SAKATA INX···

VISUAL COMMUNICATION TECHNOLOGY

QC KAIZEN STORY
( May - June’14 )
 1. PROJECT TITLE

“33% Time Reduction in Lamitop

Medium Production at Gravure Plant”
Team Members
1. Anuj Jain ( QA)
2. Ashok Dogra (Production)
3. Narinder Kumar (QA)
4. Shakif Alam (Production)
 2: REASON FOR PROJECT SELECTION

Production lead time of Medium for Graphical presentation for

different product range understanding

Production Lead Time(Minutes)

S.No. Product Range
for 1Ton Batch size

1 Lamitop 157.5

2 Lamiall 95

3 DX-60 105

4 SP-PVC 100

5 Bellecolor 95

Over all Average Lead time For Gravure Plant , Bhiwadi is 216 Min.
2. REASON FOR PROJECT SELECTION
 3.IMPROVEMENT TARGET & SCHEDULE

Actual Lead Time Target Lead Time

Decrease in Production Lead time of May--14 June--14
Lamitop Medium (Min./2 MT) by
33% May June
Activities
315 Min.
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7
213 Min.
8 9 10 11 12 13 14 15

1. Understanding the current

situation

2. Factor Analysis

3.Consideration and
Implementataion of Counter
measure

4. Confirmation of the
improvement results

5. Horizontal Deployment &

 4: UNDERSTANDING THE CURRENT SITUATION

Man -Machine chart of LT Medium Production Avg time for May-14 ( Minutes)
Total time -315 min for 2 MT Batch i.e. 157.5 minutes/MT

Activity TIME IN MINUTES

6.30 7.00 7.30 8.00 8.30 9.00 9.05 9.15 9.35 10.05 10.15 10.35 10.55 11.25
Cleaning of 1st MBT 30

Weighing of RM / Resin charging 30 One LT medium

Mixing 120 Batch of 1 MT
QC testing 5 Batch taken in
Cleaning of 2nd MBT 30 MBT take 157.5
Min.
Half Material taken from 1st MBT 10
Weighing of Rest RM 20
Mixing 30
QC Testing 10

Weighing of Rest RM in Ist MBT 20

Mixing 30
5: FACTOR ANALYSIS & CAUSE INVESTIGATION
( 1ST CAUSE)

First cause is Nonavailability of MBT

Phenomenon Why 1 Why 2 Why 3

Cleaning time
MBT not cleaned
is too long

High Production Lead

Nonavailability of
time in Production of
MBT
Lamitop Medium

Number of MBT are not

Lack of MBT
sufficient as per requirement
5:FACTOR ANALYSIS & CAUSE INVESTIGATION
(2ND CAUSE)

Second cause is Nonavailability of Mixers

Phenomenon Why 1 Why 2

Limited number of
mixers available for
Medium Production

High Production Lead time

Nonavailability of
in Production of Lamitop
Mixers
Medium
 5:FACTOR ANALYSIS & CAUSE INVESTIGATION
(3RD CAUSE)
Third cause is Loss of time in Mixing at various stages

Phenomenon Why 1 Why 2

Currently we are making GV-5 in 1300 Ltr.

MBT having batch size 1000 Ltrs, then shifted
High Production Lead Loss of time in 500kg to another MBT and add balance
time in Production of mixing at various materials of Lamitop Medium in both the
Lamitop Medium stages MBT. That is how we require 3 times mixing
during production.
 6. ACTION PROPOSED BY THE TEAM AFTER
INVESTIGATION
Through Brain storming with team following findings are reported :-

1.Shortage of MBT to prepare a batch.

2.Shortage of Mixer to mix the batch as mixers are busy in

varnish production & other type of Medium

3.Only single weighing balance lead to the delay in charging.

Proposed Counter Measures
1. We have one fixed tank of 2 MT batch size for GV-A varnish and
utilization of tank is less(1 Batch/ Day)
2. This tank can be utilize to make the LT medium
simultaneously.
 7:CONFIRMATION OF THE IMPROVEMENT RESULTS
AND RECURRENCE PREVENTION

Corrective Action – Now we have shifted the whole process to a Fix tank having
capacity 2.0 ton. All charging to this tank is PLC operated

Effectiveness of Kaizen
S.NO. Before After

Two numbers of MBT required for the

1 No MBT required
production of 2 ton batch

PLC operated and for rest materials one weighing

2 Don't have sufficient capacity weighing balance
balance is sufficient

Mixing time is 90 min. to complete the 1 MT Mixing time reduced to 150 min for the completion of 2
3
batch MT batch

No cleaning required, hence no solvent wastage for

4 MBT cleaning time is high
cleaning
7:CONFIRMATION OF THE IMPROVEMENT
RESULTS AND RECURRENCE PREVENTION

Before Kaizen After Kaizen

1 MT MBT Utilization of GV-A 2MT Batch

 7:CONFIRMATION OF THE IMPROVEMENT RESULTS AND
RECURRENCE PREVENTION

Man-Machine chart of Lamitop Medium Production Avg. production for June-14 (Minutes.)
Total Time -210Min
ACTIVITY TIME IN MINUTES

6.3 7.0 7.3 8.0 8.3 8.35 8.50 9.20 9.30 9.50
Lead
Weighing of RM / Resin charging 30 time
reduced
Mixing 120 by 33%

QC testing 5.0

Weighing of Rest RM 15.0

Mixing Actual Lead Time 30.0

Target Lead Time
Decrease in Production Lead time of May--14 June--14
QC Testing
Lamitop Medium (Min./2 MT) 10.0
 7:CONFIRMATION OF THE IMPROVEMENT RESULTS
AND RECURRENCE PREVENTION

Time cycle
improved
@33%
MINUTES

MINUTES
 7 CONFIRMATION OF THE IMPROVEMENT RESULTS AND
RECURRENCE PREVENTION

Recurrence Prevention
1.Regular calibration of PLC and Weighing Balance will be carried
out as per plan.

2. Regular cleaning of tank will be carried out on Quarterly basis.

3.TPM Promotion to conduct regular audits.

 9: FUTURE PLAN

.
Future Plan
1. 50 % Improvement in packing time of Lamitop Medium.
2. 25 % Improvement in solvent recovery to improve the
production losses.
3. 40% Flow rate improvement in Yellow ink production
through Mighty mill.
4. 10% Improvement in same day dispatches for customer
satisfaction.
5. 10% Improvement in production losses.
THANK YOU