Lean Sigma Project

Injection Molding Department

30-10-2014

History of Color Changing

24 g PET Preforms Rejection White to Clear changeover
1000
900

860

800
700
611

582

Kilograms

600
522
500

390

400

336

344
278

300
200
100
0
Pet # 2

Pet # 3

Pet # 3

Pet # 3

Pet # 2

Pet # 3

Pet #3

Pet #3

30-Dec-13

10-Feb-14

27-Mar-14

14-Apr-14

22-May-14

30-Aug-14

2-Oct-14

18-Oct-14

OEE % in PET # 3, 24 grams Preforms

White to Clear changeover
80

73.86

70.62

70
60

58.67

54.32

OEE %

50
40
30
20
10
0
Series1

14--Apr-14

30--Aug-14

2--Oct-14

18--Oct-14

58.67

73.86

70.62

54.32

Got Improvement on 30th

August & 2nd October
Got less in 18th October due
360 minutes down time
Last 90 minutes down due to
color line in preforms
Action Plan:- Running with
72 cavities. Hence blocked
cavities are affecting
By end of Dec-14, new parts
will arrive & run complete
cavities


Savings in SAR- 24 g Preforms Changoever
2500
2000

SAR

1500
1000
500
0

30--Aug-14

2--Oct-14

18--Oct-14

Savings in SAR

1432.44

1927.44

1492.38

Savings from Target

Value of 400 kgs

420.06

915.06

480

OEE Gain-24g Pet Preform Changover

20.00%
15.19%

15.00%

11.95%

10.00%
5.00%
0.00%
-5.00%
-10.00%
OEE Gain %

Against target of 400 KG,

savings in SAR
Still blocked cavities are
affecting the changeover
process, especially during
start up
Action Plan:- Running with
72 cavities. Hence blocked
cavities are affecting
By end of Dec-14, new parts
will arrive & run complete
cavities

-4.35%
30--Aug-14

2--Oct-14

18--Oct-14

15.19%

11.95%

-4.35%

On 18th October, 360 mins

down due to color line
preforms (last 90 mins)
Action Plan:- Running with
72 cavities. Hence blocked
cavities are affecting
By end of Dec-14, new parts
will arrive & run complete
cavities

PET Preforms White to Clear Changeover

24 grams White to Clear
S.No

Date

M/ C down time during color

change (Start up + purge+ color
change)

OEE Measures

Units
Minutes

Before

After

Gain

14-Apr-14

30-Aug-14

270

220

50

a)Aavailabitly measures

62.50%

69.44%

6.94%

b)Performance Measures

100%

100%

0.00%

c)Quality Measures

85%

91.16%

6.12%

d)OEE

58.67%

73.86%

15.19%

191

Scrap

Kgs

534.984

343.992

Finance Impact

SAR

4012.38

2579.94

1432.44

24 grams White to Clear

S.No

Date

Units

M/ C down time during color

change (Start up + purge+ color Minutes
change)

OEE Measures

Before

After

Gain

14-Apr-14

2-Oct-14

270

165

105

a)Aavailabitly measures

62.50%

77.08%

14.58%

b)Performance Measures

100%

99%

-0.63%

c)Quality Measures

85%

92.22%

7.22%

d)OEE

58.67%

70.62%

11.95%

Scrap

Kgs

534.984

277.992

257

Finance Impact

SAR

4012.38

2084.94

1927.44

24 grams White to Clear

S.No

Date

M/ C down time during color

change (Start up + purge+ color
change)

OEE Measures

Units

Minutes

Before

After

Gain

14-Apr-14

18-Oct-14

270

360

-90

a)Aavailabitly measures

62.50%

50.00%

-12.50%

b)Performance Measures

100%

100%

0.00%

c)Quality Measures

85%

88.29%

3.29%

d)OEE

58.67%

54.32%

-4.35%

199

Scrap

Kgs

534.984

336

Finance Impact

SAR

4012.38

2520

1492.38

Caps Process
Implemented check list in order to avoid blockage in
hoses- running OK & found no off-color caps
Working on Pumps calibration and rework of color
which got expiry still under process
Due to regulation of Government it is not easy to
send liquid colorant to UK for processing
Plan to make granules trial by end of December 2014
with Elopak & Al Marai