BILT GRAPHIC PAPER

PRODUCT LIMITED
Unit: Bhigwan
To Reduce Tension variation during splicing

 SIX SIGMA project presented by VIKAS KUMAR

TO REDUCE Tension Varition DURING SPLICINGProject detail

BLACK BELT –

Name: Vikas Kumar

Dept :Coating plant

Location : BHIGWAN PUNE

Brief Job description : during splicing
process web is moving , up 2.5cm
movement paper not breaks but when ites
cross more than 2.5cm paper breaks at
rewind station its chance to break the
paper.(As we are trimming the edges at
rewind )


Champion:

Project description: To reduce tension
drop during splicing in omc.

Project scope: To reduce tension drop
during splicing in omc.

Business Case: 6 breaks per month and
4hrs loss in omc.

Project start / Estimated end: JAN 2011July 2011.

PROJECT STATUS-

Close Define

Dilip Wadodkar , Raghavendra Hebbar
Control

Team Members: Ajit Dubey, Sanjay Bhoite,
Rama Krishana, Hemant Kale, Nitin Patil,
Karson, DSN , Nagbhusan.

Measure


Improve.Analysi

s

Coating is a continuous process so need to joint the rolls during running . If we not open coater this make the paper break in paper.Process description- Process Description. The raw material ( base paper ) coming in the from of 10mt wt of rolls . In the process of coating we are applying color to paper . due to thickness issue we need to remove blade during splicing.The off machine coater is a converting process use for making uncoated paper in to coated paper. this increasing the thickness of paper . . During roll to roll joint done by adhesive tape called splicing process. paper is supported by the rolls and extra color scrapped by a blade and after coating paper going to slitting edges for calendaring process. Due to coater open and close process tension drop .

 Paper Coating process- Paper Backing roll Coater blade color Applicator roll Coater pan .

We had carried load cell calibration from ABB even though this problem still persist with our machine.During commissioning of PM2 we have also called VOITH expert to solve this problem but they could not address web movement problem.Project Charter The purpose of this six sigma project to reduce the WEB MOVEMENT problem in coating machine pm1. machine equipment and quality . We have taken this cross functional project under guidance and support of Mr I. We are facing web movement problem in coating machine from last 13years. deckle marking in papers .Guha (Unit Head). Mr Dilip Wadodkar (GM ENGG) & Mr Raghavendra Hebbar (PROCESS HEAD).Our aim to taking six sigma project under guidance of ISI to under stand the contributing factors for web movement factors.  As the web breaks frequency of web movement is experienced intermittently hence we were unable to conclude the reason of the problem. . causing web breaks in coating machine .Web breaks contributes loss of energy. deckle marking in filled rolls . paper .N.

Keep records. Draft the charter. Lead team work. . Use of improve methods. Sujeet Mhetre(MECH). Carry out assignments. Participate in meeting. Monitor the implementation. Contribute knowledge and expertise. See the doc . Assist in piloting.(Process dept) Review purpose of project. Sanjay Bhoite. Lead meeting. Hemant Jain(ELECT) . Karson Kulkarni. .ROLE AND RESPONSIBILITYBLACK Belt(VIKAS KUMAR) Team memberAjit Dubey. Nitin Patil. Learn necessary skills and methods.Hemant Kale . Update the lessons captured. Monitor the results. Finalize team member. DSN. Nagbhusan. Use the improve methods. Manage schedule.

NO OF BREAKS DUE TO WEB MOVEMENT TREND- SIX SIGMA PROJECT START FROM JAN11 .

SIPOC Color Kithen PAPER MACHINE COATING COLOR COATED PAPER FINISHING HOUSE BASE PAPER COATIN COATER PROCESS COATER cylinder MANAGEMENT G PROCESS MAINTANCE COATER BLADE BASE PAPER COATING COLOR COATER CONSUMA BLE COATING APPLICATIO N COATED PAPER .

. . Measurement Defect definition Through load cell.5cm . If tension drop more than 120 N then this web movement crosses more than 2. Tension drop more than 120N in coater.5 cm web movement converting to passable breaks. As we can measure only tension . Up to 120N tension drop max web movement is 2.Identification of CTQ: Need of customer CTQ Less rework Tension difference during splicing. the web movement we can only observed we don’t have man power to record this but the web movement directly proportional to tension drop so we consider this measurable unit as a CTQ.

Dryer load. Screen tension. Speed of machine. Screen tension Tension drop/Variation SPEED DIFF Base smoothness. Blade setting. Dryer mech condition. LOAD CELL.Fish bone diagram- Gsm of paper. Cobb of paper. Backing roll load Hydraulics pressure. Applicator & backing roll gap. Blade thickness. .

45 4 5 5 23 10 Hydraulics pressure. 56 6 6 6 13 TENSION VALUE 55 4 6 3 14 SPEED DIFF 56 6 7 6 15 Backing roll load 86 4 8 4 29 23 30 30 By the basis of team view(numbering from 1 to 10 scale) . 54 6 4 4 23 2 LOAD CELL. 24 6 4 3 19 3 Dryer load. 44 5 6 6 25 8 Cobb of paper. 76 7 8 8 36 5 Blade thickness.Priority Matrix: OUT PUT VARIABLES(WEB MOVEMENT) S.N INPUT VARIABLES(X) 1 2 3 4 5 TOTAL 1 Speed of machine. 77 6 5 4 29 7 Base smoothness. 66 4 5 5 26 11 Screen tension. 45 4 5 5 23 9 Gsm of paper. 56 5 6 7 29 6 Blade setting. 67 8 4 5 30 12 Applicator & backing roll gap. 88 9 7 8 40 4 Dryer mech condition.

Data collection plan-  After priority matrix we decide to collect data on shift wise basis .  Six sigma team decide to collect data up to 45 day . tension drop data and speed difference data collected by electrical dept . . in every shift process operator and shift in charge collection data in once every 8hrs . in the mid time of the shift .

9 26 830 210 7.7 07-01-2011a 3 11 130 2d 3.3 1.5 80 -0.9 28.8 224 7.8 227 7.9 27.5 04-01-2011b 2 12 130 2d 3.5 174 -2.1 227 4.7 232 7 110 -0.9 26 480 300 6.9 06-01-2011b 18 18 128 2d 4 0.2 01-01-2011c 14 12 130 2d 3.5 950 130 6.1 06-01-2011a 6 14 128 2d 3.9 25.9 26 583 300 6.9 735 250 6.5 230 2 06-01-2011c 3 10 130 2d 3.77 729 250 7.9 26 548 300 7.3 0.9 27 950 130 6.2 01-01-2011b 1 12 128 2d 3.7 227 7.1 227 7 180 03-01-2011b 4 21 130 2d 4.5 290 -1 05-01-2011b 8 18 130 2d 4 0.8 227 5.4 0.2 27 728 250 6.7 227 7.1 227 7.8 227 7.5 90 -1 07-01-2011c 4 12 128 2d 3.8 32 7 230 -1 02-01-2011b 8 20 130 2d 4 0.7 34 7 90 -1.9 -1.7 220 7.9 26 583 300 6.3 0.9 26 583 300 6. 01-01-2011a 2 11 130 2d 3.5 110 -0.9 26 830 170 6.5 270 05-01-2011a 12 20 130 2d 4 0.5 08-01-2011b 3 11 128 2d 3.9 26 548 300 6.5 950 130 6.4 .3 1.4 0.5 330 1.8 227 7 170 -2 -1 03-01-2011a 2 20 128 2d 4 0.5 05-01-2011c 8 21 128 2d 4 0.2 80 -1 08-01-2011a 44 18 128 2d 4 1.3 1.8 230 6 180 -0.9 26 570 300 6.9 224 7 250 -2 03-01-2011c 4 19 130 2d 4.9 26 830 170 6.Data collection .8 04-01-2011a 4 9 130 2d 3.9 735 250 6.5 830 210 6.2 28.(shift wise) date cylinder load backing roll load hydrulic blade pentration gap angle speed gsm base smoothness cobb sk Tension drop Diff between backing roll and cylinder group.8 227 7.2 02-01-2011a 2 20 130 2d 4 0.7 07-01-2011b 3 11 128 2d 3.3 0.9 26 570 300 6.5 04-01-2011c 8 21 128 2d 4.9 227 6.5 270 -2.3 1.8 08-01-2011c 7 18 130 2d 4 1.9 26 548 300 6.2 80 -0.2 27 727 250 6.8 45 7 180 -0.9 26 830 210 6.9 227 7.7 38 7 90 -1.5 0.7 227 7.2 30 520 300 6.5 02-01-2011c 1 20 130 2d 4 0.4 0.2 28.2 0.9 26 533 300 6.8 230 7.2 288 0.2 28.5 120 -2.5 0.5 310 3.7 34 7 110 -1.3 0.

Analysis of data- Process is stable- .

533067 -1.932 * 0.272 <0.006 <0.005 Lognormal 2.110 <0.000 Weibull 2.005 0.00791 Goodess of Fit Test Distribution Normal AD P LRT P 3.005 3-Parameter Loglogistic 1.607 84.010 3-Parameter Weibull 1.001 3.005 3-Parameter Lognormal Exponential 1.490 <0.005 2.003 2-Parameter Exponential 3.490 <0.282 <0.097 15.564 <0.438 <0.010 Gamma 2.005 3-Parameter Gamma Logistic Loglogistic 1.010 0.000 Smallest Extreme Value 4.257 <0.487 * 0.803 <0. .023 As all the p value is less than 0.4106 160 60 370 0.Distribution ID Plot for Tension drop Descriptive Statistics  N N* Mean StDev Median Minimum Maximum Skewness Kurtosis 117 0 178.05 we conclude it doesn’t fit any theoretical distribution.519 <0.849 * 0.010 Largest Extreme Value 2.

Before six sigma project- The performance is 632478 ppm equivalent to .

473 1.75 0.14050 0.39 sk Predictor Constant Diff between backing roll and c Cylinder load Backing roll load Hydrulic Pentration Coef 65.553 1.605 7.228 cobb + 5.3 Sk 5.9 0.82 hydrulic + 120 pentration .108 15..017 4.Analysis of dataRegression Analysis: Tension drop versus Diff between.8%  The vif greater than 5 in 4 cases i.509 cylinder load + 1.49 T P VIF 0.000 7.62 0.554 1.0.8 Base smoothness 3.001 1.229 0.0153 0.695 SE 457.3% R-Sq(adj) = 73.42 0.141 speed 0.156 2.94 Gap -24.24.50 -0.5 -1..76 0.0.0 0.e.34 4.864 1.1.60 Cobb -0.59 18.14 3.452 3.09428 -2.70 Speed -0.015 gsm + 3.06 0.950 17.2 base smoothness .7 gap .387 0.2449 -0.52 0.0 11.9 7.136 S = 43.823 120.22 41. .7 0.7071 0.2 1.16 backing roll load .2262 R-Sq = 76.0 0.5092 0. cylinder loa.349 Coef 0.1 0.6 3.08668 -1..22820 0. . multicolinertiy exist.17 0.72 0.1 Gsm -0.7 Diff between backing roll and c + 0.32 3.887 0. The regression equation is Tension drop = 65 + 11.070 24.

VIF - We are considering pentration and speed as a reference. .

5 44.3 11.91 72.5 134.078 -0.000  Diff between backing roll and c 10.81 0.93 3.56  P-Value 0.000 0.0 -166.26 71.57 R-Sq(adj) 68.6  pentration  T-Value  P-Value 0. .6 0.9 16.3 10.198  T-Value -3. .7 2.5 69.147  T-Value -2.15 Alpha-to-Remove: 0.10 16.49 12.5 153.62 74..15  Response is Tension drop on 9 predictors.33 75.34 3.70 Mallows C-p 24.6  T-Value 2.8 151. hydrulic.000 P value of less than 0.7 132.. Alpha-to-Enter: 0.000 0.85 -4.05 so all significant.005 0.001  speed -0.32 12.2 42.99 70. with N = 117  Step  Constant -392.002  S 47.33  P-Value  cobb -0.41 73.004 0.9 17.Regression analysis  Stepwise Regression: Tension drop versus cylinder load.1 11.3 -252.21  P-Value 0.000 45.0  R-Sq   1 2 3 4 -378.001 0.

The regression equation is Tension drop = .78 0.06177 -3.000 -0.000 Diff between backing roll and c 11.0.000 Residual Error 112 201916 Total 116 826518 MS F P 1803 AS P.4597 R-Sq = 75. Diff between.Regression analysisRegression Analysis: Tension drop versus pentration.0.198 cobb Predictor Coef SE Coef T P Constant -166.61 0..256 3. .89 10.19797 0.21 0.166 + 133 pentration + 11. As cobb value can not be reduce because of cost factor .14667 0.006 pentration 132.81 0.6% R-Sq(adj) = 74.VALUE 0F ALL FOUR LESS THAN 0.49 59.33 0.002 S = 42. .03389 -4.608 Speed  cobb 3..147 speed .And speed of the machine can not increase because of machine design problem .38 12.001 -0.05 SO ALL ARE SIGNIFICANT TO TENSION VARIATION.56 0.6 Diff between backing roll and c .7% Analysis of Variance  Source DF SS Regression 4 624602 156150 86.89 -2.

Tension drop before six sigma project- Data shows normal. .

.5 value. AFTER CHECKING WE FOUND THAT CONDENSATE REMOVAL SYSTEM HAVE PROBLEM AND SERVICING REQUIRED.  NOW WE DECIDED TO MONITER THIS PROBLEM IN ALL COATER SECTIONS.  SPEED DIFF ATTENDED BY ELECT DEPT WHEN REQUIRED.  PENTRATION on higher side this will crate tension drop problem in coater head so we decide to maintane it near to 3 to 3.DATA ANALYSIS AND VARIFICATION PLAN-  DURING BRAINSTROMING WE DECIDED TO CHECK DRYER CYLINDER CONDENSATE REMOVAL SYSTEM .

HIGH LOAD ON BACKING ROLL.Action plan- Problem REASON ACTION TAKEN Responsible dept 1. 1. AOS PROBLEM CHANGE THE SCALING. STEAM PRESSURE PROBLEM. 3.5 max) OMC dept.(keep less than 3. . USE LOW THICKNESS BLADE. 2. LOAD DIFFANCE. Electrical. SYPHEN PROBLEM. 2. SYPHEN TO BE MAKE ALRIGHT DURING SHUT. Mechanical. Power plant.PENTRATION. SPEED DIFFERENCE. CHECK STEAM PRESSURE. REDUCE PENETRATION.

After six sigma project- .

Difference after and before six sigma project- Before the six sigma project STDEV of the process was 87 . . After the project we are not observed any nonconformity.5 . after six sigma project 13.

.Web break during splicing after six sigma project- All above data showing month wise breaks .

Are the customer satisfied. After SIX SIGMA project trend shows reduction of WEB MOVEMENT.4NOS PER MONTH.  AFTER SIX SIGMA PROJECT – 80000INR PER MONTH.960000INR PEY YEAR. . YEARLY SAVING. TOTAL SAVING PER BREAKS – 20000INR PER BREAKS. TOTAL NO OF BREAK SAVED.

 Thanks .