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PRODUCT WASTAGE ANALYSIS AND
MANAGEMENT
PROJECT REPORT
SAHAN NIPUNA
IN-PLANT TRAINEE (PRODUCTION) – PERSONAL CARE PLANT
HEMAS MANUFACTURING (PVT) LTD, DANKOTUWA, SRI LANKA
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PROJECT SCOPE AND OBJECTIVES
SCOPE:
In order to recap on what the material usage variance is, what the material yield variance is and to analyze the difference
between how many actual materials we used for and how much we expected to use.
OBJECTIVES:
1. Identify material usage variances
Identify Overfilling/Under filling of each product
o Toothpaste / Mouthwash
o Cream / Lotion
o Shampoo / Hand wash
o Gel
o Oil
o Cologne
Cleaning wastes
Change over wastes
Other wastes
2. Identify material yield variances
The actual level of outputs vs. for given set of inputs
3. Process Mapping
For all process in mixing and packing
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INTRODUCTION
Personal Care Plant
In the Personal Care Plant six different types of products are manufactured. Mixing section is the first floor and after the
bulk is being manufactured there, it is pumped to the packing section which is the ground floor. There are six separate
mixing areas and six separate production lines. The main production categories are,
Colognes
Oil
Shampoo/Hand Wash
Hair Gel
Cream/Lotion
Toothpaste
There are several stock keeping units (SKUs) of those product categories which are given below.
1. Colognes
Type Size
Cologne
Baby Cheramy
Regular Cologne 50ml 100ml 200ml
Herbal 50ml 100ml 200ml
Floral 50ml 100ml
Bedtime Calming 50ml 100ml
BabyCheramy
Fun time
Lucky Ducky 50ml 100ml
Kitty Katty 50ml 100ml
Cuddly Bunny 50ml 100ml
Angel Fairy 50ml 100ml
Bien Aime Bien Aime 50ml 100ml 200ml
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Gold
Black Jeans 50ml 100ml
Classic 50ml 100ml
Commando 100ml
Cool Splash 100ml
Hot Splash 100ml
Pro Sport
Extreme After Shave 90ml
Deep After Shave 90ml
Deep Cologne 100ml
Extreme Firm 100ml
Heat Seeker 100ml
Fresh Current 100ml
Chill Factor 100ml
Goya
Black Rose Cologne 35ml
Gardenia 35ml
Jasmine 35ml
Love Affair Body Spray 75ml
Secret Crush Body Spray 75ml
Mischief Maker Body Spray 75ml
Summer Kiss Body Spray 75ml
Paris
Floral 50ml
Jasmine 50ml
Capri
Capri Cologne 50ml
Shimmer Cologne 50ml
2. Oil
Oil Baby Cheramy
Regular 50ml 100ml 250ml
Herbal 50ml 100ml
Kumarika
Herbal 50ml 100ml 200ml 415ml
King Coconut & Rice
Split End Control 50ml 100ml 200ml
Anti-Dandruff 50ml 100ml 200ml
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3. Shampoo/Hand Wash
Shampoo Baby
Cheramy
Shampoo 100ml 200ml
Bedtime Head to Toe Wash 100ml 200ml
Dandex
Plus Shampoo 100ml 200ml
Family Shampoo 100ml 200ml
Plus Sachet 5.5ml
Family Sachet 5.5ml
Kumarika
100ml 200ml
100ml 200ml
100ml 200ml
100ml 200ml
100ml 200ml
Sachet 6.5ml
Velvet Hand Wash 250ml
Cheramy
Touch
Face Wash 100ml
Body Wash 250ml
4. Hair Gel
Gel Gold
Gold Gel 100ml
Gold Gel Sachet 4g
Pro Sport
Firm Hold Gel 120ml
Extreme Firm Hold Gel 120ml
Wet Shine Gel 120ml
Pro Sport Gel Sachet 4g
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5. Cream & Lotion
Cream
&
Lotion Baby
Cheramy
Regular Cream 50ml 100ml 200ml 400ml
Herbal Cream 50ml 100ml 200ml
Nappy Rash Cream 100ml
Regular Lotion 50ml 100ml
Bedtime Calming Lotion 50ml 100ml
Cheramy
Touch
Body Lotion-Lightening 100ml 200ml
Body Lotion-Hydrating 100ml 200ml
Face Cream 30g
Goya Body Lotion 100ml
Gold Hair Cream 100ml
Pro Sport Hair Cream 100ml
6. Toothpaste
Toothpaste
Clogard
Regular 40g 70g 120g 160g 200g
Fresh Mint 40g 70g
Non Fluoride 40g 70g 120g 160g 200g
Sachet 14g
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OVERFILLING / UNDER FILLING OF PRODUCTS
1) Overfilling/Under filling of Colognes
To determine the overfilling of cologne products individually, the following procedure was used.
Procedure:
First any cologne product was taken and its SKU’s were identified.
As most cologne products use glass bottles, a separate procedure was undertaken because of the variations in
the bottles.
Random samples of empty bottles of relevant cologne product were taken from several batches where the
production was online.
Sample size was 50 or 100.
They were numbered and weighed with the relevant insert or spray pump and noted.
Then they are filled with the cologne from the ongoing production line.
They are weighed again and the filling weight of each sample bottle was calculated.
The above procedure was repeated for several batches of the same product.
From those data ‘average filling weight per a bottle’ was calculated.
From that value overfilling/ under filling was calculated comparing with the lower value given in the relevant In-
Process sheet.
Reasons and solutions for overfilling / under filling issue were suggested.
Formula:
Overfilling/Under filling% = (Average Filling Weight per a Bottle/Tub – Lower Value of In-Process Sheet) *100
Lower Value of In-Process Sheet
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Type
Volume
Overfilling/
Under filling Amount
Per a Bottle (ml)
Overfilling/
Under filling %
Gold
Black Jeans 50ml -0.1 -0.2
100ml 0.3 0.3
Classic 50ml -0.1 -0.2
100ml 0.3 0.3
Commando 100ml 0.3 0.3
Cool Splash 100ml 1.3 1.3
Hot Splash 100ml 1.3 1.3
Bien Aime
50ml 0.6 1.1
100ml -1.8 -1.8
200ml -6.4 -3.2
Pro Sport
A/S Extreme 90ml -2.2 -2.5
A/S Deep 90ml -2.2 -2.5
Deep 100ml 2.0 2.0
Goya
Black Rose 35ml 0.5 1.3
Jasmine 35ml 0.5 1.3
Gardenia 35ml 0.5 1.3
Capri Cologne 50ml 1.4 2.8
Shimmer 50ml 1.4 2.8
Paris Jasmine 50ml 0.7 1.4
Floral 50ml 0.7 1.4
Baby
Cheramy
Regular/Herbal
50ml 1.2 2.4
100ml -0.8 -0.8
200ml -5.5 -2.7
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Type
Volume
Overfilling/
Under filling Amount
Per a Bottle (g)
Overfilling/
under filling %
Baby
Cheramy
Floral 50ml 2.0 4.4
100ml 0.8 0.9
Bedtime
Calming
50ml 2.0 4.4
100ml 0.8 0.9
Kitty Katty
50ml
1.1
2.4 Cuddly Bunny
Lucky Ducky
Angel Fairy
Kitty Katty
100ml
-0.9
-1.0 Cuddly Bunny
Lucky Ducky
Angel Fairy
Reasons for overfilling/under filling:
Colognes are filled by a level sensing vacuum filler and if there is a variation in the bottle volume, it will be filled
with a different volume of cologne other than the standard volume, as the level is same in both incidents. This
may lead to overfilling or under filling of cologne.
Some bottles have deeper bottoms and some have shallow bottoms. Hence the filling volume will be different as
the filling level is the same.
In Funtime cologne line the colognes are filled manually. Then the filling is not accurate. Filling will vary due to
the filling person’s accuracy and experience.
Also Funtime cologne empty bottles have more volume than its standard value due to manufacturing errors (mold
issues) as they are made of plastic material.
For some cologne products there is no exact level to fill.
Solutions:
Use volume wise filler or a weight wise filler other than level filler. Then the exact amount of volume can be filled
to each bottle.
Correct or reduce the variations in glass bottles.
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For Funtime cologne production line, it’s better to semi-automate the line by installing an automatic filler instead
of manual filling.
Update In-Process sheets to relevant filling volumes and give standard levels of filling for the production line.
2) Overfilling/Under filling of Shampoo
Since all the shampoo bottles are made out of plastic there will be no vast variations as glass bottles. So empty
bottles are weighed separately and an average value was calculated for empty bottles. Then the filled bottles
were weighed and noted. From these data ‘average filling weight per a shampoo bottle was calculated. The
calculation is the same as the sample calculation given in the previous category.
The relevant values are given below.
Type
Volume
Overfilling/
Under filling Per a
Bottle (g)
Overfilling/
Under filling %
Baby Cheramy Shampoo 100ml 0.6 0.6
200ml -0.2 -0.1
Dandex Plus 100ml 0.4 0.4
200ml 0.2 0.1
Dandex Family 100ml 0.4 0.4
200ml 0.3 0.1
Kumarika 100ml 0.4 0.4
200ml 0.7 0.3
BC Head to Toe Body
Wash
100ml 1.0 1.0
200ml 0.1 0.05
Velvet Liquid Hand Wash 250ml 0.1 0.04
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3) Overfilling/Under filling of Cream/Lotion
Cream and lotion bottles are also made of plastic and don’t give any significant amount of variations among bottles. So
the same procedure as shampoo was taken to determine the overfilling or under filling of cream and lotion bottles.
According to the tables given above it’s clear that the percentages of overfilling/under filling of creams, lotions
and shampoos are quite low when compared with other products. So there are no exact reasons to be checked,
but sometimes there will be some variations of the bottles. As they are filled according to the weight, the overfilling
or under filling amount depends on the worker who checks and adjusts the filling weight.
Furthermore there are some mechanical issues with the filling machine, so it’s better to replace the machine to
improve the efficiency.
Type
Volume
Overfilling/
Under filling
Amount Per a Bottle (g)
Overfilling/
Under filling %
Baby Cheramy Cream 50ml -0.4 -0.8
100ml 0.8 0.8
200ml 1.4 0.7
400ml 1.5 0.4
Baby Cheramy Lotion 50ml 0.4 0.8
100ml 0.6 0.6
Goya Body Lotion 100ml -0.2 -0.2
Nappy Rash Cream 100ml 1.1 1.1
BC Moisturizing Lotion 50ml 0.3 0.6
100ml 1.0 1.0
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4) Overfilling/Under filling of Toothpaste
When determining the overfilling/under filling amount in toothpaste tubes, each tube was tare by an empty tube and
weighed and results are noted, because there are hardly any variations can be seen on lami tubes. From those data
‘average filling weight per tube’ was calculated.
For mouthwash bottles the same procedure that used for shampoo bottles was used to determine the overfilling/under
filling amount.
Type
Size
Overfilling/Under filling
Amount Per a Bottle (g)
Overfilling/
Under filling %
Clogard Toothpaste
40g 0.69 1.75
70g 0.60 0.86
120g 0.56 0.47
160g 0.66 0.41
200g 0.65 0.33
Clogard Mouthwash 200ml 1.53 0.74
Reasons and Solutions:
There is no significant amount of overfilling among toothpaste tubes according to the data analysis. Since weight
is adjusted manually there may be little amount of overfilling or under filling until the worker sets machine’s
settings for the relevant weight.
But in mouthwash bottles the overfilling percentage is high. It’s mostly due to the variations of volume in the
bottles. And also the diameter of the bottle’s neck is larger and bottles are filled manually. While filling manually,
even if there is a slight change in the level, the volume will be varied much larger due its large diameter of the
neck of the bottle.
H H
V1 V2
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d D
D > d , V1 < V2
Same height, but the volumes are different. Slight change in the height can cause a much large effect on the
volume (V2).
5) Overfilling/Under filling of Oils
Some bottles of oil products have certain amount of variations. So that there may have significant amount of
overfilling or under filling for each bottle. Therefore for each product, samples of empty bottles and filled bottles
were weighed separately for several batches and calculated the ‘average filling weight per a bottle’ and
determined the overfilling or under filling percentage by comparing with the lower value of the In-Process sheet.
Type
Volume
Overfilling/
Under filling Amount
Per a Bottle (g)
Overfilling/
Under filling %
Baby Cheramy Baby oil 50ml 0.9 2.17
100ml 0.4 0.48
Kumarika
Split End Control
50ml 1.3 3.12
100ml 0.1 0.12
200ml 3.3 1.97
Herbal Oil
50ml 1.4 3.36
100ml 0.5 0.60
200ml 1.7 1.02
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Reasons and Solutions:
Overfilling or under filling occurs in oil bottles mainly due to the variations in the volume of the bottles. In Kumarika
Hair Oil 200ml bottles, when the oil is filled to the required level, the volume exceeds about 2ml from the lower
value given in the In-Process sheet. It’s certain that volume of those bottles needs to be standardized again and
also the In-Process sheets have to be updated.
Since the oil lines of Kumarika 50ml and 200ml are manual, it’s impossible to maintain an exact filling level since
there will be human errors. According to the table the overfilling of 100ml bottles are low because it’s an automated
line. If a semi-automated line can be implemented for others as well, the overfilling percentage can be reduced.
A machine, filling according to the weight or volume wise can be implemented to the line and maintain a uniform
filling level.
6) Overfilling/Under filling of Hair Gel
Samples of hair gel tubs were weighed individually for each SKU and calculated the ‘average filling weight per a
tub’ and hence calculated the overfilling or under filling percentage.
Type
Volume
Overfilling/
Under filling
Amount Per a Tub (g)
Overfilling/
Under filling %
Pro
Sport
Extreme Firm Hold Gel 120ml 0.6 0.5
Firm Hold Gel 120ml 0.6 0.5
Wet Shine Gel 120ml 0.2 0.2
Gold Hair Gel 100ml 0.1 0.1
Reasons and Solutions:
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Since the gel bulk is directly coming from the mixing vessel, there may be filling weight variations time to time
during the filling process. It has to be adjusted by checking manually. During the time which takes to correct the
weight, there will be overfilling or under filling in the tubs.
7) Overfilling/Under filling of Skin Care Products
The same procedure as cream/lotions was used for determining the overfilling or under filling amount of skin care
products.
Type
Volume
Overfilling/ Under filling
Amount Per a Bottle (g)
Overfilling/ Under filling
%
Cheramy
Touch
Milk Lotion-Lightening 100ml 0.39 0.4
200ml 0.86 0.4
Milk Lotion-Hydrating 100ml 0.79 0.8
200ml 0.38 0.2
Face Wash 100ml 0.59 0.6
Bottles are filled automatically according to the weight. When the vessel in the filling machine is completely filled
then the weight will vary. Again when the vessel is going to empty, there will be weight variances. Those are the
moments that mostly overfilling or under filling will occur. Time to time the filling weight has to be checked and
the machine has to be adjusted.
Sometimes there will be variations in the container bottles or tubs. Since the weight is checked including the bottle
or tub, the reading will not be accurate if the weight of the empty bottle or tub changes from one another. Then
there will be overfilling or under filling as the machine is adjusted to the inaccurate reading to be filled thereafter.
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CLEANING AND CHANGEOVER WASTAGES
After a batch is mixed there is remaining bulk in the mixer walls and propellers. They are washed with hot water or water
first. There is an exact washing procedure for each mixing process. So the leftovers of the bulk which are washed away
by the relevant washing method are wastage. It cannot be used for production.
Method used to calculate cleaning and changeover wastages:
To determine the amount of remaining bulk at the mixer after pumping for production, a known weight of water
was added to the mixer and cleaned the mixer from it. Then the remaining bulk was washed away with water. Finally the
weight of the water was weighed again.
Cleaning or changeover wastage = Weight of (water + remaining bulk) - Weight of water
1) Toothpaste
Size of a batch = 1500 kg
Average Total Filling Weight = 1200 kg
Overall Wastage = 300kg
Wastage due to Monthly Cleaning and Changeovers:
Remaining bulk in the mixer after pumping a batch = 178 kg
Remaining bulk in pump and pipe lines = 36 kg
Remaining bulk after cleaning = 35 kg
Remaining bulk at the filter = 4.1 kg
2) Hair Cream
Size of the batch = 100 kg
Average Total Filling Weight = 96 kg
Overall wastage = 4 kg
Wastage due to cleaning of the mixer:
Remaining bulk in the mixer after pumping a batch = 1.2 kg
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Remaining bulk in buckets = 0.2 kg
3) Shampoo – Kumarika
Size of a batch = 450 kg
Average Total Filling Weight = 426 kg
Overall Wastage = 24 kg
Wastage due to Cleaning and Changeovers:
Remaining bulk in the mixer after pumping a batch = 2.8 kg
Remaining bulk in pump and pipe lines = 4.2 kg
4) Hair Gel
Size of a batch = 400 kg
Average Total Filling Weight = 388 kg
Overall Wastage = 12 kg
Wastage due to Cleaning and Changeovers:
Remaining bulk in the mixer after pumping a batch = 0.9 kg
Remaining bulk in pump and pipe lines = 7.2 kg
.
5) Lotion
Size of the batch = 400 kg
Average Total Filling Weight = 374.2 kg
Overall Wastage = 25.8 kg
Wastage due to Cleaning and Changeover:
Remaining bulk in the mixer after pumping a batch = 1.0 kg
Remaining bulk in the pump and pipe lines = 4.4 kg
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OTHER WASTAGES
There are some other wastages other than overfilling, cleaning and changeover wastages in manufacturing processes.
They were separately calculated for each manufacturing process in the Personal Care plant.
For a batch,
1) Toothpaste
Amount of CaCO3 removing from the siever = 0.6 kg
Amount of CaCO3 removing from the blower = 1.2 kg
Evaporation in the Gel Kettle (800C-650C) = 4.0 kg
Amount of bulk removing due to vacuum = 16 kg
2) Hair Cream
Evaporation in the pre-mixer (800C) = 0.05 kg
Amount of bulk removing due to vacuum = 2.90 kg
3) Hair Gel
Amount of bulk removing due to vacuum = 8.0 kg
4) Lotion
Amount of bulk removing due to vacuum = 3.4 kg
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Other possible ways of wastage in the production lines:
1) Cologne Production Line
Filling machine spillage and leakages.
During the checking of some SKUs of colognes. (When turning upside down to check whether there are
any dust particles or not)
During the pouring of cologne in rejected bottles to the vessel again.
Some amount of cologne is left with each rejected bottle.
Evaporation of cologne in every production step until the bottles are capped.
2) Funtime Cologne + Oil Manual Line
Spillage and leakage due to manual filling.
Due to mistakes done by labors.
A certain amount of oil is removed with rejected bottles.
Filling is done according to the naked eye level, which can be vary among labors according to their
experience and attitude towards the work.
3) Cream/Lotion/Shampoo Line
A certain amount of bulk removed during the process of removing trapped air in pump lines.
Filling weight variance is high during the starting period and ending period of a production.
Some amount of bulk is removed with the rejected bottles.
Spillage during the filling process.
4) Toothpaste Line
A certain amount bulk is removed with damaged tubes. (They are not used again due to microbial
issues.)
There may be some other ways of wastage in production lines, but they can be neglected since the amount of wastage
due to that particular reason is low or it may be a onetime incident.
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CONCLUSION
In a manufacturing process there are different ways of wastages. Basically in a production process, those wastages can
be divided into two types; wastages during the manufacturing process of bulk and wastages during bottling and packing
processes. In practically 0 % variance cannot be achieved in both ways. The only solution is to reduce it as far as possible.
Negligence of workers, poor manufacturing procedures, poor equipment or not enough equipment, poor raw material and
packing material and poor quality measures may lead to rise the variance for a certain high level. From this project I have
standardized the overfilling and under filling percentages for each product SKU in the Personal Care Plant. And I have
separately analyzed the other wastages including cleaning and changeover wastages during the production. I have also
given some suggestions to reduce the wastage in each production lines.