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    R Y B Average Units/day/Machin e MC #1 3.78 3.12 2.76 3.220 52.70

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    praveenchinna
    This document discusses continuous improvement projects at a manufacturing facility. It analyzes the top defects from the previous year to identify root causes. One project aims to reduce defects from a twist wrap machine by installing a secondary sensor to detect sudden stoppages. This is expected to reduce cut pieces, jamming, and save power. Another project focuses on reducing rework by controlling humidity in the cooling tunnel and twist wrap area to prevent candy from sticking together. Maintaining the proper humidity range throughout production reduced doubles formation and rework.

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    R Y B Average Units/day/Machin e MC #1 3.78 3.12 2.76 3.220 52.70

    Uploaded by

    praveenchinna
    16 views3 pages
    This document discusses continuous improvement projects at a manufacturing facility. It analyzes the top defects from the previous year to identify root causes. One project aims to reduce defects from a twist wrap machine by installing a secondary sensor to detect sudden stoppages. This is expected to reduce cut pieces, jamming, and save power. Another project focuses on reducing rework by controlling humidity in the cooling tunnel and twist wrap area to prevent candy from sticking together. Maintaining the proper humidity range throughout production reduced doubles formation and rework.

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    This document discusses continuous improvement projects at a manufacturing facility. It analyzes the top defects from the previous year to identify root causes. One project aims to reduce defects from a twist wrap machine by installing a secondary sensor to detect sudden stoppages. This is expected to reduce cut pieces, jamming, and save power. Another project focuses on reducing rework by controlling humidity in the cooling tunnel and twist wrap area to prevent candy from sticking together. Maintaining the proper humidity range throughout production reduced doubles formation and rework.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    16 views3 pages

    R Y B Average Units/day/Machin e MC #1 3.78 3.12 2.76 3.220 52.70

    Uploaded by

    praveenchinna
    This document discusses continuous improvement projects at a manufacturing facility. It analyzes the top defects from the previous year to identify root causes. One project aims to reduce defects from a twist wrap machine by installing a secondary sensor to detect sudden stoppages. This is expected to reduce cut pieces, jamming, and save power. Another project focuses on reducing rework by controlling humidity in the cooling tunnel and twist wrap area to prevent candy from sticking together. Maintaining the proper humidity range throughout production reduced doubles formation and rework.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 3

    Project title – Continuous Improvement

    · Selected the top 3 defects from the last year PQRS to analyse the VOC.

    Smiling packs / Loose packs 0.14%

    Product sticking to the wrapper 0.14%

    Visible Impurities / Foreign Matter 0.10%

    · Analysed (primary and secondary causes for the defects from twist wrap machines.

    · Developed Root Cause analysis for the cut pieces (impurities/loose packing)

    · Analysed the OEE for the twist wrap machine

    · (Break down the list into conditional and un conditional break down)

    · In Un conditional break down (causes for stoppage analysed)

    · Jamming of laminates with knife causes generation of FM

    · Even NCNW senses disk empty, secondary source of detection required for sudden
    stoppage(Eg: after NCNW sensor 8 slots of disk is available hence if NCNW detects,
    turret and disk rotates only break mechanism and rubber roller will stop)

    · Sometimes overlapping in knife results in laminate damages.

    Proposed system:

    Once the secondary sensor detects no wrapper in the candy for continuously more
    than 5.5 milli second in turret automatically stops the entire system,

    Scope:

    1) Operator independent (even candy is not available protects the equipment’s by


    sudden stoppage)

    2) Cut pieces and jamming of laminates reduction.

    3) Power saving by stopping the system during un availability of candies.

    Units/day/Machin
    R Y B Average
      e
    MC #1 3.78 3.12 2.76 3.220 52.70

      MC #3 MC #7 MC #10
    W/O Sensor Total minutes 300 300 300
    W/O Sensor Actual minutes 286 278 282
    Breakdown including (Lam change and other
    11 8 35
    BD)
           
      MC#1    
    After Sensor Total minutes 300    
    After Sensor Actual minutes 281    
    Breakdown including (Lam change and other
    8    
    BD)
    Machine stop time due to candy unavailablity /
    9    
    jamming
    Stoppage time / day / machine (Mins) 43.2    
    Units Savings / Machine 1.6 Units
    Units Savings for 12 Machines 19.8 Units
    Cost savings / Day 168.3 Rs
    Cost savings / Month 4375.2 Rs

    Average wastage of other machine /Day 0.368 Kg


    Average wastage of implemented machine/Day 0.239 Kg

    % wastage reduction in laminate at


    machine 35.05%

    Project Title: Rework Reduction:

    · Analysed the rework generation area, major part is from cooling tunnel and twist
    wrap

    · Rework is in the form of candy sticking to one other (doubles,) once it broke pitting
    generates.

    · Initial study done to reduce the candy sticking after the cooling tunnel,(i.e. to reduce
    the generation of sugar bloom after the cooling tunnel due to varied R.H)

    · First step taken to maintain the RH inside the cooling tunnel from 57-65%)

    · Compressor functioning set up changed as per the temperature of inlet air

    · The running hours of compressor increased rather than frequent cut off (This results
    in the maintain the RH in std for more hours)

    · Trial has taken from output of cooling tunnel to twist wrap (checked the time interval
    for candy withstanding capacity before sticking to formation of doubles)

    Time interval of candies in holding bins before doubles generation.

    No of double drops
    S.n 20 40 60 Holding bins kept for more than 20 min
    o Candy weight(g) mins mins mins
    resulting in showing more moisture
    1 1206 0 2 13
    absorbance tendency.
    2 1536 3 8 22
    3 2011 2 35 12
    4 2465 1 27 17
    5 3004 3 11 13
    6 3485 2 31 41

    Time interval for doubles generation in Twist wrap

    Candies no of
    doubles% at
    added in doubles Qty in g
    disc
    T.W (g) generated
    6030 0.19% 2 11.2
    8000 0.56% 8 44.8
    10200 0.55% 10 56
    12900 1.22% 28 156.8

    For good ideal running 6 kg is sufficient to add in twist wrap for


    complete run, the no of doubles generated during this run is minimum.

    The R.H Maintained in the cooling tunnel is (62-67%)

    Further separate humidity control set up to be installed in the cooling tunnel, to maintain the
    R.H at all time, in present set up its not available.

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