -3.32 P-Value = 0.004 DF = 17

Two-Sample T-Test and CI: WT.182, WT.192

Two-sample T for WT.182 vs WT.192

N Mean StDev SE Mean

WT.182 10 1.4142 0.0260 0.0082

WT.192 10 1.4513 0.0239 0.0076

Difference = mu (WT.182) - mu (WT.192)

Estimate for difference: -0.037100

95% CI for difference: (-0.060673, -0.013527)

T-Test of difference = 0 (vs not =): T-Value = -3.32 P-Value = 0.004 DF = 17

Hypothesis testHo: WT-182= WT-192HA: WT-182= WT-192

P- Value is less than 0.05Reject Null Hypothesis

regression1.1

Regression Analysis: W BEAD versus length

Regression Analysis: W BEAD versus length, thickThe regression equation is

W BEAD = 0.7390 + 0.003710 length

The regression equation is

W BEAD = 0.522 + 0.00387 length + 2.64 thick

S = 0.0249841 R-Sq = 38.0% R-Sq(adj) = 34.5%

Predictor Coef SE Coef T P

Constant 0.5224 0.3495 1.49 0.153Analysis of Variance

length 0.003868 0.001148 3.37 0.004

thick 2.641 3.394 0.78 0.447Source DF SS MS F P

Regression 1 0.0068821 0.0068821 11.03 0.004

Error 18 0.0112357 0.0006242

S = 0.0252626 R-Sq = 40.1% R-Sq(adj) = 33.1%Total 19 0.0181178

Analysis of VarianceFitted Line: W BEAD versus length

Source DF SS MS F P

Regression 2 0.0072684 0.0036342 5.69 0.013

Residual Error 17 0.0108494 0.0006382

Total 19 0.0181178

Source DF Seq SS

length 1 0.0068821

thick 1 0.0003863

Unusual Observations

Obs length W BEAD Fit SE Fit Residual St Resid

16 182 1.46500 1.41130 0.00882 0.05370 2.27R

R denotes an observation with a large standardized residual.

financial benifit1.1

Sr.noLengthThicknessT.WeightWt.withoutBeadSr.noLengthThicknessT.WeightWt.withoutBead

OpenCloseMidAvg.S.IBeadWt.OpenCloseMid.Avg.Single wallBeadWt.

11920.1360.1420.1450.1410.0711.6611.4790.181

20.1330.1470.1500.1430.0721.6071.4120.192

30.1260.1400.1440.1370.0681.6491.4550.192192Min.0.1260.1360.1420.1370.0681.6071.4120.181

40.1450.1400.1540.1460.0731.6711.4680.202Max.0.1450.1470.1540.1460.0731.6791.4800.224

50.1330.1460.1510.1430.0721.6791.4800.197Range0.0190.0110.0120.0100.0050.0720.0680.043

60.1270.1360.1480.1370.0691.6641.4540.208Avg.0.13410.14050.14760.1410.0701.6531.4510.200

70.1350.1380.1460.1400.0701.6541.4390.214

80.1330.1410.1440.1390.0701.6561.4310.224182Min.0.1290.1320.1380.1360.0681.4931.3830.187

90.1330.1360.1520.1400.0701.6611.4710.189Max.0.150.1530.1540.1470.0741.6771.4650.251

100.1400.1390.1420.1400.0701.6271.4240.202Range0.0210.0210.0160.0110.0050.1840.0820.064

SummeryMin.0.1260.1360.1420.1370.0681.6071.4120.181Avg.0.13790.14220.14670.1420.0711.6201.4140.225

Max.0.1450.1470.1540.1460.0731.6791.4800.224

Range0.0190.0110.0120.00966666670.00480.0720.0680.043Difference0.0000.0000.1140.029-0.006

Avg.0.13410.14050.14760.14073333330.07041.65291.45130.2001-0.001-0.00030.0020.015-0.027

-0.001-0.001-0.112-0.014-0.021

Sr.noLengthThicknessSingle wallT.WeightWt.withoutBead-0.002-0.0010.0330.037-0.025

OpenCloseMidAvg.BeadWt.

11820.1440.1400.1490.1440.0721.6291.4030.224

20.1320.1520.1480.1440.0721.6011.3960.204

30.1420.1430.1540.1460.0731.6771.4300.246

40.1380.1320.1400.1370.0681.6451.3970.248

50.1400.1390.1490.1430.0711.6681.4460.222

60.1300.1420.1480.1400.0701.4931.4650.227

70.1290.1370.1430.1360.0681.6351.3830.251

80.1500.1440.1380.1440.0721.6181.3940.224

90.1360.1400.1480.1410.0711.6241.4060.217

100.1380.1530.1500.1470.0741.611.4220.187

SummeryMin.0.1290.1320.1380.1360.0681.4931.3830.187

Max.0.150.1530.1540.1470.0741.6771.4650.251

Range0.0210.0210.0160.01066666670.00530.1840.0820.064

Avg.0.13790.14220.14670.14226666670.07111.6201.4140.225

Difference

SummeryMin.0.0000.0000.1140.029-0.006

Max.-0.001-0.0000.0020.015-0.027

Range-0.001-0.001-0.112-0.014-0.021

Avg.-0.002-0.0010.0330.037-0.025

loosely load

Length RangeHigher length

182-186187-192

Tightly LoadLoosely Load

No Air pocket

Air Pocket

aoql1.1

49

66

54

QA Testing in Month of Sept.04 PHD Bgwise testing per bag 80

No ofNo of%Holes Break up and analysis

SamplesDefectsDefectsPositionNo of HolesDirtCoagulumClearbubbleDamageOther

413601940.4690522244BT49474324749

BM6651012331566

BB54597423654

Teat2523835425

Total194162931138322194

%8.2514.9515.986.7042.7811.34100

0.00444874270.4448742747%0.0390.0700.0750.0310.2010.053

clearCoagulumBubbleM.damageText damageDirtWet patchW.spotCluster

1940.469052224431291383916661

1860.4497098646

1820.4400386847

PHD Bagwise Testing By QA in Month of Sept.04

Sample Size : 80 Pcs / Bag. Total sample tested : 41360

PositionBTBMBBTeatTotal

Holes49665425194

PHD Bagwise Testing By QA in Month of Sept.04

Sample Size : 80 Pcs / Bag. Total sample tested : 41360

PositionBTBMBBTeatTotal

Holes49665425194

Holes Analysis

Dirt455216

Coagulum7109329

Clear4127831

Bubble334313

Damage243123583

Other756422

Current proc. Average 0.46 % for 194

Projected Proc.Average 0.44 %

Process Average Improvement By 0.02 %

B/T= 4925.3%

Teat=2512.9%

B/B = 5427.8%

B/M = 6634.0%

Finincial benifit1.1

Projected Cost -Benefit calculationTRIAL - 1With BeadWithout BeadXY

With BeadWithout BeadBead Wt.

Total annual plant capacity250 MpcsSr. no182192182192DifferenceDifference

11.531.521.331.39-0.010.060.2

36% of product is90000000(90 Mpcs)21.541.531.341.38-0.010.040.2

having Higher length100000031.591.571.371.42-0.020.050.22

25041.591.551.381.39-0.040.010.21

Each higher length condom3600000In gms25000000051.541.631.331.440.090.110.21

consumes 0.04 gm excess61.561.551.351.38-0.010.030.21

Material71.561.591.361.370.030.010.2

81.581.571.371.39-0.010.020.21

Converted to Kgs3600Kgs91.571.521.381.37-0.05-0.010.19

101.551.581.361.390.030.030.19

Cost of compounded51Rs/Kg.Average0.035

LatexTester : SAMin0.01

Max0.11

Cost benefit51 X 3600In INR

Cost benefit183600In INRTRIAL - 2

Without Bead length measurement after bead removel

Cost benefit in dollars USD3906in US$182--186187-192

LengthWeightLengthWeightDifference

Annual Cost Benefit4.0K1851.451871.540.09

1841.471871.490.02

1841.521871.520

1841.481881.490.01

1851.391901.510.12

Tester : SAAverage0.048

TRIAL -3

With Bead length measurement

182--186187-190

WeightWeightDifference

1.41.35-0.05

1.371.40.03

1.361.34-0.02

1.341.380.04

1.361.360

1.351.390.04

1.331.370.04

1.361.34-0.02

1.371.370

1.341.390.05

Tester : SR

TRIAL - 4With bead 190 mm lengthWith bead 185 mm lengthDifferenceBead Weight

Double wallSingle wallWeightDouble wallSingle wallWeight

0.1360.0681.550.1360.0681.60-0.0500.1978

0.1390.0701.610.1450.0731.62-0.0100.1938

0.1360.0681.620.1430.0721.63-0.0100.2307

0.1360.0681.610.1310.0661.570.0400.2323

0.1410.0711.560.1370.0691.63-0.0700.2079

Without bead 190 mm lengthWithout bead 185 mm lengthDifferenceBead Weight

Double wallSingle wallWeightDouble wallSingle wallWeight

0.1340.0671.360.1390.0701.37-0.0100.2156

0.1390.0701.410.1410.0711.410.0000.1937

0.1350.0681.430.1440.0721.400.0300.2007

0.1420.0711.420.1370.0691.400.0200.1934

0.1380.0691.380.1320.0661.370.0100.2270

Tester : LPK

Bead

beading brush adjustment from both side is equal

and directly affecting on th length

SMART1.2

Specific

Does it address a real business problem?

Yes, Higher oprating band(182-192) of product length leads to consume excess material.

Measurable

Are we able to measure the problem, establish a baseline, and set targets for improvement?

Yes , Our existing length range is 182 - 192 and we set target to reduce to 182 - 186.

Attainable

Is the goal achievable? Is the project completion date realistic?

Yes , Project will complete as per schedule in project Plan.

Relevant

Does it relate to a business objective?

Yes, Higher length leads to higher material consumation and it is direct related to business objective.

Time Bound

Have we set a date for completion?

Yes , 30 December,2004

SMART

revised charter

Team Charter

Project :Improve productivity of compression machine

Business CaseOpportunity Statement

Improve availability of machine,

This project supports our Business objective of improving Plant performance thru' increasing productivity of compression m/cReduce machine downtime,

Reduce Tab. wt.variation.

Goal StatementProject Scope

To increase Overall equipment efficiency by 10%Process : Compression

Start point : Dispensing

Granulation

Compression

End point : QC inspection

Project PlanTeam Members

Task/PhaseStart DateEnd DateActual EndProcess Owner :AM prod'n

Form team20-Dec-1120-Dec-1120-Dec-11Member :Maint

Finalize Charter22-Dec-1122-Dec-1122-Dec-11Member :Maint

Gather data24-Dec-1124-Dec-1124-Dec-11Member :Prod'n

Analyse Data29-Dec-1129-Dec-1129-Dec-11Member :IPQA,

Select Solution5-Jan-125-Jan-125-Jan-12Member :Mentor

Implementation6-Jan-126-Jan-126-Jan-12Member :Prod'n

Verify solution8-Jan-128-Jan-128-Jan-12Member :Operator

Close and Reco12-Jan-1212-Jan-1212-Jan-12Member :Operator

Member :Operator

Reduce glass former variationfor all types.thrua) Review of glass former specification, b) Release criteria c) Including all dimenstions, d) New gauge GO/ NO GO & e) Method of measurement.

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1.3 team building

Minutes of Meeting On Six Sigma

Project : Reduce Length variablity

Date24/09/2004

VenueTraining Room

Start Time1:00PM

End Time5:00PM

Dinesh DeshpandeGreen Belt

Team Members

R.S.TabadeProcess Owner

Yogesh DeshmukhMember

Dhiraj KandiMember

Absent

Topics of training

1Introduction / Overview of Six Sigma Program

2How our project is selected

3Six Sigma Foundations

4Define Phase

1.1 Identify , Prioritize and select the improvement opportunity

1.2 Develop Project Team Charter

1.3 Build Effective Team ( Team Growth Stages , Code of conduct , Brainstorming)

1.4 Customer & customer requirement

5Recap of topics disccussed.

1.3Team Brain storming

Minutes of Meeting On Six Sigma

Project : Reduce Length variablity

Date01/10/2004 & 02/10/2004

VenueLaboratory

Start Time11:00PM

End Time12:30PM

Dinesh DeshpandeGreen Belt

Team Members

Yogesh DeshmukhMember

Dhiraj KandiMember

Manish DixitMember

L.P. KhandagaleMember

Topics of Brain StormingDiscussion on Topics

1Charter evaluation1Next steps of project

2Sipoc2Success criteria of project

3Process Flow Chart3Milestones to reatch target

4Top Down Charting4Effort required

5VOB-VOC5Data collection

6Functional deployment chart6Effect of length on AOQL

7Quick win Opportunity7Roll of beading brush

on length of condom

Information shared to absent member

Kano analysis

Customer : PHD Dept. Internal customer (process Partner)

Satisfaction+

DelightersLength Range 182-186

Service Fully Functional

Service Dysfunctional

-Dissatisfaction

Must be - Satisfy condom standard requirement

Kano Analysis: Classifying Customer Needs

VOB

Voice Of Buisness

CTQ'SCCR'SCustomerVOC

Issues

Produce productlength shouldHigher length condom

with lowbe in thenot fully load on mandrillHigher length

length range ofrangeand forms air pocket>186 leads

182-186 mm182-186at teat area which isto increase

not detected for holesPHD RT %

VOBBusinessCBR'SCTP'SLower length condomLower length

Cost EffectiveIssuesMaintain lowNot match to the mandrill

Copyright 2002 Motorola. All rights reserved.

1.4 -- *

1.4 Identify Customers & Customer Requirements

Kano Analysis: Classifying Customer Needs

Primary Satisfiers

Length range 182-192

Airlines Example:

Must Be: Bin Space, luggage delivered with person

Primary Satisfiers: Leg space, arrival time

Delighters:Extra miles for web based reservations

Point out how this fits into VOC

Have an awareness discussion

Whether you formally do Kano Analysis isnt the point.

The end result is that GBs have things theyre measuring that are important to the customer. And it is a moving target, very dynamic, changes. Its difficult to measure what they (customer) want and what changes. Prioritization and classification can help.

Airlines Example:

Must Be: Bin Space, luggage delivered with person

Primary Satisfiers: Leg space, arrival time

Delighters:Extra miles for web based reservations

Point out how this fits into VOC

Have an awareness discussion

Whether you formally do Kano Analysis isnt the point.

The end result is that GBs have things theyre measuring that are important to the customer. And it is a moving target, very dynamic, changes. Its difficult to measure what they (customer) want and what changes. Prioritization and classification can help.

MBD0002CF5F.unknown

MBD0001CF94.unknown

MBD0002C332.unknown

MBD0001C7A6.unknown

PROCESS FLOW CHART

STARTDISPENSINGSIFTING/DRYINGGRANULATIONCOMPRESSIONBLENDINGCOATINGSORTINGBLISTERINGPACKINGB.S.R.

CHECK

DispatchDefineFocus

ABOUT COMPRESSION MACHINECompression machine is used for producing oral dosage (tablets) by applying of required pressure.Compression m/c consists of upper punches, lower punches & die cavity in which upper & lower punches are forced to form a tablet applying requisite pressure.

Upper PunchLower PunchGranulesDieDefine

Define

Define

SIPOCSupplierInputProcessOutputCustomerStoresGranulationCompressionDispensing Dept.- Change over processCompressedPrimary packing Accuracy in weighingGranulationTabletsDepartmentCross check - Granulation end point RPMThickness-LOD - Line clearancescrap - Sieving - Friability- Bulk Density - Avg.wt.Defective Secondary -Hardness/ThicknessTab. scrappackingBlending - Disintegrity DepartmentLubrication - Batch YieldLeft overMixing time - Documentationscrap - QC CheckCoating

Highlight key suspected Xs for focus & analysis

Measure Spare (M)Fine granules (L)Change over frequency (H)Prodn plan (L)RPM (M)Room temp.high (L)Lab testing method (M) COMPRESSION M/CMachine start (H)Machine setting (M)Skill (H)Pully alignment (H)Vibration(H)Speed (H)Old/new M/c (H)R.M.quality (L)Loading plan (L)Noisy (L)Dusty (L)Moral(H)Discipline (M)Idle time(H)Tab.wt. (L)Granulation procedure (L)High moisture (L)Over dry granules (L)Training(H)Punches variation (M) Prev. Maint. (H)Break down (H)Compression m/c outputMan

Measure

out put indicators

Process Element and Indicator Relationship

SupplierInputProcessOutputCustomer

Compounding Dept.Compounded latexGlass former fitting

Ammonia solutionto conveyor chainUntestedPHD Dept.

Glass former supplierGlass Formerswith assemblyCondoms

Assembly componentAssembly componentcomponent

supplier-CupCondom ManufacturingNon stripping

-Rubber sleve- Dippingscrap

- Spindle- Drying

- Bearing- Bead formationDefective

- Star washer- Leatchingcondom scrap

- Check Nut- Stripping

- Gear- Treatmentsilica powder

HCL and NaOH- Hydroextrationscrap

Process chemicalM-D & M-T chemicals- Vulcanisation

supplierSilica- QC Dim. Check

Silicone defomer

Input IndicatorProcess indicatorOutput Performance

Sweel indexDipper latex tempRaw material actual cost

Latex CTRDrying oven temperatureProcess average

ViscosityBead brush adjustmentVisual defect

PHBeading rackDimention of condom for

MSTLeach tank tempLength

TSCID & IT concWidth

Assembly component sizeTreatment screen speedThickness

Glass former sizeSilica slurry spc.gr.Weight

Cup & spindleSizeSilica drum speedBead diameter

sleve sizeHCL acid concentrationEx-vulcanisation result

Conveyor PlateHot water rinsing

Machine speed

Glass former & asembly fitting

Latex level

Oven filter

Sheet2

MSA for condom Length Measurement

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Project Focus-1

MSA for condom Length Measurement

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project focus-2

Condom Length

X1X2X3

INPUT VARIABLEPROCESS VARIABLEMEASUREMENT VARIABLE

X11X13X21X22X31X32

Glass former sizeAssembly component SizeFormer & Ass. FittingDipping ProcessOperatorDimensionalCheck

X111X112X131X132X211X212X213X221X222X223X311X312X313X321X322X323

X12

Different Former SupplierOld and New FormersConveyor PlateDifferent size of componentsOld / new componentsCup & GF FittingSpindle cup FittingAss.Fitting to conveyorBeading Brush AdjustmentBeadingrack adjustmentLatex Dip Tank LevelOperator-1Operator-2Operator-3SamplingTest methodTest Equipment

Y

cause & Effect

Conveyor plate

Adjustment

C&E Matrix

ProductivityQualitywt.variation

Y1Y2Y3Output indicator

123importance

Sr.NoInput /Process indicator------Correlation of input to output----------Total----

1Prev.maint./ Break down930114

2M/c change over time90090

3M/c setting390102

4Granulation390102

5Speed (RPM)933129

6Training33054

7Skill33369

8Machine loading plan90090

9Priority30030

Scale :NoneLowModerateStrong

0139

operational defination

OPERATIONAL DEFINITIONS

Condom length : Length of condom is length Measured Excluding Teat Portion.

Condom Length : Length of condom is a smallest value of length can be read

on the Scale of Length mandrill to the nearest milimeters out

side open end of condom

Sample Size : 5 condoms measured for length at Ex-Vulcanisation

Dimentional Check

Testing frequency : 5 Pcs from each Bag (2 Hrs Dipping Production per line)

Condom Standard Requirement : Minimum individual condom length should

Not be less than 180 mm

Current operating range is : 182mm To 192 mm

Project target range is : 182mm To 186 mm

Process Average : No of Defects X 100

No of samples

Glass former : : Glass shape or mould of condom profile

Cup : : Glass former is fixed in it with help of sleves

Spindle : Cup fitting in spindle and it fixed to line conveyor plate

Beading Brush : : Brush which forms bead to open end of condom

Sheet1

QC Operator-1QC Operator-1QC Operator-1QC Operator-1QC Operator-1

Sample-1Sample-2Sample-3Sample-4Sample-5Sample-1Sample-2Sample-3Sample-4Sample-5

Reading -1Reading -2Reading -1Reading -2Reading -1Reading -2Reading -1Reading -1Reading -1Reading -2Reading -1Reading -2Reading -1Reading -2Reading -1Reading -2Reading -1Reading -1Reading -1Reading -2

MSA

MSA - Measurement System Analysis For Length

Operator-->RSPRSKSRRLPKGage R&R Study - ANOVA Method

Sample NoReading-1Reading-2Reading-1Reading-2Reading-1Reading-2Reading-1Reading-2Gage R&R for Result

1180180180181182182182182Gage name: Length Mandrill

2188188189189189189188188Date of study: 27/10/04

3179179180180180180180180Reported by: Dinesh

4181181182181182182182181Tolerance: 1mm

5191191191191192192191191Misc: Condom Standard Applicable - Schedule'R'

Two-Way ANOVA Table With Interaction

Source DF SS MS F P

Part 4 835.900 208.975 491.706 0.000

Operator 3 7.275 2.425 5.706 0.012

Part * Operator 12 5.100 0.425 5.667 0.000

Repeatability 20 1.500 0.075

Total 39 849.775

Gage R&R

%Contribution

Source VarComp (of VarComp)

Total Gage R&R 0.4500 1.70

Repeatability 0.0750 0.28

Reproducibility 0.3750 1.41

Operator 0.2000 0.75

Operator*Part 0.1750 0.66

Part-To-Part 26.0688 98.30

Total Variation 26.5187 100.00

StudyVar %StudyVar

Source StdDev (SD) (6*SD) (%SV)

Total Gage R&R 0.67082 4.0249 13.03

Repeatability 0.27386 1.6432 5.32

From Above Analysis Graphs and Statistical anova it is clear that the measuring system is stable and producing result is compatable and giving result in the variablity of 13.03%.Repeatablity 5.32%and Reproduceablity is 11.89% As per six sigma methadology.Operator 0.44721 2.6833 8.68

Operator*Part 0.41833 2.5100 8.12

Part-To-Part 5.10576 30.6345 99.15

Total Variation 5.14964 30.8978 100.00

Number of Distinct Categories = 10

Gage R&R for Result

Base line performance

PLRPLDWSP

Batch NoLengthWeightBatch NoLengthWeightBatch NoLengthWeightBatch NoLengthWeight

0408210223PLR0408230323PLDWSPPLP0409160123

11871.8111851.7511951.6211881.70

21891.7521841.7521851.6121901.77

31871.7331871.7931871.6231951.73

41861.7741851.841851.6641851.68

51851.7551881.7851921.651861.73

11841.7311821.7711851.5811851.70

21861.6521841.7321951.6121841.76

31871.7331781.7631951.6231861.74

41851.7641851.7141861.5841851.71

51801.7351801.7751901.5951881.67

11851.811881.811861.611841.70

21841.7321851.7721901.6421901.68

31851.7831861.7731901.5831881.74

41881.7241841.8241881.5841901.75

51851.851851.7951901.6451861.75

11851.811851.7211901.5911901.76

21801.7521861.7521891.5921821.70

31861.8131881.8231881.6131881.69

41861.841861.7141851.6341901.74

51851.7151851.7651901.651821.73

11871.7211901.711851.6511851.73

21901.7421871.7321861.5721861.75

31891.7331921.7931851.6931881.76

41861.7141901.6941901.6641901.76

51851.8551881.6451881.6451881.76

11801.8111871.7211901.611851.71

21871.6921881.721841.6921901.74

31881.6831851.7631901.7231921.75

41851.841841.7141841.641881.77

51871.7151861.6551841.6251861.75

0408220223040824032311901.7211851.70

11861.7411811.721851.6821841.70

21861.821811.6831901.6431901.72

31841.931801.6841901.6641861.73

41891.8741841.6851891.6751851.80

51901.7751791.6311841.6211851.73

11801.7811821.7321841.6721861.75

21821.7121851.7231891.5931881.77

31801.831851.6741851.5841901.78

41861.7141821.6951841.5751891.79

51851.851851.6811891.6311941.76

11801.8311841.6721901.6321891.78

21801.6921801.6831891.6131891.70

31861.7231851.6741851.6241861.80

41851.8741861.6651901.5951881.76

51841.8751851.7111851.6111891.67

11851.7911841.6521861.6221861.65

21861.9521851.6331901.6431881.66

31901.7431861.6741891.6141861.67

41861.8241841.6651901.6451881.65

51851.7251851.6711801.6211891.63

11871.6211841.6521841.5921881.68

21861.7321871.5931801.6131851.68

31851.7131841.541851.5741901.69

41841.7441841.5951841.6351901.72

51851.7451791.6311801.6111861.69

11881.7911861.6621851.6221861.66

21871.821841.6531901.6431841.66

31851.8131841.6341901.6241881.66

41861.7141811.6751901.6351921.73

51871.7151841.61

040823022304082503231

11801.9911841.642

21841.5821811.633

31831.7931801.654

41761.841831.695

51851.8151841.681

11841.7811801.592

21801.8521801.693

31821.7731791.734

41831.7741791.665

51841.7851831.671

11801.6811841.72

21851.7921881.683

31841.6831861.754

41801.7241871.725

51861.851871.681

11861.6511881.72

21901.8621871.653

31881.7531871.634

41891.8241881.715

51881.7251881.681

11801.6611841.682

21861.7921841.73

31871.6931831.774

41851.7241881.755

51871.7351881.681

11791.7711881.722

21861.6921861.723

31871.631881.774

41871.6941851.665

51781.5651861.75

Measurement Plan

Sr.NoPerformance MeasureOperational DefinitionData source and locationSample SizeWho will Collect dataWhen will the data be collectedHow will data be collectedOther data to be collected at the same time

1Glass former lengthLength of glass former measured in mmActual measurement of glass formers for PSP variant40LPKData collection will start from 01/11/2004Data will be collected by Actual MeasurementNil

2Cup Sizecup length in mmActual measurement of Cups25LPKData collection will start from 01/11/2004Data will be collected by Actual MeasurementNil

3GF-Cup lengthTotal length after GF fitting in CupActual measurement after fitting GF-CUP100LPKData collection will start from 01/11/2004Data will be collected by Actual Measurement

4GF-Cup -Spindle lengthDistance between Spindle coller to GF after GF-Cup-Spindle fittingActual measurement after fitting .GF-CUP-Spindle100LPKData collection will start from 01/11/2004Data will be collected by Actual MeasurementNil

5Condom length Side -A Side-BLength of condom produced from line side-A and line Side BActual measurement on the length Mandrill samples collection from Ex-Vul.60+60LPKData collection will start from 01/11/2004Data will be collected by Actual MeasurementBead Diameter of same sample

6Line triallength of condom produced in line trial after implementing all solutionActual measurement on the length Mandrill samples collection from Ex-Vul.15 daysShift testersData collection will start from 25/11/2004 to 28/11/2004Data will be collected by Actual MeasurementThickness, weight,Bead diameter

Road map

PartRoad MapVariationSolution

11) 100 GF collected from glass former stock mix (korian & JBB) DotttedYES

2) Without cup 100 GF Measured for lengthSorting and

3) Analyse data and prove that there is variation in glass former size in two sizesGrouping

4) Sorting of glass formers in size wise groupsof glass

5) Collect Separate samples from korian and techno (Korian & JBB)

6) Analyse data and prove that no variation within groups

21) Glass formers samples fitted in cups with sleves

2) Measured their length including cupsNONot needed

3) Analysis of data to give no contribution of cup and Sleves fitting in length variation

31) Cups with GF is then fitted to spindle on line.YESCheck fitting

2) Measured their length including spindle.measure length from spindle coller

3) Analyse to prove that there is a variation in spindle fitting giving different lengths

4) Make arrangement of GF checking after fitting on the line and remove misfit GF

5) Analyse that no variation in fitting of spindle and cups after checking on line

41) After completing above activities collect samples from A side and B side of lineYesBeading Brush Adjustment

2) Measure length and analyse the data to prove length variation side-A & side -B

3) Adjust beading brush to equal level and collect samples from side-A and side-B

4) Measure length and analyse data to prove no variation in length side-A & Side-B

51) Take the line trial with improved GF grouping, fitting and beading brush adjstmentNOProject success

2) collect condom samples and measure length for 3 days production 5 pcs/bag

3) Compare with base data (before improvement) and analyse the data.

4) To prove improvement in length variation in terms of Stdev and Sigma level

6Replicate the solution to all lines and all type glass formersNOFinish

MBD000B108E.doc

MBD0018E55B.unknown

MBD000512DA.unknown

*Overall Equipment Effectiveness

Metric: Measure of Utilization / PotentialCalculation:

OEE: What is OEE ?Process: Data Info Action

Measure

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**MeasureOEE: What is OEE ?

OEE FactorWorld ClassAvailability90.00%Performance95.00%Quality99.90%Overall OEE85.00%

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Product out put Compressed uncoated tabletM/c set up loss At the beginning of machine start tab. Parameter needs to set Hardness,avg.wt.etcBatch changeover Same product batch change over with same machine change part.Product C/o All sets of change part needs to replace, clean wash of machine & m/c areaLine Clearance IPQA inspection prior to machine start.OEE Time ExplanationTotal available time 720 Min. (8.30 to 20.30)Change room time 15 Min.Tea break Time 15 Min.Lunch break Time 30 Min.Machine cleaning 20 Min.Net available time 640 Min.

MeasureOPERATIONAL DEFINITION

OEE TOOL IN MEASURE PHASE FOR DATA COLLECTIONMeasure

Analyze

Analyze Prioritization of root causes

YAnalyzePROJECT FOCUS

ImproveACTION PLAN

Interpretation & Action plan to increase machine outputOwnerStatus1) Machine Availability time A) Reduction of Product changeover time Apply skill matrix for operator skill improvement SSMDONE Change over steps analyzed & removed idle timeSSMDONE M/c loading plan displayed on board for advanceSSMDONE planning for c/o to operator B) Reduction of machine break down Monthly Plan Preventive Maint. schedule to be circulated to production (Display on Board)BhumkarDONE Some of Plan preventive Maint. schedule revisedBhumkarDONE Spare list & MOL should maintain display on board ( kanban in proposal)BhumkarDONE M/c break down history should maintain by prod'n & maint.(Autonomous Maint.)BedreDONE2) Machine Performance A) Improvement of m/c setting time & RPM Machine ownership system develop (kaizen approach)SSMDONE Track to increase m/c RPM daily, prepare guideline checklistSurvanshiDONE product wise to set standard for RPM Apply skill matrix to reduce operator to operator variation.SawarkarDONE

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Improve

Machine wise Ownership (KAIZEN)Sr.noM/c nameowner1CMB-4 (35 Station)Wagh S.SDouble Rotary "B" Tooling (Old)2Cip.(27 Station)Sarode A.G.Doule Roatary"D" Tooling (Old)3CMB-2 (45 station)M.A. JagtapDouble Roatary "D B" Tooling (Old)4CMB-5 (35 Station)Kapse M.D.Double Roatary "B" Tooling 5SR-1 (16 Station)Wetal S.B.Single Rotary "D" Tooling (Old)6Rimek-( 45 station)Patil M.J."B" Tooling 7Rimek-( 37 station)Wetal S.B."D" Tooling 8Rimek-( 37 station)Sarode A.G."D" Tooling 9Process co-ordinaterSurvanshi

Compression m/c (Product) change over processImprove

Step no. ActivityActivity Description Time- 1 M/P Time- 2 M/P Actual Avg.Before Actual Avg.after1Machine & area cleaning Previous product powder removal40203030 Machine area dedusting Area cleaning with air Nozzle Cubical area cleaning walls cleaning2Equipment cleaning Deduster cleaning30302020 Metal detector cleaning Dust collector cleaning3Dismantle of parts Punches45303030 Hopper Feed Frame Channel4Washing & cleaning with IPA Hopper30153030 Feed Frame Channel5 cleaning New c/o punches cleaning301515156 Polishing Punches polishing if required453045457 Fitting Punches fitting to machine604560458Part fitting Hopper30202020 Feed Frame Channel9 IPQAI PQA LINE CLEARANCE1515151510 Material Batch movement1010101011 Unaccounted Tool/equipment unavailability450Total280210320260

The Skill matrix used for work allocation for machine set up & c/oExpert operator will train , guide to Trainee and trained operators for Machine RPM and parameter set up to optimize machine speed to reduce performance lossImprove

Operator Skill MatrixName of operatorSarode A.G.SurvanshiWagh S.SM.A. JagtapSkill MatrixTraineeTrainedTraineeTrainedTraineeTrainedTraineeTrainedSkilledExpertSkilledExpertSkilledExpertSkilledExpertName of operatorKapse M.D.Wetal S.B.Patil M.J.SawarkarSkill MatrixTraineeTrainedTraineeTrainedTraineeTrainedTraineeTrainedSkilledExpertSkilledExpertSkilledExpertSkilledExpertName of operatorP V DeshpandeBhusareJagdaleGoradeSkill MatrixTraineeTrainedTraineeTrainedTraineeTrainedTraineeTrainedSkilledExpertSkilledExpertSkilledExpertSkilledExpertNotification :1)Under Training : -Trainee3)Can work without guidence :-SkilledTraineeTrained2)Can work under guidence :-Trained4)Train others :- ExpertSkilledExpert

Standardized Product wise checklist to set RPMImprove

Sr.No.Product NameMachine NameRPM1NRemik 45 station m/c352NCMB-2 Dob.ROT.243C-1SR-1284C-2 CMB-5 , 35 station m/c255C-3CMB-5 , 35 station m/c246L-1CMB-5 , 35 station m/c247T-1CMB-5 , 35 station m/c238O-1CMB-4 machine229L-2CMB-4 machine2010E-1CMB-4 machine2011P-2CIP double roat m/c2212E-2Remik 37 station m/c2013C-4Remik 37 station m/c2414C-5CMB-5,35 station m/c1815C-6CMB - 420

Improve

Project Comparison & financial gain calculationControl

OEE Gains explanation m/c availability time64010%64Min.saved for 8 m/c512ave.rpm20Rotation ave.50Tab./min.1000Tab/day512000Tab/month15360000Tab.in million /M15.36Cost Minimum/M2227200

START WITH A VISION.

..BENCHMARK..

AND KEEP YOUR EYE ON THE DASHBOARD.

ANY QUESTIONS

The journey continues Learning of project Replicated, Initiated project on Blister machine

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