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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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