Professional Documents
Culture Documents
Project Identification
For purpose of project identification Brain
Storming session is conducted.
Focus of Management is to improve
availability of line, so production quantity
at Colour Coating Line can increase.
Project Identification-Y
Producti
on Delay
CTQ
Data
Type
UOM
Operational
Definition
Primary
Colour
Change Time
Continuou
s
Min/Change
Secondar
y
Number of
Accidents
Attribute
Number
Secondar
y
Quality
Diversion
Continuou
s
%age
Secondar
y
Manpower
Attribute
Number
Manpower used in
colour change activity
Business Case
Delays due to Colour Change is primarily
the time lost between two camping of
orders.
Reducing Colour Change time per colour
change would significantly improve the
availability of line.
Hence , this extra available time would
help to achieve production targets of
Organization, due to this extra production,
organization can have more orders from
customers which will give benefits.
Problem Statement
In the Last 6 Months sum of Colour
Change Delay has been contributing on
13267 Min in Production Delay at Colour
Coating Line i.e. 29.74 Min per Colour
Change.
Reducing the colour change
time(Min/Change) will significantly
increase available time for production,
Hence this will give benefit to
organization.
Objective Statement
Reducing Colour Change Time(Min/Change)
at Colour Coating Line-1 from 29.74
Min/Change to 25 Min/Change
Goal Settings
Metrics
CTQ
Data Type
UOM
Target
Primary
Continuous
Min/Chan
ge
25
Secondar
y
Number of
Accidents
Attribute
Number
Secondar
y
Quality Diversion
%age
<=1.10%
Secondar
y
Manpower
Number
Continuous
Attribute
Financial Benefits
Saving Calculation
A
B
C
D
E
Benchmark
Actual KPI/Month
Number of Colour Change/Month
Contribution (Rs./MT)
Utilization
Productivity(TPH)
Savings(X)D
Team Members
Project Title
Name
Mentor
Team Leader
Member-1
Member-1
Member-1
Member-1
Member-1
Member-1
Department
Production Head
SIPOC
Supplier
Input
Company
Employee
Paint
Store
Paint
CCL Store
Cleaning
Material
IP Coil
Unloadin
g at CCL
Bay
Coil
Loading
in line
Coating
Stop
Process
Output
Customer
Colour
Change
Coater
ready for
coating
Colour
Coating Line
Coater
Colour
Change
Inspectio
n
Coating
Start
Finish
Product
Send to
Next
Stage
MEASURE PHASE
Data Collection
All delay data including Colour Change
data has been recording in Manufacturing
Execution System(MES).
Hence, no requirement of data collection
plan because past data in available.
Data
Recording in
MES
Goal Settings
Descriptive Statistics: Delay(min.)
Variable
Delay(min.)
Total
Count
446
Mean
SE Mean
StDev
29.747
0.537 11.333
Q1
Median
25.000 30.000
Benchma
rk
Target
Title
UOM
Benchmark
Target
Colour Change
time
Min/Change
29.74
25
ANALYSE PHASE
Hypothesis Test
Hypothesis
Normality Check
P-Value
>0.05
Shift
A
B
C
N<
71
65
72
N>=
75
88
75
DF = 2
Median
30.00
30.00
30.00
Q3-Q1
10.00
15.00
15.00
P = 0.445
P-Value
>0.05
Delay(min.)
100
80
60
40
20
0
A
B
Shift
N<
40
30
48
19
68
N>=
49
43
62
22
59
Median
30.00
30.00
30.00
30.00
25.00
Q3-Q1
10.00
10.00
15.00
15.00
15.00
P-Value
>0.05
Delay(min.)
100
80
60
40
20
0
#NA ASHOK
BIBEK
PADHI
Operator
PRADEEP
RD SINGH
07:12
14:24
21:36
28:48
36:00
Activity
Head Disengage
Back up roll cleaning
Remove running hose pipe ,Cleaning of hose pipe & Stirrer cleaning.
Thinner supply is given on applicator rolls
Tray down
Maintain gap between applicator rolls
Put Applicator roll cleaning mode
Applicator rolls -cleaning
Tray cleaning
Doctor blade tray Removing,leaning and Refitting
Return Line Tray Removing, Cleaning and Refitting
Paint drum removal from coating
New paint drum put in
New Paint drum open and tray up
New paint stirring
Viscosity is checked
filter cloth fitting at hose pipe
Tie hose pipe to rolls
Settings to be checked for applicator rolls (WFT check)
Gap setting for applicator rolls
1st Sample coat
31.1
0
IMPROVE PHASE
Online/Offline
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Online
Activity
Head Disengage
Tray down
Tray cleaning
10
11
12
13
14
15
16
Viscosity is checked
17
18
20
X
No Change
Settings to be checked for applicator rolls (WFT check)
O
Change
Gap setting for applicator rolls
21
19
Status
X
X
O
X
X
X
X
X
X
O
O
X
X
X
X
O
O
X
X
X
X
Improvement 1
Hose Pipe & Pump and Stirrer Cleaning activity
Hose pipe & Pump
Before
After
Improvement 2
Hose Pipe & Pump and Stirrer Cleaning activity
Stirrer Unit
Before
After
Improvement 3
Doctor Blade Tray Removing , Cleaning & Refitting:Single
tray in
use
tray in
use &
Spare tray
Before
After
Previously Doctor Blade Removing , Cleaning & Refitting activity was done out of
which cleaning the doctor blade was taking more time.
So one extra spare of doctor blade used in colour change ,This spare doctor blade is
replaced by old one with out time loss for cleaning activity of doctor blade.
Old Doctor blade is cleaned after colour change over and kept ready in spare.
Improvement 4
Return Line Tray Removing , Cleaning & Refitting:tray in
use &
Spare tray
Single
tray in
use
Before
After
Previously Return line Tray Removing , Cleaning & Refitting activity was done out of
which cleaning the doctor blade was taking more time.
So one extra spare of Return line Tray is used in colour change ,This spare tray is
replaced by old one with out time loss for cleaning activity of Return line Tray.
Old Return Line Tray is cleaned after colour change over and kept ready in spare.
Improvement 5
Filter cloth fitting at hose pipe
Hose
pipe
with
filter
cloth in
use
After
07:12
14:24
21:36
28:48
23.0
2
Before Improvement
After Improvement
31.1
0
CONTROL PHASE
Control Plan
After all implementation of improvements to
achieve results team has taken some
initiatives to maintain this results
Team has provided training to Operators
Team has created awareness to Operators
about each colour change over time
Team has prepared internal SOP for colour
change over.
Financial Benefits
All the improvement results are converted in
money terms to see the benefits to
organization from this project. Below table
shows both tangible & intangible benefits
Sr.
No
1
2
3
Particular
Colour Change Time
Savings
Power Consumption
Savings
Fuel Consumption
Savings
Total Savings
Saving
Total
Rupees
Monthly 272304.5
Monthly
10511.1
Monthly 46367.6
Monthly 329183.1
Achievements
Metri
cs
CTQ
Data Type
UOM
Befo
re
After
Target
Primary
Continuous
Min/Change
29.74
21.62
25
Secondar
y
Number of
Accidents
Attribute
Number
Secondar
y
Quality Diversion
Continuous
%age
1.66
0.92
<=1.10%
Secondar
y
Manpower
Attribute
Number
Thank You