PROJECT TITLE:

“Automatic Reject Conveyor Motor of VIM and VIC at SMYAC Furnace YA “

1. INTRODUCTION

1.1 Company Background

San Miguel Yamamura Asia Corporation (SMYAC) is a joint venture company of San Miguel
Corporation and Nihon Yamamura Glass., Ltd. Japan. SMYAC is a glass container manufacturing
company which was inaugurated in July 1991. From an initial capacity of 180MT/D, it has grown to
465MT/D, the biggest glass container plant in the country today. It was one of the first companies in the
Philippines to be ISO-9000 certified by Bureau of Product Standards (BPS) in December 1992. SMYAC
is also a two-time Philippine Quality Award Recipient on Commitment for Quality and Proficiency in
Management System in 1998 and 2012 respectively. In 2013, SMYAC was certified by SGS as
compliant to ISO 22000:2005 and ISO/TS 22002-4:2013. SMYAC through WIT and WISE program
empowers employees to share their innovative ideas that could continuously improve its systems and
processes.

The team is composed of member of SMYAC’S Production Services Department Team 2. It is

composed of Engineers and Technicians dedicated to address problems and concerns relevant to the
Production Services Department’s specific objectives on equipment downtime, customer satisfaction
and cost management. With the dedication of the department to attain the specific objective, each
member of the team is deeply involved in maintaining the performance of each and every Cold End
Equipment.

1.2 Team Background

GROUP NAME: TEAM AUTOMATIC

TEAM ADVISER: ROBERTO LUCERO

LEADER: Jhoer John M. Aguilar

MEMBERS:

Louie Santos Bernard John Abril

Janer Estrella James Faith Trajico

Rholan Dave Sosa Deo Cabahug

Simplicio Villajin Kevin Mendoza

Edyson Venzon Leo Condino

Rovgene Soria Leonardo Rocillo

Mark Joseph Moratalla Mark Hamil Valerio

 1.3 PROJECT ABSTRACT

One of the PSD 2’s main role is to ensure 100 percent of bottles produced at SMYAC are
securely conveyed from lehr end to 100% quality inspected to packing machines. SMYAC’s YA and YB
bottle conveyor system is composed of Inverter, AC motor, table top chains, sprockets and other
moving parts. In the year 2018 there is an increase incidence of reject conveyor sudden stoppages,
audit findings and including parts replacement. With the commitment of the team to reduce this
occurrence, this project aims to reduce the event of reject conveyor stoppages along with lengthen the
lifespan of reject conveyor system

1.4 ACTIVITY PLAN

MONTH AUGUST SEPTEMEBER OCTOBER NOVEMBER

W13

W14

W16
W10

W11
W12

W15
W1

W3

W5

W6

W7

W8
W2

W4

W9
ACTIVITIES

A. Problem                        
Identification and
Selection
B. Cause and Data                        
Analysis
C. Solution                        
Formulation
D. Deployment                        

E. Monitoring and                        
Evaluation of
Results
F. Standardization                        
G. Self-Evaluation and                        
Future Plans
Legend: Target Actual

2.1 PROBLEM IDENTIFICATION

Team AUTOMATIC gathered and records all data from transport conveyor checklist, Daily Operations
Report and cold end team leaders report from Jan-Dec 2018.

1. Reject Conveyor Concerns:

2. Flex-T Infeed Jamming
3. Flex-T Outfeed Toppling
4. Flex-T Broken Finger
 Fig. 2.1.1 Number of Occurrences (Source: January – December 2018 Daily Operation Report)

Number Of Concerns
25
21
20

15

10 8
5 6
5

0
Reject Conveyor FlexT Infeed Jamming FlexT Outfeed Toppling FlexT Broken Finger
Cocerns

Analysis: Based on the number of occurrences of incident at Daily Operation Report from January 2018 to
December 2018, it shows that Reject Conveyor Concerns has the highest number of occurrences at 21.

Fig. 2.1.2 Number of Occurrences (Source: January – December 2018 Daily Operation Report)

250 Number of Downtime

220
200
150
100 90
65
50
50
0
FlexT Broken FlexT Outfeed FlexT Infeed Reject Conveyor
Finger Toppling Jamming Cocerns

Table 2.1.1 Prioritization Matrix

Criteria Rating: 5 Rating: 3 Rating: 1

 No. of
>15 7-14 1-6
Occurrence

Downtime >141 71- 140 1-70

Controllability Within Control Functional Control Beyond Control

Table 2.1.2 Selection Matrix and Prioritization

No. Of
Downtime Controllability Total Rank
Occurrences

1. Reject conveyor 5 1 5 11 1st

concerns

2. Flex T infeed 3 1 5 9 2nd

jamming

3. FlexT Outfeed 1 3 5 9 2nd

Toppling

4. FlexT Broken 1 5 3 9 2nd

finger

Using the prioritization matrix, the team selected to address the concerns regarding reject
conveyors.
The team analyzed these concerns and categorized them into 4 classifications:
a) Oil Leak
b) Conveyor Jerking
c) Sudden Stoppage (Inverter Trip)
d) Motor humming noise

The team stratifies the classifications of reject conveyor concern using the selection
criteria of occurrence, downtime and controllability.
 Table 2.1.3 Selection Matrix and Prioritization

Number of Concerns of Reject Conveyor

14
12 12
10
8
6
4
4 3
2
2
0
Oil leaked Conveyor jerking Sudden stoppage motor humming noise
( inverter trip )

Table 2.1.4 Selection Matrix and Prioritization

Number of Downtime
35
30
30
25
20
15
15
10
5
5
0
0
Oil leaked Coveyor jerking Sudden stoppage motor humming
( inverter trip ) noise

Table 2.1.5 Selection Matrix and Prioritization

 Criteria Rating: 5 Rating: 3 Rating: 1

No. of
>9 5-8 1-4
Occurrence

Downtime >21 11-20 1-10

Controllability Within Control Functional Control Beyond Control

Table 2.1.6 Selection Matrix and Prioritization

No. of Total Rank

Downtime Controllability
Occurrence

Oil Leaked 5 5 5 15 1st

Conveyor jerking 1 3 5 9 2nd
Sudden stoppage
(inverter trip ) 1 1 5 7 3rd
Motor humming
noise 1 1 5 7 3rd

After assessing each incidence, the team concluded that the concerns of oil leak on reject
conveyors of inspections machines are the prioritized problem.

INITIAL PROBLEM STATEMENT:

A total of 12 occurrences of oil leaked motors of reject conveyor of

inspection machines equivalent to 30 minutes of downtime was experienced at
SMYAC furnace YA from January to December 2018.
3. CAUSE AND DATA ANALYSIS

3.1 ANALYSIS OF THE PRESENT SYSTEM

In the Cold End lines, transport conveyor plays an important role to

ensure that the bottles produced from the hot end lines are carried to every
inspection machine up to the bulk palletizers. Each inspection machines have
independent bottle conveyor installed to support bottle transfer from one process
to another. These conveyors are used as transport and reject conveyors. Each
conveyor is driven by a three-phase motor continuously during production runs.
But during this process, a series of concerns regarding oil leak on reject conveyor
motors arises and are encountered by the PSD 2 team.

Picture of process of transport conveyors in a line

To stratify more, the team analyzed the gathered incident reports and daily operation’s
record to further study the contributions of each inspection machine to the total occurrence of
the problem.

Pie graph of occurrence of oil leaked motor of each inspection machines.

 Oil leaked motor per Inspection machine

FlexT Flex T- 0
VIM VIM - 6
VIC VIC - 6
VIB VIB - 0

The graph shows that the VIM and VIC are the highest contributor on oil leaked motors
at six occurrence each. So the team decided to address these problems.

3.2 FINAL PROBLEM STATEMENT

A total of 12 motor oil leak occurrences of reject conveyor of VIC & VIM
inspection machines equivalent to 30 minutes of downtime was experienced at
SMYAC furnace YA from January to December 2018.

3.3 INITIAL OBJECTIVE STATEMENT

To have eliminated the occurrences of motor oil leak of reject
conveyors of VIM and VIC inspection machines at SMYAC furnace YA by
September 2019.

.4 IDENTIFICATION OF ROOT CAUSES

MATERIAL MACHINE

A total of 12 occurrence of oil

leaked motors of reject
conveyors of VIM and VIC
equivalent to 30 minutes of
downtime occurred at SMYAC
 December 2018.
.

METHOD MAN

Oil leaks occur due to long period of time of PSD personnel failed to intercept motor
operation oil leaks.

PSD personnel didn’t see symptoms of

Occurrence of worn out oil seal of motors. possible oil leaks of reject conveyor
motor.
Low quality of
motor’s oil seal.
High temperature of motor running Checking status of reject conveyor
might not be so in depth.
Repaired motor
uses much lower
quality of oil seal Temperature exceeds the required temperature of
than original. motor PSD personnel in charge of checking
transport conveyors and cullet conveyor
may be focused on other much
Repaired motor has a prioritized activity
lower cost than brand 2. Continuous run of repaired reject
new. conveyor motor.

3. Not enough personnel to

1.Quality of repaired support checking of transport,
motor cannot be put back cullet and reject conveyors.
to its pristine state

A total of 12 occurrence of oil

leaked motors of reject conveyors
of VIM and VIC equivalent to 30
minutes of downtime occurred at
SMYAC furnace YA from January to
December 2018.
 MATERIAL MACHINE

Oil leaks occur due to long period of Oil leaks occur due to long period
time of operation of time of operation

Occurrence of worn out oil seal of Occurrence of worn out oil seal of
motors. motors.

Low quality of motor’s oil

seal.
High temperature of motor
High temperature of motor running running

Repaired motor uses much

lower quality of oil seal
Temperature exceeds the than original.
Temperature exceeds the required required maximum temperature
maximum temperature of motor of motor

Repaired motor has a

lower cost than brand new.
Repaired motor tends to have higher
temperature in the long run
2. Continuous run
of repaired reject
conveyor motor. 1. Quality of
repaired motor
4. Repaired motor has a
cannot be put
lower life span.
back to its
pristine state
 3.5 VERIFICATION OF ROOT CAUSES

FACTOR CAUSE # 1

METHOD and 1. Quality of repaired motor cannot be put back to its

MACHINE pristine state

DISCUSSION/FINDINGS: (Date of Verification: 1st week MARCH 2019)

Occurrence of motor oil leaks are due to worn out oil seal of motors. This seal are tending
to last same with the motor’s life span. But in the case of reject conveyor motors, oil seal
have much lower life span compared to brand new motor. Upon validation, reject
conveyor uses repaired motor which uses a lower quality of oil seal.
IN – CHARGE VERIFICATION VERIFICATION CONTROLLABILITY CONCLUSION
METHOD RESULT

Analysis and True Root Cause Within control Real Root Cause
RDT Sosa
Observation

FACTOR CAUSE # 2

METHOD and 2. Continuous run of repaired reject conveyor motor

MACHINE
DISCUSSION/FINDINGS: (Date of Verification: 2nd week MARCH 2019)

Based on analysis and observation of PSD personnel, repaired motor emits a higher
temperature than brand new. And since reject conveyor motor is used to transfer rejected
bottles to cullet whenever it is needed, this motor is designed to run continuously throughout
the operation.
.

IN – CHARGE VERIFICATION VERIFICATION RESULT CONTROLLABILITY CONCLUSION

METHOD

MJ Moratalla Analysis and True Root Cause Within Control Real Root Cause
Observation

FACTOR CAUSE # 3

MAN Not enough personnel to support checking of transport,

cullet and reject conveyors.
DISCUSSION/FINDINGS: (Date of Verification: 3rd week MARCH 2019

Based on analysis and observation, there is only one person assigned on the checking of all
transport, cullet and reject conveyors motors in each Cold End line. During checking and
monitoring, some PSD personnel require additional help from other personnel when attending
other machine troubles and concerns. In this case, only quick check up of reject conveyor
motor was done by the person in charge
IN – CHARGE VERIFICATION VERIFICATION RESULT CONTROLLABILITY CONCLUSION
METHOD

RAB Soria Analysis and True Root Cause Within Control Real Root Cause
Observation

FACTOR CAUSE # 4

MATERIAL Repaired motor has a lower life span.

DISCUSSION/FINDINGS: (Date of Verification: 4th week of MARCH 2019)

Occurrence of motor oil leaks are normally coming from repaired motors which are used
on reject conveyors of inspection machines. During analysis and validation, oil leaks came
from worn out oil seal that are caused due to too much heat coming from the motor.
Upon analysis, these motors are considered defective, causing higher temperature during
operation. In addition, this motor hasn’t reached its expected life span.
IN – CHARGE VERIFICATION VERIFICATION CONTROLLABILITY CONCLUSION
METHOD RESULT

MH Valerio Analysis and True Root Cause Within control Real Root Cause
Observation
 1. SUMMARY OF ROOT CAUSES

Control Expected Expected

True Root Causes Downtime
(%) reduction Result (%)

1. Quality of repaired motor

cannot be put back to its pristine
state 4 100 4 33.33

2. Continuous run of repaired

reject conveyor motor. 3 100 3 25

3. Not enough personnel to support

checking of transport, cullet and
reject conveyors 1 100 1 8.33

4. Repaired motor has a lower life

span. 4 50 2 16.67

TOTAL 12 10 83.33

As agreed by the team members, we set the values for control percentage on the
criteria as illustrated below:

Expected Percent
Reduction Reduction from
X 100 = Total
Total Contribution
Contribution
 3.6 FINAL OBJECTIVE STATEMENT
Assessing the root causes identified and the team’s controllability on it, the team set the
Final Objective Statement as follows:

To have reduced the occurrence of oil leaked motors of reject

conveyors of VIM and VIC occurred at SMYAC furnace YA by 83.33% by the
end of December 2019.

1. SOLUTION FORMULATION

Root Causes Desired Effect Probable Solutions

1. Quality of Improve quality of  Request a different oil seal for repaired motor
repaired motor repaired motor
cannot be put back
to its pristine state

Intercept life span of  Reschedule reject conveyor motor

reject conveyor motor replacement to 2 years.
 Use brand new motor

2. Continuous run To have an automatic  Design a circuit to support automatic

of repaired reject conveyor motor operation of reject conveyor
reject conveyor
motor To have an option to turn
off the conveyor when in
not in use

3. Not enough To have additional  Assigned a backup personnel for checking and
personnel to personnel to support monitoring of transport, cullet and reject
support checking of checking of transport, conveyors
transport, cullet cullet and reject .
and reject  Include checking of reject conveyor to the VIC
conveyor motor.
conveyors and VIM machine checklist.

Evaluation Criteria
 A B C D E F

Effectiveness Feasibilit
Cost of Safety
Time Frame to Solve Root Controllability y of Rating
Implementation Level
Causes solution

Very Php500 and Within

1-3 week High High 5
Effective below Control

1 mo. To 2 Php501 – Mediu

Effective Interphase Medium 3
mon. Php50,000 m

Above 2 Slight Php50,001 Beyond

Low Low 1
mo. Effective and above Control

Tab. 4.1 Evaluation Criteria for Solution Formulation

DECISION:
1-20= NO GO 21-30 = GO

4.2 GO NO GO ANALYSIS
ROOT CAUSES PROBABLE ADVANTAGE DIS- EVALUATION TO- DE-
SOLUTION ADVANTAGE A B C D E F TAL CI-
 SION
Quality of Request a Improve May have
repaired motor different oil seal quality of oil much higher
cannot be put for repaired seal to avoid price
back to its pristine motor oil leaked
state

1 5 3 5 5 5 24 GO

Reschedule To intercept none

reject conveyor life span of
motor motor
replacement to 3 3 3 5 3 1 18 NO GO
2 years.

Use brand new Longer life Costly

motor span
1 1 1 5 5 1 14 NO GO
 Design a circuit Longer life Costly
to support span of motor
Continuous run of automatic
repaired reject operation of
conveyor motor Less
reject conveyor
maintenance
1 5 3 5 5 5 24 GO
Energy
efficient

*design circuit
and animation

Not enough Assigned a To have Additional

personnel to backup additional manning
support checking personnel personnel to
of transport, for checking support
cullet and reject and checking of
conveyors monitoring transport, cullet
of transport, and reject
5 5 5 5 5 5 30 GO
cullet and conveyor
reject motor.
conveyors
.

Include Monitor reject none

checking of conveyor
reject closely
conveyor to
the VIC and
5 5 5 5 5 5 30 GO
VIM machine
checklist.

Reschedule Intercept life none

reject span of repaired
conveyor reject conveyor
motor motor
replacement
to 2 years. 1 5 3 5 5 5 24 GO
Repaired motor
has a lower life
span.

Replaced Longer life span costly

motors with
brand new 1 3 1 5 5 3 18 NO GO
motors

Using SELECTION OF BEST ALTERNATIVE SOLUTIONS, the team was able to

identify probable solutions that could reduce the total number of occurrences of
5. DEPLOYMENT

5.1 POTENTIAL PROBLEM ANALYSIS

Potential Most Likely Preventive Contingent Triggering

Activity Responsible
Problem cause Action Action mechanism
Not effective Unable to For testing Re design Circuit not
Design a circuit support circuit functioning
to support automatic as planned
automatic reject
JR Estrella
operation of conveyor
reject conveyor

Assigned a Unable to Tight Post Review of Target

backup check and schedule schedule schedule monitoring &
personnel for monitor ahead of and update evaluation is
checking and time of activities already
monitoring of nearing (2 RD Sosa
transport, cullet days before
and reject
conveyors

Include checking PSD Double check Coordinate Machine

of reject Trouble occur personnel are condition checking of checking
conveyor to the on weekends not available before reject failed to
VIC and VIM on weekends weekend conveyor intercept JJ Aguilar
machine condition symptoms of
checklist. during oil leaked
weekend
Request a Incident may Quality of Ensure request If the
different oil seal re occurred new oil seal availability of different problem EO Venzon
for repaired spare parts supplier of reoccurred
 motor oil seal twice a year

Reschedule Incident may Quality of Ensure Request If the incident

reject conveyor re occurred repaired availability of different occur before
motor motor spare parts supplier for two years
RAB Soria
replacement to 2 motor
years repair

1.2 ACTIVITY PLAN

FACTOR ROOT CAUSE #1 BEST SOLUTION IMPACT OF SOLUTION

Quality of repaired
METHOD / motor cannot be put Request a different oil seal for repaired motor
back to its pristine 33.33%
MACHINE
state

ACTIVITIES
Target August September October November
Actual IN- CHARGE

W W W W W W W W W W W W W W W W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Search best
brand of oil seal
Team AUTOMATIC
Product request
of item

Application of oil
seal to all
repaired motor

FACTOR ROOT CAUSE #2 BEST SOLUTION IMPACT OF SOLUTION

METHOD / Continuous run of Design a circuit to support automatic operation of 25%
MACHINE repaired reject reject conveyor
 conveyor motor

ACTIVITIES
Target August September October November
Actual IN- CHARGE

W W W W W W W W W W W W W W W W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Designing of new
circuit to support
the automatic
operation of
reject conveyor Team AUTOMATIC

Installation of the
project

Monitoring of
the project

FACTOR
ROOT CAUSE #3 BEST SOLUTION IMPACT OF SOLUTION
Not enough personnel
to support checking of Include checking of reject conveyor to the VIC and
MAN transport, cullet and 8.33%
VIM machine checklist
reject conveyors

ACTIVITIES
Target August September October November
Actual IN- CHARGE

W W W W W W W W W W W W W W W W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Conduct
brainstorming
with the group
members to
create an initial Team AUTOMATIC
draft of the
procedure
Revision of
checklist of VIC
and VIM
Monitoring of the
project

FACTOR
ROOT CAUSE #3 BEST SOLUTION IMPACT OF SOLUTION
 Not enough personnel
to support checking of Assigned a backup personnel for checking and
MAN transport, cullet and 8.33%
monitoring of transport, cullet and reject conveyor
reject conveyors

ACTIVITIES
Target August September October November
Actual IN- CHARGE

W W W W W W W W W W W W W W W W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Conduct
brainstorming
with the group
members to Team AUTOMATIC
create an initial
draft of the
procedure

Assign back up
personnel

FACTOR
ROOT CAUSE #4 BEST SOLUTION IMPACT OF SOLUTION

Repaired motor has a Reschedule reject conveyor motor replacement to

MACHINE lower life span. 2 years. 16.67%

ACTIVITIES
Target August September October November
Actual IN- CHARGE

W W W W W W W W W W W W W W W W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Check
maintenance
Team AUTOMATIC
schedule
Schedule motor
replacement
every two years

6.1 INTANGIBLE BENEFITS

 Prolong life of reject conveyor motor , sprocket and any parts
 PSD personnel have more time in checking other equipment
 Improve monitoring of reject conveyor motor
6.2 TANGIBLE BENEFITS

 Lessen consumption of motor, sprocket and other parts

 To save power consumption due to automatic reject conveyor
 Eliminate occurrence of motor oil leak of reject conveyor

Number of Minutes. (Source: July 13, 2019 production Cold End Team Leaders Report)

YA 4 VIM Reject Conveyor Utilization per day

10
11
12 total minutes saved
first shift
second shift
third shift

1407

This graph illustrates the utilization of reject conveyor of YA 4 VIM in the average of
98% efficiency on July 13 2019 production based on the total number of reject bottles per shift.

Total number of bottles rejected per shift on July 13, 2019:

 1st shift = 0.29% or 73pcs or 12mins of 8 hours

 2nd shift = 0.27% or 68pcs or 11 mins of 8 hours
 3rd shift = 0.25% or 63pcs or 10 mins of 8 hours
(Data source: COLD END TEAM LEADERS REPORT 2018)

 Total number of bottles rejected (7 machines) = 4,467,421 pcs

 Seconds per rejected bottle = 10 (proposed project)
1. 4,467,421 pcs X 10sec. = 44,674210 secs or 12,409 hours

Number of Hours: (Source: YA Cold End Team Leaders Report 2018)

YA Reject Conveyor Motor Utilization per year of 7

motors

12409
Total savings ( hours per year )
total number of hours per year
spent using proposed project

48
91
1

This graph illustrates the utilization of reject conveyor of Furnace YA (3 VIC and 4 VIM) of
Jan. – Dec. 2018 production based on the total number of bottles rejected.

Reference:

Hours per year = 8,760 hrs.

Total rejected bottles in 2018 = 12,409 hrs.

Total rejected divided by 7 motors = 1,773 hrs.

Formula:

A = Total consumption per year (per motor)

Power Consumption: 1kW= Php 6.90
 0.75 x 24hrs = 18 kW per day

18kw x 365days= 6570 kW per year

6570kW x P6.90 = Php 45, 333

B = Total consumption per year (using proposed projects) (per motor)

Power Consumption: 1kW=P6.90

0.75 x 1,773 = 1329 kW per year

1329 X 6.9 =Php 9,170

A - P 45, 333 - P 9,170 = Php 36, 163 savings per year (per motor)
B - P 36, 163 X 7 (motor) =Php 253,141 savings per year

Cost of Implementation

24V power supply Php 1000.00

Timer relay Php 250.00

24V relay Php 200.00

Wire Php 0.00

Fabricated holder of circuit Php 0.00

Total Php 1450.00

PROJECTED TOTAL SAVINGS:

SAVINGS PER YEAR PER MOTOR – COST OF IMPEMENTATION X 7(motors) =

Php 36, 163 - Php1450 = Php 34,713 x 7 = Php 242,991.00 generated annual savings