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DEFINE PHASE

Project Identification
For purpose of project identification Brain
Storming session is conducted.
Focus of Management is to improve
availability of line, so production quantity
at Colour Coating Line can increase.

Project Identification-Y
Producti
on Delay

For the Project Identification Y , Delay data is


analysed using Pareto Graph.

Project Identification - Finding Y


Colour
Change
Loss

Reasons behind production delay are further analysed.


Form the Pareto Graph Colour Change Delay has taken as
the improvement project which is contributing major role
in availability loss.

Primary & Secondary Matrices


Metrics

CTQ

Data
Type

UOM

Operational
Definition

Primary

Colour
Change Time

Continuou
s

Min/Change

Time taken for single


colour change activity

Secondar
y

Number of
Accidents

Attribute

Number

Any injury during


activity of colour
change to human being

Secondar
y

Quality
Diversion

Continuou
s

%age

Quality Diversion due


to colour change
reason

Secondar
y

Manpower

Attribute

Number

Manpower used in
colour change activity

Business Case
Delays due to Colour Change is primarily
the time lost between two camping of
orders.
Reducing Colour Change time per colour
change would significantly improve the
availability of line.
Hence , this extra available time would
help to achieve production targets of
Organization, due to this extra production,
organization can have more orders from
customers which will give benefits.

Problem Statement
In the Last 6 Months sum of Colour
Change Delay has been contributing on
13267 Min in Production Delay at Colour
Coating Line i.e. 29.74 Min per Colour
Change.
Reducing the colour change
time(Min/Change) will significantly
increase available time for production,
Hence this will give benefit to
organization.

Objective Statement
Reducing Colour Change Time(Min/Change)
at Colour Coating Line-1 from 29.74
Min/Change to 25 Min/Change

Goal Settings
Metrics

CTQ

Data Type

UOM

Target

Primary

Colour Change Time

Continuous

Min/Chan
ge

25

Secondar
y

Number of
Accidents

Attribute

Number

Secondar
y

Quality Diversion

%age

<=1.10%

Secondar
y

Manpower

Number

Continuous

Attribute

Financial Benefits
Saving Calculation
A
B
C
D
E

Benchmark
Actual KPI/Month
Number of Colour Change/Month
Contribution (Rs./MT)
Utilization

Productivity(TPH)

Savings(X)D

Team Members
Project Title

Name

Mentor

Mr. Veerappa Ullagadi

Team Leader
Member-1
Member-1
Member-1
Member-1
Member-1
Member-1

Department
Production Head

SIPOC
Supplier

Input

Company

Employee

Paint
Store

Paint

CCL Store

Cleaning
Material

IP Coil
Unloadin
g at CCL
Bay

Coil
Loading
in line

Coating
Stop

Process

Output

Customer

Colour
Change

Coater
ready for
coating

Colour
Coating Line

Coater

Colour
Change

Inspectio
n

Coating
Start

Finish
Product

Send to
Next
Stage

MEASURE PHASE

Data Collection
All delay data including Colour Change
data has been recording in Manufacturing
Execution System(MES).
Hence, no requirement of data collection
plan because past data in available.

Data Collection Format


Example :Manufacturing
Execution
System(MES)

Data
Recording in
MES

Validate Measurement System


Data has been collected in Manufacturing
Execution System(MES)
Production head takes data from MES &
validate the data & then share with Black
Belt, Hence it needs no further validation.

Checking Data Spared-Histogram

Data Spread for variation is checked using Histogram.


Variation(StDev.) is 11.33 in data, Hence need to work on variation
spread.

Goal Settings
Descriptive Statistics: Delay(min.)

Variable
Delay(min.)

Total
Count
446

Mean

SE Mean
StDev
29.747
0.537 11.333

Q1

Median
25.000 30.000

Benchma
rk
Target

Title

UOM

Benchmark

Target

Colour Change
time

Min/Change

29.74

25

ANALYSE PHASE

Hypothesis Test
Hypothesis

Normality Check
P-Value
>0.05

Data is check for Normality , P-Value <0.05 from


Normality check ,Hence data is Non-Normal.

Hypothesis Test- Shift Wise


Mood Median Test: Delay(min.) versus Shift
Mood median test for Delay(min.)
Chi-Square = 1.62

Shift
A
B
C

N<
71
65
72

N>=
75
88
75

DF = 2

Median
30.00
30.00
30.00

Q3-Q1
10.00
15.00
15.00

P = 0.445

P-Value
>0.05

Individual 95.0% CIs


---+---------+---------+---------+--(--------------------------------*
(--------------------------------*
(--------------------------------*
---+---------+---------+---------+--25.5
27.0
28.5
30.0

Overall median = 30.00

H0 : There is No Significant difference between cycle time of shifts.


(A = B = C)
Ha : There is a Significant difference between cycle
time of shifts.
(A B C)

Hypothesis Test- Shift Wise


Boxplot of Delay(min.)
140
120

Delay(min.)

100
80
60
40
20
0
A

B
Shift

P-value is 0.445 ,Hence we fail to reject H0


hypothesis(There is No Significant difference
between cycle time of shifts
(A = B = C))

Hypothesis Test- Operator Wise


Mood Median Test: Delay(min.) versus Operator
Mood median test for Delay(min.)
Chi-Square = 3.84
DF = 4
P = 0.429
Operator
ASHOK
BIBEK
PADHI
PRADEEP
RD SINGH

N<
40
30
48
19
68

N>=
49
43
62
22
59

Median
30.00
30.00
30.00
30.00
25.00

Q3-Q1
10.00
10.00
15.00
15.00
15.00

P-Value
>0.05

Individual 95.0% CIs


---+---------+---------+---------+--(--------------------------------*
(--------------------------------*
(--------------------------------*
(--------------------------------*
*--------------------------------)
---+---------+---------+---------+--25.5
27.0
28.5
30.0

Overall median = 30.00

H0 : There is No Significant difference between


Operators
Ha : There is a Significant difference between
Operators

Hypothesis Test- Operator Wise


Boxplot of Delay(min.)
140
120

Delay(min.)

100
80
60
40
20
0

#NA ASHOK

BIBEK

PADHI
Operator

PRADEEP

RD SINGH

P-value is 0.429 ,Hence we fail to reject H0


hypothesis(There is No Significant difference between Users.

Hypothesis Test- Conclusions


There is less variation in the user to user
therefore the scope of work is very small. Though
within the user variation ,which can be reduced
through process standardization, education and
training.
Video Study and Time Study to be done for
further analysis to reduce within operator
variation and reduce change over
time(min/change).

Time Study-Gantt Chart


00:00

07:12

14:24

21:36

28:48

36:00

Activity
Head Disengage
Back up roll cleaning
Remove running hose pipe ,Cleaning of hose pipe & Stirrer cleaning.
Thinner supply is given on applicator rolls
Tray down
Maintain gap between applicator rolls
Put Applicator roll cleaning mode
Applicator rolls -cleaning
Tray cleaning
Doctor blade tray Removing,leaning and Refitting
Return Line Tray Removing, Cleaning and Refitting
Paint drum removal from coating
New paint drum put in
New Paint drum open and tray up
New paint stirring
Viscosity is checked
filter cloth fitting at hose pipe
Tie hose pipe to rolls
Settings to be checked for applicator rolls (WFT check)
Gap setting for applicator rolls
1st Sample coat

31.1
0

IMPROVE PHASE

Finding out Solutions


Tools Used:
1. Video Study
2. Time Study & Gantt Chart
3. Brainstorming
Using these tools team has found out some
improvement area where online activities can
be converted into offline activities.
Following activities:1. List down all the activities done while colour
change.
2. Activities marked as online/offline activities.

Activity List Before Improvement


Sr.No
Activity
1
Head Disengage
2
Back up roll cleaning
Remove running hose pipe ,Cleaning of hose pipe & Stirrer
3
cleaning.
4
Thinner supply is given on applicator rolls
5
Tray down
6
Maintain gap between applicator rolls
7
Put Applicator roll cleaning mode
8
Applicator rolls -cleaning
9
Tray cleaning
10 Doctor blade tray Removing,cleaning and refitting
11 Return Line Tray Removing, cleaning and refitting
12 Paint drum removal from coating
13 New paint drum put in
14 New Paint drum open and tray up
15 New paint stirring
16 Viscosity is checked
17 filter cloth fitting at hose pipe
18 Tie hose pipe to rolls
19 Settings to be checked for applicator rolls (WFT check)
20 Gap setting for applicator rolls
21 1st Sample coat

Online/Offline
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online

Finding out Solutions


Team had Brain storming sessions with help of Video Recording to
find out where they can work upon to reduce time.
Sr.No

Activity

Head Disengage

Back up roll cleaning


Remove running hose pipe ,Cleaning of hose pipe & Stirrer
cleaning.
Thinner supply is given on applicator rolls

Tray down

Maintain gap between applicator rolls

Put Applicator roll cleaning mode

Applicator rolls -cleaning

Tray cleaning

10

Doctor blade tray Removing,cleaning and refitting

11

Return Line Tray Removing, cleaning and refitting

12

Paint drum removal from coating

13

New paint drum put in

14

New Paint drum open and tray up

15

New paint stirring

16

Viscosity is checked

17

filter cloth fitting at hose pipe

18

Tie hose pipe to rolls

20

X
No Change
Settings to be checked for applicator rolls (WFT check)
O
Change
Gap setting for applicator rolls

21

1st Sample coat

19

Status
X
X
O
X
X
X
X
X
X
O
O
X
X
X
X
O
O
X
X
X
X

Improvement 1
Hose Pipe & Pump and Stirrer Cleaning activity
Hose pipe & Pump

Before

After

Hose Pipe & Pump previously was one ,after improvement


one Hose Pipe & Pump kept in ready before colour
change so it can be replace with old one with out time loss

Improvement 2
Hose Pipe & Pump and Stirrer Cleaning activity
Stirrer Unit

Before

After

Stirrer Unit previously was one ,after improvement one


Stirrer Unit kept in ready before colour change so it can be
replace with old one with out time loss.

Improvement 3
Doctor Blade Tray Removing , Cleaning & Refitting:Single
tray in
use

tray in
use &
Spare tray

Before

After

Previously Doctor Blade Removing , Cleaning & Refitting activity was done out of
which cleaning the doctor blade was taking more time.
So one extra spare of doctor blade used in colour change ,This spare doctor blade is
replaced by old one with out time loss for cleaning activity of doctor blade.
Old Doctor blade is cleaned after colour change over and kept ready in spare.

Improvement 4
Return Line Tray Removing , Cleaning & Refitting:tray in
use &
Spare tray

Single
tray in
use

Before

After

Previously Return line Tray Removing , Cleaning & Refitting activity was done out of
which cleaning the doctor blade was taking more time.
So one extra spare of Return line Tray is used in colour change ,This spare tray is
replaced by old one with out time loss for cleaning activity of Return line Tray.
Old Return Line Tray is cleaned after colour change over and kept ready in spare.

Improvement 5
Filter cloth fitting at hose pipe
Hose
pipe
with
filter
cloth in
use

Filter Cloth Fitting


Hose
pipe
with
filter
cloth
Ready
in Spare
Before

After

Previously only one hose pipe was is in used because of


that after cleaning of hose pipe new filter cloth is fitted to
hose pipe.
After improvement extra spare of hose pipe was kept ready
before colour change so filter cloth is fitted to this spare
hose pipe before colour change which saves the time loss.

Results Before & After Gantt


Chart
00:00

07:12

14:24

21:36

28:48

23.0
2

Before Improvement
After Improvement

31.1
0

CONTROL PHASE

Control Plan
After all implementation of improvements to
achieve results team has taken some
initiatives to maintain this results
Team has provided training to Operators
Team has created awareness to Operators
about each colour change over time
Team has prepared internal SOP for colour
change over.

Implementation for X & Y


Following control plan:1. Spare Doctor Blade tray is kept clean &
ready before Colour Change.
2. Spare Return line tray is kept clean &
ready before Colour Change.
3. Spare Hose pipe pump is kept clean &
ready before Colour Change.
4. Filter Cloths is fitted to spare hose pipe
before Colour Change.
5. Viscosity Check activity is done offline.

Financial Benefits
All the improvement results are converted in
money terms to see the benefits to
organization from this project. Below table
shows both tangible & intangible benefits
Sr.
No
1
2
3

Particular
Colour Change Time
Savings
Power Consumption
Savings
Fuel Consumption
Savings
Total Savings

Saving

Total
Rupees

Monthly 272304.5
Monthly

10511.1

Monthly 46367.6
Monthly 329183.1

Achievements
Metri
cs

CTQ

Data Type

UOM

Befo
re

After

Target

Primary

Colour Change Time

Continuous

Min/Change

29.74

21.62

25

Secondar
y

Number of
Accidents

Attribute

Number

Secondar
y

Quality Diversion

Continuous

%age

1.66

0.92

<=1.10%

Secondar
y

Manpower

Attribute

Number

Thank You