Asq Meeting
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Transcript of Asq Meeting
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8/13/2019 Asq Meeting
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LEANMANUFACTUTRINGa case study
Prof. C.S.PurushothamanPromoter Director CREST PACKAGING PRIVATE LIMITED
Promoter Director PROFESSIONAL PACKAGING GROUP
Visiting Faculty & Examiner Universi ties of Mumbai, SNDT and Kerala
Retired Chair Professor Director SIES School of Packaging
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The Company
CREST PACKAGING PRIVATE LIMITED
Established 1998
Contract Packaging Professionals
ISO 9001:2008 Certified Organisation
Manufacturing Units 2nos. Total Workforce over 180
Investment Rs. 1.5 Crores
Monthly Turnover 3000 MT of Lubes Packaging
Clientele Castrol, HPCL, Reliance, Bosch, Eicher, Royal
Enfield, IOCL, BSL, BPCL & Tide Water
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Packages Handled
POUCHES
20ml, 40ml, 60ml, 100ml
Over 1 Crore pouches /month with 15 FFS m/cs
BOTTLES
1 Lt to 5 Lts
4 Complete filling lines
Filler, Capping, Inkjet, Induction Seal and Taping
PAILS
3.5 Lt to 20 Lt with 4 auto lines DRUMS
50Lt to 201 Lt
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Packages Handled
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FFS POUCHES
3 side sealed pouch
POUCH REJECTION CAUSES
Leaked Pouches
SEALING PARAMETERS
Temperature, Pressure & Dwell Time
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FFS POUCHES1998
2 nos per m/c - One Operator + One Packer For 16 m/cs 32 men
Prodn 4,00,000 pouches per day
Rejection 18% due to leaks (72,000)per day
Labour Cost Rs. 12,800 per day
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ISSUES REJECTION - LEAKED POUCHES - 18% (2880Lts)
COST OF QUALITY TANGIBLE
Sorting 8 workmen per day (Rs.2400 per day)
Reclaim - Oil loss 30% (864 Lts Rs.288000 per day)
Prodn Loss 72000 per day (equivalent to 2.7 m/cs)
6 manpower (Rs.4800) + Time + Electricity etc
INTANGIBLE
Messy Work Floor, Extra space, Image Loss
DAILY PRODUCTION 4,00,000 pouches per day
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STRATEGY
ROOT CAUSE ANALYSIS FOR LEAKAGES SYNERGISING MANPOWER
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ROOT CAUSE ANALYSIS
MATERIAL
Improper Laminate Specification Improper Laminate Curing
Improper Laminate reels
MACHINE
Improper Temperature setting Improper Pressure setting
Improper Dwell Time setting
Improper Tension setting
MEN Inadequate Training
Inadequate supervision
Improper Timing More free time
Improper manpower allocation
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ROOT CAUSE ANALYSIS
METHOD
Improper Loadingof reel Improper pulling of pouches
Improper packing and storage
Improper Handling
Optimising coding
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ROOT CAUSE ANALYSIS
MATERIAL
Improper Laminate Spec QC Check every reel Improper Laminate Curing Trial run of lot
Improper Laminate reels - Trial run of lot
MACHINE
Improper Temperature setting - Optimised Improper Pressure setting - Optimised
Improper Dwell Time setting - Optimised
Improper Tension setting - Optimised
MEN Inadequate Training Trained for the job
Inadequate supervision SOP & systems
Improper Timing More free time - Optimised
Improper manpower allocation - Optimised
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ROOT CAUSE ANALYSIS
METHOD
Improper Loadingof reel 2 m/cs per person Improper pulling of pouches 2 m/cs per person Improper packing and storage - SOP
Improper Handling - SOP
Optimising coding Ink Jet Coding
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RESULT
Rejection - 0.2% due to leaks
SYNERGISING MANPOWER
For 16 m/cs 10 men
1 person per day
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TANGIBLE Sorting 7 workmen per day (Rs.2100 per day)
Reclaim - Oil loss 17.8% (2484 Lts Rs.248400 per day)
Prodn Loss 71,800 per day (equivalent to 2.7 m/cs)
6 manpower (Rs.4800) + Time + Electricity etc
INTANGIBLE
No Messy Work Floor, Litt le space, Improved Image
SAVINGS
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THANKS
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