L QC Case Studies

PPPL-BHUJ-LEAN QC/VCCQC-12
2
Page 2 of2 20
Printing
Plant
Corrugated
Plant
Biscuit
Plant
Lean Quality Circle
PIONEER
Member
Leader
PRAVIN
YADAV
SANJAY
GUSAI
Facilitator
ATUL DER
Member
JASWANT
PANCHAL
Member
ASHWIN
PUROHIT
7
In the year 2009 our management guided us to start some projects

for the development of Workers (Team mates). We had started this
activity and it was named as Team-mates Development Project
(TDP). In this process they were also solving work relates
problems with less resources and short time.
In the magazine Quality Circle India of Jan-10 to March-10 a
article
on
Lean
Quality
Circle
by Mr. D. K. Srivastava was published.
Followed by a training programme on Lean Manufacturing at Our
Khopoli plant by Mr. D. K. Srivastava, which was the first training
programme conducted on Lean Manufacturing by our QCFI.
QCFI.
Lean means to get more, from less resources

Lean means the ability to achieve more with fewer
resources by eliminating waste.
Lean is about speed and getting it right the first
time.
Lean is about eliminating waste.
Lean is about uninterrupted flow of work.
Less time, inventory, space, people and money
Lean Quality Circle

With minimum documentations:
Steps for Problem solving
1) Define the problem.
2) Measure the problem.
3) Analysis the problem.
4) Improve the problem.
5) Control the problem.
10
To reduce Wheat
flour dusting in
cutting line for
cracker variety
11
Gauge roll-2
Wheat flour
hopper
Brush
Cutting roll
sheet
Gauge roll-3
Gauge roll-1
Cutting line
12
To removed the stacked biscuits from cutting

roll, we had to use more wheat flour dusting
between 20 to 22 kg.
kg./MT production and due
to these dusting, we were facing the problem
of Blister in the Biscuits.
Biscuits.
Biscuits
Cutting roll
13
Sr. no
Month
Wheat flour
dusting used in
Kg per MT of
bis. Production
Aug-11
19.35
BEFORE
Sep-11
16.7
BEFORE
OCT-11
16.5
BEFORE
Nov-11
17.4
BEFORE
14
Date
12
Wastage
Raw biscuit Finished Bis

( Kg ).
(Kgs.)
TOTAL
(Kgs.)
05/09/2011
0.5
8.5
06/09/2011
0.75
7.75
8.5
07/09/2011
0.8
9.25
10.05
08/09/2011
0.65
8.25
8.9
10
WASTAGE TOTAL IN KG.
Wastage
8
6
4
2
09/09/2011
0.45
7.75
10/09/2011
0.66
10.25
8.2
10.91
PPPL-BHUJ-LEAN
QC/VCCQC-12
DAYS
15
Due to more dusting of Wheat Flour

on cracker sheet, the problem of
blister can be occurred and also it
may reduced the biscuit shining, so
in short it effects the biscuit quality.
16
Wheat flour dusting to be reduced from 22kg.

/MT biscuits to 6 kg/ Per MT biscuits
production.
17
Quality Loss due to wheat flour

dusting.
Chances of blister high due to more
wheat flour dusting.
Biscuits sticking on the die

roll, creates production loss.
One team mates per shift
engaged in monitoring the
hopper of Wheat flour dusting.
18
Root cause Analysis

Blisters in the biscuits
Due to more wheat floor dusting
Due to biscuits sticking on die roll
Due to wet surface of the cup
19
We have installed two air pipes on

cutting roll. These two air pipes
with 2mm holes in a raw blow the
continuously air on top surface of
cutting roll to dry the cups so it
eliminates the problem of biscuit
sticking on cutting roll.
20
We have used 1/2 pipe parallel to cutting

roll and
Hole sizesize-2 mm and 4 mm chamfering on
hole.
Distance between two holes (pitch) is 50 mm
and .
Air used: compressed dry air with PR.
6kg/cm2
21
Air pipe
Air flows
Cutting roll
Air pipe
22
Date
Wastage at Finished
TOTAL
raw
biscuits in WASTAGE
biscuits
Kg
KG.
12/09/2011
0.25
1.5
1.75
13/09/2011
0.1
2.1
14/09/2011
0.1
1.5
1.6
15/09/2011
0.15
1.75
1.9
16/09/2011
0.2
1.55
1.75
17/09/2011
0.1
1.85
1.95
IN KGS.
We had implemented the solution for the 15 days

period and observed the below mentioned reduction
in the wheat floor dusting.
2.5
2
1.5
1
0.5
0
DATE
23
Wheat flour
dusting used in
STAGE
Kg per MT of
bis. Production
Sr. No
Month
DEC-11
6.8
AFTER
JAN-12
6.2
AFTER
FEB-12
6.1
AFTER
MAR-12
5.9
AFTER
24
25
1
2
19.35
16.7
6.8
6.2
20
Wastage in Kgs.
MONTHS
Wheat flour dusting

used in Kg per MT of
bis. Production Before
Wheat flour dusting

used in Kg per MT of
bis. Production
After
15
10
5
16.5
6.1
0
17.4
5.9
4
25
Daily avg.
production
30
SAVING IN
SAVING IN
WHEAT FLOUR RUPEES /
DUSTING/ MT
MT
11.24
224.8
PER DAY
PER MONTH
SAVING IN
SAVING
RS.
6744
168600
26
After fitted two pipes we are

getting following benefits.
Biscuit sticking on cutting roll
problem solved
Wheat flour dusting reduced.
Batter shining on top surface
of biscuits
Improvement in biscuits
Quality
27
AFTER
(KGS)
SAVING
(KGS)
DAY
BEFORE
(KGS)
1.75
7.25
8.5
2.1
6.4
10.05
1.6
8.45
8.9
1.9
8.2
1.75
6.45
10.91
1.95
8.96
12
10
8
6
4
2
0
BEFORE
AFTER
28
Wheat flour
dusting used in
STAGE
Kg per MT of bis.
Production
Sr. No
Month
APRIL-12
6.1
AFTER
MAY-12
AFTER
JUNE-12
5.4
AFTER
JULY-12
AFTER
29
10
10
10
10
30

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PPPL-BHUJ-LEAN QC/VCCQC-12

Lean Quality Circle

In the year 2009 our management guided us to start some projects

Lean means to get more, from less resources

Lean Quality Circle

To removed the stacked biscuits from cutting

Raw biscuit Finished Bis

Due to more dusting of Wheat Flour

Wheat flour dusting to be reduced from 22kg.

Quality Loss due to wheat flour

Biscuits sticking on the die

Root cause Analysis

We have installed two air pipes on

We have used 1/2 pipe parallel to cutting

We had implemented the solution for the 15 days

Wheat flour dusting

Wheat flour dusting

After fitted two pipes we are

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