HOW TO CONTROL

WASTAGE DURING
CHANGE OVER AND LESS
QUANTITY PRODUCTION

PREPARED AND PRESENTED BY

SONU NIGAM
 CHANGE OVER
•
• Changeover is the process of converting a line or set of m/c’s machine
from running one product to another Product. This process requires
highly experienced teammates that are aware of what to be done
and what parts are to be changed and opened for cleaning and
again set the parts to its area keeping the complete changeover
activity in defined set time .
• There are two types of changeover that we usually take as per
Production requirements at our end .
I. SKU Changeover in PG Line like from 50gm to 100gm (DS), 100
gm(SS),250gm ,800gm
II. Variety Flavor change over in Kream Line from Elaichi to Orange ,
Orange to chocolate and vice versa
We have change over format which we maintain everytime when
changeover is taken.
It covers all points related to Quality and cleanliness after clearances from
QC and site officers then only another product Production begin.
 WASTAGE
• Shell broken due to all m/c not timely started after changeover , Broken
generation due to m/c malfunction or breakdown due to m/c parts not
perfectly set .
• Initially from every m/c s/w broken till line not formed or synchronize
with conver speed .
• Shell broken at s/w jaali end due to unskilled teammates and Liner
operator casual approach .
• Wrapper wastage and broken generation from all packing m/c during
initial m/c setting
• s/w section all m/c leftover cream in Bowl get wasted .
• At mixing Left over cream in cold room , prepared colour , Blend lecithin .
• At mixing Remaining kream from last variety run.
 HOW TO MINIMIZE WASTAGE
• Skilled teammates to be deployed for changeover that is dedicated head
operator should perform changeover .
• Regular maintenance of the machine that is frequently opened during
changeover as there might be chances of worn and torn out of parts .
• Cleaning of the parts opened to be done more precisely as Bowls and Mathani
are very sensitive a minor bend or dislocation will prevent smooth running and
effect its performance and ultimately broken generation.
• Also it is to noted that no interchange of parts between m/c should be
allowed , as it will impact the m/c performance .
• Sufficient time to be allowed for changeover as during peak season ,
changeover are performed very rapidly , during which some operation are
missed and not done completely creates lot of broken generation.
• Critical spare parts buffer stock to be maintained as sometimes due to
unavailability of parts old/damaged are run despite its poor performance .
 HOW TO MINIMIZE WASTAGE
• Proper prior calculation of the number of batch of shell required to meet
target and accordingly kream batch to be made so that no kream left
after production.
• It is better to make last batch of kream as per quantity required from
calculation not full batch .
• Proper planning and communication between mixing supervisor and
packing supervisor is essential.
• Zero Tray stock to be maintained , because more the tray stock more
broken will be generated .
• We should take a short production gap if one or two m/c breakdown
instead of Tray Stock .
 HOW TO MINIMIZE WASTAGE
• We have procured two inhouse high pressure water jet system for
cleaning purpose .
• We have separate trolley for Taking individual m/c bowl & change parts so
chance of damage get reduced and no mixing of parts
• For every m/c separate air nozzle ports provided near it with gun
provided for better and timely cleaning of all conveyor and machines .
THANKING YOU