To analyze & improve discharging time of Aqueous FG Products using SPC Tool

2016

Target (Discharging Time)

2

Target >>>> 30 min. from 35 min./ batch

List of FG Products analyzed for discharging time using SPC tool

3

List of FG- Aqueous Plant  

S.NO SAP CODE OLD CODE DESCRIPTION BATCH SIZE (Kg)

1 10-603778-1.1350 11006393LW/B OP INK HIGH GLOSS

ANTIBLOCKING 3000

2 10-603780-7.2660 11006391L WB OP INK NEUTRAL FINISH 3000

3 10-603785-6.2660 11006374Y WATER BASED PRIMER INK - TA 2800

4 10-603787-2.2660 11006386L WB OP INK- HIGH GLOSS HIGH SLIP 3120

5 10-603788-0.2660 11006385L WATER BASED OP INK - HIGH GLOSS 3120

6 10-603789-8.2660 11006378LWATER BASED OP INK - INLINE

PRIMER 3000

7 10-603868-0.2660 894275L WATER BASED OP INK - HIGH SCUFF 3120

8 10-603871-4.2660 894390Y PRIME FIX OP INK - PRIMER 3120

9 10-006541-6.2660 W987502 UNI PAPER TRANS WHITE HV 3120

10 10-615417-2.2660 10-615417-2/1 WB TOB ST OPL 3000

 11 10-007024-2.1350 21271268B WB TOB HR CLEAR 3000

 12 10-604870-5.1350 BEW00033 AQUAKOTE GLOSS 18 3120

13 10-603870-6.2660 894201Y Heat sealable WB blister coating 3000

14 10-603867-2.2660 894371X WATER BASED OP INK MATT 3000

15 10-007296-6.2660 BEW00018 WB TECH MEDIUM LCB 1653 3000

4

Data Collection from 16.03.2016 to 02.04.2016 – Daily monitoring

Sr. No. Total Discharging Time in min. Mean Product Mean USL LSL

1 39 34.9 11006385L #DIV/0! 30 0

2 37 34.9 894390Y #DIV/0! 30 0

3 33 34.9 894371X #DIV/0! 30 0

4 35 34.9 11006385L #DIV/0! 30 0

5 35 34.9 11006378L #DIV/0! 30 0

6 35 34.9 W987502 #DIV/0! 30 0

7 34 34.9 BEW00033 #DIV/0! 30 0

8 37 34.9 11006386L #DIV/0! 30 0

9 34 34.9 894390Y #DIV/0! 30 0

10 35 34.9 11006385L #DIV/0! 30 0

11 34 34.9 BEW00033 #DIV/0! 30 0

12 37 34.9 11006385L #DIV/0! 30 0

13 33 34.9 10-615417-2/1 #DIV/0! 30 0

14 32 34.9 11006374Y #DIV/0! 30 0

15 34 34.9 BEW00033 #DIV/0! 30 0

Run Chart of the data from 16.03.2016 to 02.04.2016

5

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Key Factors for Analysis

• Power Tripping Problem

• Discharge line

• Pump Capacity

• Batch Viscosity

• Air Pressure

• Batch Size

Action Plan Identification

7

1. We have taken Power tripping Problem with maintenance team .

2. We identified that pump is having long suction, which slow down the

discharge process.

Product/Shade

Power Tripping

No. of times Total time loss due to power tripping

Action Identified to reduce power tripping Problem

W987502 Yes 3 12 min 01 Person must be available at electric sub station to reset.

894390Y Yes 2 08 min

Action Plan Implemented

8

1. Shifting of discharge pump from mezzanine floor to ground floor.Before After

2. Power Tripping was arrested by deploying one person/shift at electric sub station to reset the tripping issue at the earliest.

Power tripping time reduced from 04 min. to 02 min.

Pump Location(Earlier)

Pump Present

9

Data Collection after Action implementation from 30.05.2016 to 10.06.2016

Sr. No. Total Discharging Time in min. Mean Product Mean USL LSL

1 28 24.4 11006385L #DIV/0! 30 0

2 28 24.4 894390Y #DIV/0! 30 0

3 24 24.4 894371X #DIV/0! 30 0

4 24 24.4 11006385L #DIV/0! 30 0

5 24 24.4 11006378L #DIV/0! 30 0

6 24 24.4 W987502 #DIV/0! 30 0

7 24 24.4 BEW00033 #DIV/0! 30 0

8 23 24.4 11006386L #DIV/0! 30 0

9 21 24.4 894390Y #DIV/0! 30 0

10 25 24.4 11006385L #DIV/0! 30 0

11 24 24.4 BEW00033 #DIV/0! 30 0

12 24 24.4 11006385L #DIV/0! 30 0

13 26 24.4 10-615417-2/1 #DIV/0! 30 0

14 25 24.4 11006374Y #DIV/0! 30 0

15 25 24.4 BEW00033 #DIV/0! 30 0

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Run Chart after action implementation (30.05.2016 to 10.06.2016 )

Benefits

11

• Discharging time reduced from 35 min. to 27 min. average resulting in saving of 08 min. per batch.

• Total saving per day = 30 min.

• Due to this saving we are able to manage our daily Production effectively & can utilize this half an hour in other Production related activities.

• Savings

12

THANK YOU