Description of Problem

Objectives of this workshop

The rejections of paper manufactured by a company

exceeds 30%. The magnitude of the problem has
increased recently. Problem is observed at the end
of the paper production process where the entire
paper produced is tested for its quality.
 Scope the problem

Black Spots

Thin
Highest
Spots contribution to
Others
Accepted
rejections
product

Most
serious

Product Holes
Rejection “A”
36% 50%
Rs18 crore
per annum
Drawn to scale
HOLES ARE THE MAJOR CONTRIBUTORS TO REJECTION.
1% rejection corresponds to a PROBLEM IS SCOPED TO: REJECTION OF PAPER CAUSED DUE
revenue loss of Rs 50 lakh pa TO PRESENCE OF HOLES
The pet theory of the personnel in the plant was:
“Roller Number 1 is root cause”
It picks up fibre or something and leaves a hole”
Capex of Rs.2 crore would be required
to replace the roller with a larger one.
 We take a systematic problem
solving approach, that uses:
• only data and no opinion
• strict logical analysis
• experimental confirmation

THE DATA OF %DEFECTS OVER A PERIOD OF TIME INDICATED

THAT THE PROBLEM IS OF VARIATION TYPE.
 Is/Is-Not Matrix: Data Collection Format

Problem Is Present in Is Absent in

Problem Problem
1. What

2. Where

3. When

4.
Quantity
 Data Obtained on “What”

Problem Present Absent

What is the unit with defect Paper Not applicable

What is the defect on the unit Holes Not applicable

(this is the defect under
study)
What other defects are None Not applicable
present on the defective unit
What other defects are Not Profile, Thickness,
absent on the defective unit applicable GSM, Porosity,
etc..is available in this case
Yellow is where data
The Holes in the Paper

Hole
Hole

The paper with holes does

not have any other
problems
 Data Obtained on “Where”

Problem Present Absent

Where – on which part of defective Anywhere across Not present at any
unit machine profile specific location

Hole
Detector

Roller Hole

M/C width
Number
1
 View across width
of machine

Red: Medium size hole

Blue: Large size hole
WIDTH OF MACHINE
 The Holes in the Paper
Where is present?

Problem Present Absent

Where – on which part of defective Anywhere across Not present at any
piece machine profile specific location
Absence of specific location, and presence
of random spread suggests that the holes
are not machine related, but related to
something that contacts machine anywhere
randomly

Roller Hole

M/C width
Number
1
 Data Obtained on “Where”:

Problem Present Absent

Where - on which part of defective Anywhere across Not present at any
piece machine profile specific location
Where – on which product variety Imported RM, Indian RM,
More hardwood. Less hardwood.
Where – after which operation, and not Cannot measure Cannot measure
before which operation
Where – on which machine or line Only one m/c Only one m/c
available available
Where – in which plant/ area Not checked Not checked
 Input feed to the
process is randomly
distributed

Data obtained in “where” indicates that:

oles do not appear to be correlated with machine
and
Holes appear to be correlated with something Corroboration:
randomly distributed across the process. Holes are
correlated with
type of input
into process
 Detailed Problem Specs Sheet
for “When”

Problem Present Absent

When – draw time line and

show occurrences of defect
When – in which shift and which
part of the shift (hr/min)
When – in which month; in
which season
When – in which year

Yellow is where data is available in this case

 Detailed Problem Specs Sheet
for “When”

Problem Present Absent

When – draw time line and No clear pattern,

show occurrences of defect trend or periodicity
When – in which shift and which No pattern visible
part of the shift (hr/min)
When – in which month; in
which season
When – in which year

Yellow is where data is available in this case

 Data on “When” – Time line

2
No clear pattern
no build ups,
no periodicity
3

Today
 None of the recorded machine
parameters and none of the recorded
input parameters correlate with the
ups and downs in the rejection
percentage on the time line, when
compared for the same grade of
material.
 Detailed Problem Specs Sheet
for “Quantity”

Problem Present Absent

Quantity – How much (how

deep/wide…) are the defects
Quantity – How many defective
pieces in the batch
Quantity – How many defects
on defective piece

Yellow is where data is available in this case

 Data Obtained for “Quantity”

Problem Present Absent

Quantity – How much (how Approx circular holes, Not steaks,

deep/wide…) are the defects which are most tears,
common
Quantity – How many Many Not zero
defective pieces in the batch
(roll)
Quantity – How many defects
on defective piece
 Physically search for
“mura” (inconsistency)
in input material
 Found foreign
Found no bodies in fresh
contamination in water!
Found no
input raw materials
contamination in
recycle water!

Found foreign Found no

bodies in head box contamination in
input! chemicals and
other streams
 Hypothesis:
Foreign bodies from
fresh water
lead to holes
 Testing of Hypothesis

Experimental confirmation:
• Experiment : Stop fresh water: Rejections should reduce
 Experimental Testing of Hypothesis

Roll No Grade Meters Holes Holes Holes Dark Sp Dark sp Dark sp Thin sp Thin sp Thin sp Bobbins %
small medium large small medium large small medium large reject bobbins
reject

234 TR 3 21111 2 70 57 0 0 0 335 142 29 56 With

fresh
water
235 TR 3 26251 2 30 41 2 0 0 114 67 14 39 With
fresh
water
236 TR 3 28214 1 33 30 0 0 2 137 78 19 49 With
fresh
water

244 TR 3 21,676 3 28 15 0 0 0 66 34 4 14 5% No
fresh
water
 Conclusion

Foreign particles from fresh water are

primary chronic causes of holes,
resulting in rejections

Machine parts, including “roller number 1”

aggravate the problem, and are causes of
instability problem (cyclic trend), resulting in
rejections.
 Countermeasures

•Reduce contamination in fresh water

 This is a sporadic problem
of holes in shape of cracks

This is a instability problem.

Not to be confused with chronic problem.
Cause for this is different, and known.
Difference between Sporadic and Shift

Sporadic

Shift

We are
solving this
Now the real challenge is on!

1. Completing the countermeasures

2. Sustaining the gains
3. Preventing and immediately correcting
sporadic problems
Can you
meet it?

Should become redundant

 Learning’s

8D approach makes no assumptions.

It starts with data, from scratch on blank slate.
t uses logic to narrow down the area of search for the root cause.

It does not require only technical expertise.

It also requires reliable data.
It obtains data by asking a series of questions.
The questions are in strict sequence.