BILT GRAPHIC PAPER

PRODUCT LIMITED
Unit: Bhigwan
To Reduce Tension variation during splicing

SIX SIGMA project presented by VIKAS KUMAR

TO REDUCE Tension Varition DURING SPLICINGProject detail

BLACK BELT

Name: Vikas Kumar

Dept :Coating plant

Location : BHIGWAN PUNE

Brief Job description : during splicing

process web is moving , up 2.5cm
movement paper not breaks but when ites
cross more than 2.5cm paper breaks at
rewind station its chance to break the
paper.(As we are trimming the edges at
rewind )

Champion:

Project description: To reduce tension

drop during splicing in omc.

Project scope: To reduce tension drop

during splicing in omc.

Business Case: 6 breaks per month and

4hrs loss in omc.

Project start / Estimated end: JAN 2011July 2011.

PROJECT STATUS-

Close Define

Dilip Wadodkar , Raghavendra Hebbar

Control

Team Members: Ajit Dubey, Sanjay Bhoite,

Rama Krishana, Hemant Kale, Nitin Patil,
Karson, DSN , Nagbhusan.

Measure

Improve.Analysi

Process description-

Process Description- The off machine coater is a converting

process use for making uncoated paper in to coated paper.
In the process of coating we are applying color to paper , paper is
supported by the rolls and extra color scrapped by a blade and
after coating paper going to slitting edges for calendaring process.
The raw material ( base paper ) coming in the from of 10mt wt of
rolls , Coating is a continuous process so need to joint the rolls
during running . During roll to roll joint done by adhesive
tape called splicing process, this increasing the thickness
of paper , due to thickness issue we need to remove blade during
splicing. Due to coater open and close process tension drop . If we
not open coater this make the paper break in paper.

 Paper Coating process-

Paper

Backing roll

Coater blade

color
Applicator roll

Coater pan

Project Charter

The purpose of this six sigma project to reduce the WEB MOVEMENT problem in

coating machine pm1. We are facing web movement problem in coating machine from
last 13years, causing web breaks in coating machine , deckle marking in filled rolls ,
deckle marking in papers .Web breaks contributes loss of energy, paper , machine
equipment and quality .
We had carried load cell calibration from ABB even though this problem still persist

with our machine.During commissioning of PM2 we have also called VOITH expert to
solve this problem but they could not address web movement problem.
As the web breaks frequency of web movement is experienced intermittently hence

we were unable to conclude the reason of the problem.Our aim to taking six sigma
project under guidance of ISI to under stand the contributing factors for web
movement factors.
We have taken this cross functional project under guidance and support of Mr

I.N.Guha (Unit Head), Mr Dilip Wadodkar (GM ENGG) & Mr Raghavendra Hebbar
(PROCESS HEAD).

ROLE AND RESPONSIBILITYBLACK Belt(VIKAS

KUMAR)

Team memberAjit Dubey, Sanjay

Bhoite, Hemant
Jain(ELECT) ,Hemant
Kale , Sujeet
Mhetre(MECH), Nitin
Patil, DSN,
Nagbhusan, Karson
Kulkarni.(Process
dept)

Review
purpose of
project.
Draft the
charter.
Finalize team
member.

Manage schedule.
Lead meeting.
Keep records.
Lead team work.

See the doc .

Update the
lessons captured.
Monitor the
implementation. .
Monitor the
results.
Use the improve
methods.

Participate in meeting.
Carry out assignments.
Assist in piloting.
Contribute knowledge
and expertise.
Learn necessary skills
and methods.

Use of improve
methods.

NO OF BREAKS DUE TO WEB MOVEMENT TREND-

SIX SIGMA PROJECT START FROM JAN11

SIPOC

Color Kithen

PAPER MACHINE

COATING COLOR

COATED PAPER

FINISHING HOUSE

BASE PAPER
COATIN

COATER PROCESS COATER cylinder

MANAGEMENT

G
PROCESS

MAINTANCE
COATER BLADE

BASE

PAPER

COATING
COLOR

COATER
CONSUMA
BLE

COATING
APPLICATIO
N

COATED PAPER

Identification of CTQ:
Need of
customer

CTQ

Less rework

Tension
difference
during
splicing.

Measurement

Defect
definition

Through load cell.

Tension drop
more than 120N
in coater.

As we can measure only tension , the web movement we can only observed we dont

have man power to record this but the web movement directly proportional to tension drop
so we consider this measurable unit as a CTQ. Up to 120N tension drop max web
movement is 2.5cm .
If tension drop more than 120 N then this web movement crosses more than 2.5 cm web

movement converting to passable breaks.

Fish bone diagram-

Gsm of paper.

Speed of machine.

LOAD CELL.

Dryer mech condition.

Dryer load.

Blade thickness.

Blade setting.

Screen tension

Tension drop/Variation

SPEED DIFF

Base smoothness.

Cobb of paper.

Backing roll load

Hydraulics pressure.

Screen tension.

Applicator & backing roll gap.

Priority Matrix:
OUT PUT VARIABLES(WEB MOVEMENT)
S.N

INPUT VARIABLES(X)

1 2

TOTAL

Speed of machine.

54

23

LOAD CELL.

24

19

Dryer load.

88

40

Dryer mech condition.

76

36

Blade thickness.

56

29

Blade setting.

77

29

Base smoothness.

44

25

Cobb of paper.

45

23

Gsm of paper.

45

23

10

Hydraulics pressure.

66

26

11

Screen tension.

67

30

12

Applicator & backing roll

gap.

56

13

TENSION VALUE

55

14

SPEED DIFF

56

15

Backing roll load

86

29
23
30
30

By the basis of

team
view(numbering
from 1 to 10
scale)

Data collection plan-

After priority matrix we decide to collect data on shift wise

basis , in every shift process operator and shift in charge
collection data in once every 8hrs , in the mid time of the
shift , tension drop data and speed difference data
collected by electrical dept .

Six sigma team decide to collect data up to 45 day .

Data collection - (shift wise)

date

cylinder
load

backing roll
load

hydrulic

blade

pentration

gap

angle

speed

gsm

base
smoothness

cobb

sk

Tension drop

Diff between
backing roll
and cylinder
group.

01-01-2011a

11

130

2d

3.3

0.9

27.5

950

130

6.7

38

90

-1.2

01-01-2011b

12

128

2d

3.3

0.9

28.5

950

130

6.7

34

90

-1.2

01-01-2011c

14

12

130

2d

3.3

0.9

27

950

130

6.7

34

110

-1.2

02-01-2011a

20

130

2d

0.9

26

830

170

6.8

32

230

-1

02-01-2011b

20

130

2d

0.9

26

830

170

6.8

45

180

-0.5

02-01-2011c

20

130

2d

0.9

26

830

210

6.8

227

170

-2
-1

03-01-2011a

20

128

2d

0.9

26

830

210

7.1

227

180

03-01-2011b

21

130

2d

4.2

0.9

25.5

830

210

6.9

224

250

-2

03-01-2011c

19

130

2d

4.4

0.9

26

583

300

6.7

220

7.5

330

1.8

04-01-2011a

130

2d

3.4

0.9

26

570

300

6.7

227

7.5

120

-2.5

04-01-2011b

12

130

2d

3.5

0.9

26

570

300

6.8

224

7.5

110

-0.9
-1.5

04-01-2011c

21

128

2d

4.4

0.9

26

583

300

6.8

227

7.5

270

05-01-2011a

12

20

130

2d

0.9

26

583

300

6.8

230

7.5

290

-1

05-01-2011b

18

130

2d

0.9

26

548

300

7.1

227

7.5

174

-2.5

05-01-2011c

21

128

2d

0.9

26

548

300

6.9

227

7.5

270

-2.1

06-01-2011a

14

128

2d

3.5

0.9

26

548

300

6.7

227

7.5

310

3.9

06-01-2011b

18

18

128

2d

0.9

26

533

300

6.8

227

7.5

230

06-01-2011c

10

130

2d

3.3

0.9

26

480

300

6.8

227

7.5

80

-0.7

07-01-2011a

11

130

2d

3.3

1.2

30

520

300

6.8

227

5.2

80

-0.7

07-01-2011b

11

128

2d

3.3

1.2

28.77

729

250

7.1

227

4.5

90

-1

07-01-2011c

12

128

2d

3.3

1.2

27

728

250

6.9

227

6.2

80

-1

08-01-2011a

44

18

128

2d

1.2

27

727

250

6.7

227

7.2

288

0.5

08-01-2011b

11

128

2d

3.3

1.2

28.9

735

250

6.7

232

110

-0.8

08-01-2011c

18

130

2d

1.2

28.9

735

250

6.8

230

180

-0.4

Analysis of data-

Process is stable-

Distribution ID Plot for Tension drop

Descriptive Statistics
N N*

Mean

StDev Median Minimum Maximum Skewness Kurtosis

117 0 178.607 84.4106

160

60

370 0.533067 -1.00791

Goodess of Fit Test

Distribution
Normal

AD

P LRT P

3.490 <0.005

Lognormal

2.006 <0.005

3-Parameter Lognormal
Exponential

1.849

* 0.097

15.282 <0.003

2-Parameter Exponential 3.438 <0.010 0.000

Weibull

2.490 <0.010

3-Parameter Weibull

1.519 <0.005 0.000

Smallest Extreme Value

4.803 <0.010

Largest Extreme Value

2.564 <0.010

Gamma

2.257 <0.005

3-Parameter Gamma
Logistic
Loglogistic

1.487

* 0.001

3.272 <0.005
2.110 <0.005

3-Parameter Loglogistic 1.932

* 0.023

As all the p value is less than 0.05 we conclude it doesnt fit any theoretical distribution.

Before six sigma project-

The performance is 632478 ppm equivalent to

Analysis of dataRegression Analysis: Tension drop versus Diff between, cylinder loa, ...
The regression equation is
Tension drop = 65 + 11.7 Diff between backing roll and c + 0.509 cylinder load + 1.16 backing roll load - 1.82 hydrulic + 120 pentration - 24.7 gap - 0.141 speed 0.015 gsm + 3.2 base smoothness - 0.228 cobb + 5.39 sk

Predictor
Constant
Diff between backing roll and c
Cylinder load

Backing roll load

Hydrulic

Pentration

Coef
65.0
11.695

SE
457.6
3.349

Coef
0.14
3.49

VIF

0.887
0.001

1.0

0.5092

0.7071

0.72

0.473

1.2

1.156

2.229

0.52

0.605

7.0

0.554

1.1

0.000

7.7

0.553

1.5

-1.823
120.32

3.070
24.34

4.94

Gap

-24.70

Speed

-0.14050 0.08668

-1.62

0.108

15.1

Gsm

-0.0153 0.2449

-0.06

0.950

17.9

0.17

0.864

1.8

Base smoothness

3.22

41.50

-0.59

18.76

0.60

Cobb

-0.22820 0.09428

-2.42

0.017

4.3

Sk

5.387

0.75

0.452

3.9

7.136

S = 43.2262 R-Sq = 76.3% R-Sq(adj) = 73.8%

The vif greater than 5 in 4 cases i.e., multicolinertiy exist.

VIF -

We are considering pentration and speed as a reference.

Regression analysis

Stepwise Regression: Tension drop versus cylinder load, hydrulic, ...

Alpha-to-Enter: 0.15 Alpha-to-Remove: 0.15

Response is Tension drop on 9 predictors, with N = 117

Step

Constant

-392.6

pentration

T-Value

P-Value

0.000

Diff between backing roll and c

10.1

11.3

11.6

T-Value

2.93

3.34

3.56

P-Value

0.004 0.001 0.001

speed

-0.078 -0.147

T-Value

-2.85 -4.33

P-Value

cobb

-0.198

T-Value

-3.21

P-Value

0.002

47.0

R-Sq

-378.3

-252.0

-166.5

153.8

151.5

134.7

132.9

16.10

16.32

12.49

12.81

0.000

0.000

0.000

45.5

44.2

42.5

69.26

71.41

73.33

75.57

R-Sq(adj)

68.99

70.91

72.62

74.70

Mallows C-p

24.9

17.3

10.7

2.6

0.005 0.000

P value of less than 0.05 so all significant.

Regression analysisRegression Analysis: Tension drop versus pentration, Diff between, ...
The regression equation is

Tension drop = - 166 + 133 pentration + 11.6 Diff between backing roll and c - 0.147 speed - 0.198 cobb
Predictor

Coef SE Coef

Constant

-166.49

59.89 -2.78

0.006

pentration

132.89

10.38 12.81

0.000

Diff between backing roll and c

11.608

Speed

cobb

3.256 3.56

0.001

-0.14667 0.03389 -4.33

0.000

-0.19797 0.06177 -3.21

0.002

S = 42.4597 R-Sq = 75.6% R-Sq(adj) = 74.7%

Analysis of Variance

Source

DF

SS

Regression

4 624602 156150 86.61 0.000

Residual Error

112 201916

Total

116 826518

MS

1803

AS P- VALUE 0F ALL FOUR LESS THAN 0.05 SO ALL ARE SIGNIFICANT

TO TENSION VARIATION.
As cobb value can not be reduce because of cost factor ,And speed of the machine can not

increase because of machine design problem .

Tension drop before six sigma project-

Data shows normal.

DATA ANALYSIS AND VARIFICATION PLAN-

DURING BRAINSTROMING WE DECIDED TO CHECK

DRYER CYLINDER CONDENSATE REMOVAL SYSTEM ,
AFTER CHECKING WE FOUND THAT CONDENSATE
REMOVAL SYSTEM HAVE PROBLEM AND SERVICING
REQUIRED.

SPEED DIFF ATTENDED BY ELECT DEPT WHEN

REQUIRED.

PENTRATION on higher side this will crate tension drop

problem in coater head so we decide to maintane it near to
3 to 3.5 value.

NOW WE DECIDED TO MONITER THIS PROBLEM IN ALL

COATER SECTIONS.

Action plan-

Problem

REASON

ACTION TAKEN

Responsible dept

1. SPEED
DIFFERENCE.

AOS PROBLEM

CHANGE THE
SCALING.

Electrical.

2. LOAD
DIFFANCE.

SYPHEN
PROBLEM.

SYPHEN TO BE
MAKE ALRIGHT
DURING SHUT.

Mechanical.

STEAM
PRESSURE
PROBLEM.

CHECK STEAM
PRESSURE.

Power plant.

HIGH LOAD ON
BACKING ROLL.

1.

3.PENTRATION.

2.

USE LOW
THICKNESS BLADE.
REDUCE
PENETRATION.(keep
less than 3.5 max)

OMC dept.

After six sigma project-

Difference after and before six sigma project-

Before the six sigma project STDEV of the process was 87 ,

after six sigma project 13.5 .

After the project we are not observed any nonconformity.

Web break during splicing after six sigma project-

All above data showing month wise breaks .

Are the customer satisfied.

After SIX SIGMA project trend shows reduction of WEB MOVEMENT.
TOTAL NO OF BREAK SAVED- 4NOS PER MONTH.
TOTAL SAVING PER BREAKS 20000INR PER BREAKS.

AFTER SIX SIGMA PROJECT 80000INR PER MONTH.

YEARLY SAVING- 960000INR PEY YEAR.

Thanks