IMPLEMENTATION OF LEAN IN

SEGREGATION & REWORK AREAS OF

PACKING SECTION AT HLL LIFECARE LTD,
THIRUVANANTHAPURAM

Bibin M Abraham
0920006
MBA- A
COMPANY PROFILE
• Formerly known as Hindustan Latex Ltd
• Started on March 1, 1966. The company
commenced its commercial operations on
April 17 , 1969 at Peroorkada in Trivandrum.
• HLL Lifecare Ltd is the only company in the
world in manufacturing and marketing wide
range of Contraceptives and Healthcare
products
• HLL’S PRODUCTS :- Contraceptives, Health
Care Products (Surgical Instruments, Blood
Collection Bags, Vaccines, Iron and Folic Acid
Tablets Oral Rehydration Salts etc)
 COMPANY PROFILE
• Production Capacity- 1.3 billion condoms every year
HLL Production Facilities:
• Peroorkada Factory , Trivandrum
• Akkulam Factory , Trivandrum
• Kanagala Factory , Belgaum
• Kakkanad Factory , Cochin
• Manesar Factory , Gurgaon
New Ventures
• LifeSpring Hospital Chain
• Integrated Vaccine Project
• Hindlabs
 RESEARCH DESIGN
Problem Statement
• To carry out a study in Packing Section and to analyse
the Condom Segregation & Rework Areas of Packing
Section as there prevails some bottlenecks in data
recording, backtracking and accountability
Objectives Of The study:
• Study the existing process flow of the Primary Packing
Section.
• Spot a specific area for improvement where some
bottlenecks exists.
• Add my suggestions to see whether they could improve
the processes in a more efficient and effective manner.
• To understand how lean concept is implemented in a
company.
• Operation Tool used for the study was PROCESS
FLOW MAPPING

Data Collection
• Observing the activities on the shop floor
• Reference to Packing Manual

Limitations
Contradictions between the feedbacks given by the
workers and the procedures printed in the manual
 FINDINGS(1/3)
(Process Flow Map for Primary Packing )
 FINDINGS(2/3)
• My primary area of observation- Condom Segregation & Rework
area of the Primary Packing Section.
Current Procedure
• The strip packed condoms weighing area (weight of each
strip packed lot is recorded )
• Weighed strip packed condoms segregation area (for the
separation of good and bad strips)
• Inspects strip packed condoms for visual defects and the waste
details will be entered in the ‘Segregation Waste Sheet’
• Segregated strips Rework Area (strip packed condoms are
peeled and are further segregated into good and bad condoms
and the details are recorded in ‘Packing Machine Waste Details’
sheet)
 FINDINGS(3/3)
• Good condoms QA Department
• Bad condoms will be transferred to disposal area
Limitations of the current procedure
• Future reference to the recorded details is complex.
• Difficulty in back-tracking
• Inaccurate Accountability (along with the waste details, the
employee details are not recorded)
• Impossible to analyse the employee productivity as well as the
machine performance.
• Incur a lot of cost in stationery as well as it consumes a lot of
physical space.
 SUGGESTIONS(1/4)
• The above mentioned problems could be solved by the
implementation of eIMIS
Framework for Segregation Area
 SUGGESTIONS(2/4)
• Upon entering the DATE, SHIFT and BATCH NO. the
corresponding lots will be displayed in the form of drop down
list (The lots in the drop down list consists of those lots which
have been issued from the condom issue area)

• Once the lot number is selected from the drop down list the
corresponding MACHINE NO. & the EMPLOYEE ID will be
displayed in their corresponding columns.

• The weight of condoms (in kg) with visual defects (which is

determined by segregating the strip packed condoms) will be
entered in the WASTE column corresponding to the particular
lot no. & Employee ID.
• After segregation the total waste will separated as Reworkable
and Bad condoms
 SUGGESTIONS(3/4)
Framework for Rework Area
 SUGGESTIONS(4/4)
• Upon entering the DATE, SHIFT & BATCH NO., the
corresponding lots will be displayed in the form of a drop down
list (The lots in the drop down list consists of those lots which
have been entered in the segregation area)
• Upon selecting the lot no. the corresponding total weight will
be displayed in the TOTAL WASTE column.
• The total weight of condoms that can be sent to QA
department will be then entered in the REWORKABLE
CONDOMS column.
• The total weight of damaged condoms that are to be
transferred for disposal are entered in the CONDOM WASTE
column.
• The total weight of the waste strips are entered in the STRIP
WASTE column
 ADVANTAGES OF THE PROPOSED SYSTEM
• Future reference is made simple
• Accurate accountability is possible
• Back tracking can be done more efficiently
• This system takes relatively lesser time for operation as
compared to the current system followed.
• Stationery cost incurred could be minimised.
Other Suggestions
• Suggested for improving the working conditions of machines
by ensuring the working of air conditioners, as the machines
are very sensitive to dust and other particles which would be
an advantage for the operators also.

• Autonomous Maintenance
Other Suggestions continued
• Integration of foil printing with the packing machine:
This could save a lot of time as well as manpower.
Thus pre-printing of foils could be stopped and the
manpower in printing rooms could be utilised in some
other areas.

• Use of colour coded crates: crates containing oil

stains can be differentiated from the dry ones so that
the condoms will not get damaged
THANK YOU..!!