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QC KAIZEN STORY

Elimination of In-Process Defects

Due to Improper Dyno Mill
Washing in Gravure.
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Team Members

1. Mr. Anuj Jain

2. Mr. Atul Agrawal

3. Mr. Narinder Kumar

4. Mr. Rakesh Mohan

5. Mr. Ashok Dogra

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2.Reason for Project Selection

Number of In Process Defects during last six Months of
2014(Apr-Sep’14)
In our last Kaizen story we have eliminated
Settling & Separation Defects
No. of defects

Now we have to reduce the remaining

In-Process defects
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2.Reason for Project Selection

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2.Reason for Project Selection

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2.Reason for Project Selection

From above slide we can say that the main reason for
In-Process defects is Improper Dyno Mill Washing.

By improving Dyno mill washing we can avoid most of

the In-process defects like Viscosity, Gloss, Adhesion,
strength and sediments related issues.

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2.Reason for Project Selection

In-Process Defects during Nov-14 to April-15

Total 42 number of
defects came due
to various reasons
No. of defects

Types of Defects

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2.Reason for Project Selection

Total 18 In-Process
defects came due to
No of defects

improper dyno mill

washing

In-Process Defects
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2.Reason for Project Selection

Total No. of complaints due to Various reasons during Nov’14-Apr’15

These 11 complaints are came out due to

various reasons but majorly it is due to
No. of customer complaints

improper Dyno-mill washing

Type of Customer complaints These complaints are related to technical

reasons like Blocking, Bond Strength etc .
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Plan

3.Improvement Target & Schedule Actual

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4.Understanding the current Situation

When Dyno Mill washing is required ?
1.Dyno mill washing is required during color change.
2.Required during changeover of one type ink to
another type of Ink.

Why Dyno Mill Washing is required?

1.Dyno Mill washing is required for ensuring no
contamination in printing Ink.
2.To avoid long term defects like Sedimentation,
Settling & Separation of Ink.

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4.Understanding the current Situation

 Operators do the Machine

washing as per Process Order &
then clean the Machine for next
Batch.
 For Cleaning the machine,
operator takes the solvent from
the letdown part either in his
own way or the available
quantity in process order.
 Hence machine cleaning
procedure is not consistent even Dyno Mill
for different batches of same ink.

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4.Understanding the current Situation

Currently, operators are just
passing the solvents one time
through Dyno Mill for Dyno Mill washing as per old SOP
cleaning, but some times this
solvent is not sufficient to
remove the resin / additive
particles from dyno mill.

We check the drain solvent

quality on paper and if it is
colorless then approve the
washing for next batch , but
not verifying that all the
resin / additive particles
come out from dyno mill .

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4.Understanding the current Situation

Old SOP

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4. Understanding the current Situation

1. Exact Quantity for cleaning
and the type of Reducer is not
defined for changeover.
2. Most of the Operators are
new and don’t understand
the criticality of the process.
3. There is simple QC check of
taking drain solvent on paper
for ensuring no color
contamination but not
verifying that all the resin /
additive particles come out
from dyno mill after washing.
4. No involvement of Shift In- Checking the solvent
charge during the cleaning color on white paper
process.

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4. Understanding the current Situation

If Dyno Mill washing is not

h
stre ur
Low

ngt
good, then it may lead to

colo
Resin / Colour contamination
& this contamination may
cause several quality defects
like adhesion failure, low
gloss, low strength, lining
etc. in production as well as

n fa esio
in printing.

e
ilur
Adh
Settling & Separation type of
defects may also come
during long storage of Ink.

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5.Factor Analysis & Cause Investigation

Creation of
Improper Pass the solvent one
defects due to New SOP is
Dyno Mill time for Dyno Mill Follow the old SOP
improper required
Washing washing
washing

Need to be
Solvent taken from let Operator take the Reducer type &
defined the
down part available in solvent in his own its quantity not
type & Qty.
batch card way defined in SOP
for washing

Crosscheck
Operator only check the
No QC / Production sheet need to
color of solvent on No crosscheck
supervisor be introduced
paper & not confirm the procedure
crosscheck after for verifying
resin removal from dyno available
dyno mill washing no resin
mill
contamination
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6. Consideration & Implementation of

Countermeasures
Initially it was decided to increase the
solvent qty. in washing and shift in-
charge will take the decision of type of
solvent but it looks not sufficient as
problem is coming intermittently. Then
decided recirculation of solvent from
dyno mill and fix the reducer solvents
for the ink for cleaning and revise the
SOP accordingly.
QC will check the color of solvent and
will do the GC for toluene free batches
and also check the resin contamination
through IR. After QC approval,
production team will take next batch. QC person ensuring proper
dyno mill washing

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6. Consideration & Implementation
of Countermeasure
As per New SOP
1) Pass the varnish as per the Re circulation
washing part in process order. Process

2) Pass 30 Kg reducer solvent of

running ink for KD-45 & 20 Kg for
KD-25 Dyno Mill (if Quantity of
reducer solvent is less , take
balance solvent from let down part)
.
3) Again pass 30 Kg reducer solvent
from KD-45 & 20 kg from KD-25
reducer solvent(taken from washing
part or from let down part) and
circulate the solvent for 15 minutes
and take out the solvent from
machine.

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6. Consideration & Implementation

of Countermeasure
5) Again pass the 30 Kgs reducer
solvent (take from let down part)
from KD-45 & 20 Kg from KD-25 Solvent
dyno mill and drain the solvent. draining
6) Pass 30 Kg for KD-45 & 20kg for
KD-25 reducer of next batch from
dyno mill and drain the solvent.
Use this solvent in same batch or
in same ink type.
7) Start the next batch grinding.
8) For Toluene Free Batches- Pass 60
Kg Ethyl Acetate from KD-45 & Solvent
40Kg from KD-25 dyno Mill. Drain draining
the solvent and use the collected
solvent in Toluene base ink

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6. Consideration & Implementation of Countermeasure
New
SOP

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6. Consideration & Implementation

of Countermeasures
 Demonstrate the New SOP in production on all the Dyno Mills.
 Provide the training in production to all the concerned operators.
 Make a checklist for proper dyno mill cleaning to avoid any
failure.

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7. Confirmation of the Improvement

Results and Recurrence Prevention
No. of In-process defects

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7. Confirmation of the Improvement

Results and Recurrence Prevention
We are checking the GC and IR of production batches on two Dyno
mills in a week for verifying that no contamination in the Ink.

Confirmation
of resin
contamination
through IR
Report

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8.Horizontal Deployment
 Establish the new SOP for Dyno Mill Washing to all
the dyno mills in production .

 Provided the necessary training to all the operators

with demonstration of cleaning and teach them
about the Criticality and the Importance of the
process.

 Same SOP is implemented on immediate basis at

our Panoli plant.

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9. Future Plan
1. Zero Customer complaint related to Filling / Packing.

2. Improve the Packing efficiency

3. Zero Stock of Non-Moving FG

4. Reduction of production losses through the consumption of

Retain Samples.

5. Reduction in RM / FG inventory.

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THANK YOU
CONTINOUS LEARNING AND
IMPROVEMENT FOR THE BETTERMENT

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