improving the capability of cornetto production line · unilever indonesia uses a production...

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Department of Industrial Systems Engineering and Management--IE3100R Systems Design Project Cornetto Perfect Execution Improving the Capability of Cornetto Production Line Team Members: Liao Dianze, Nathan Timothy Handoko, Wang Yalan, Yan Xu, Yu Chunhan Supervisors: A/P Tan Kay Chuan, Dr. Chen Nan | Unilever Supervisors: Mr. Carlo Fappiano, Mr. Stefanus Leonardus Define Background Information Unilever is a Fast Moving Consumer Goods (FMCG) company. Its core business is classified into four sectors: Food, Refreshments, Home Care and Personal Care. This project focuses on Unilever’s Ice Cream business under the Refreshments sector. Problem Definition Unilever Indonesia uses a production machine with eight lanes running in parallel for Cornetto production. This project investigates two types of product concepts : product A – without inclusion inside ice cream mix and product B – with inclusion inside ice cream mix. Both production process encompasses multiple stages, in which the cream dosing stage contributes to the majority of fluctuation. There exists severe fluctuation in cream dosing mass across eight lanes, and the fluctuation has greatly reduced process capability in meeting the user specification limits. Objective To improve process capability through reducing the fluctuation of dosing mass across lanes while keeping dosing mass within product specifications. 3. Under same setting, mean dosing mass is inconsistent across lanes. 2.Fraction non-conforming is high (53%). Cp is low (0.21) Different Pipe Configuration Different Pressure Drops across Four Lanes Different Pressure at Four Pipes Dosing Mass Fluctuation Old Manifold New Manifold Control Plan Proposed solutions Mechanical Approach: To Tackle Pipe Pressure Discrepancy Change new manifold with equal pipe length and curvature • Install dynamic distributor Change the Filler from time based to volumetric based Statistical Approach: To Configure Best Parameter Settings on Current Machine • Use Design of Experiments to identify significant factors causing fluctuation • Use Response Surface Methodology to investigate relationship between dosing mass and factors • Optimize machine settings that minimize fluctuation Process Monitoring Validation of Machine Performance Consistency over Time Check if pressure change at the filler corresponds to valve opening duration: High-precision measuring instruments including: • Stroboscope • High-speed camera • Strain gauge can be used to capture pressure variation with respect to valve changes during dosing process. Purpose: • To diagnose any faulty machine part when the dosing mass is out-of-control. • To check the competency of the machine, i.e. machine input parameters are accurately translated to machine output during production. When incompetent machine performance is observed: maintainance/upgrade of machine should be performed rather than using Response Surface Methodology to calibrate the incompetent machine Documentation of Experimental Approach Proper documentation enables this approach to be used to find satisfactory settings for other products fabricated by the machine and to verify whether the machine performance is consistent over time. Future projects 1. Central Composite Design A full Central Composite Design can be used to accurately identify the relationship between dosing mass and all machine parameters. Cons: • Very resource intensive and time consuming • Should be conducted when the production schedule is not hectic. 2. Robust Parameter Design To locate the best set of parameters where the effect of noise factors (such as ambient temperature and humidity, etc) is least significant. Measure Analyze Control Improve Factors Contributing to Fluctuation Root Cause Analysis Data Collection 180 consecutive samples, taken in three batches of 60 samples, are collected in each of the eight lanes to investigate dosing mass fluctuation under base case machine settings. Preliminary Findings 1. Process is in control most of the time, but is obviously not capable to meet the specification limits. Proposed Mechanical Approach was chosen. Use new manifold with dynamic distributor and volumetric filler to replace the old one. Calibration of New Manifold Comparison between New and Old Manifold for Product A Financial Implication Steps: 1. Establish relationship between Total Dosing Mass and Flow Rate. 2. Use Hill Climber Heuristics to fine tune valve open duration. Three replications of 30 samples each are used to validate dosing mass is consistent under new settings. New manifold design reduced Fraction Non-conforming for product A from 60.1% to 41.2%, this translates to savings of 109K SGD annually. The following plan should be executed to verify machine performance over time: Input Parameters Root Cause Output Comparison between New and Old Filler for Product B New filler increased dosing process capability (Cp) from 0.40 to 0.66.

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Department of Industrial Systems Engineering and Management--IE3100R Systems Design Project

Cornetto Perfect ExecutionImproving the Capability of Cornetto Production Line

Team Members: Liao Dianze, Nathan Timothy Handoko, Wang Yalan, Yan Xu, Yu Chunhan Supervisors: A/P Tan Kay Chuan, Dr. Chen Nan | Unilever Supervisors: Mr. Carlo Fappiano, Mr. Stefanus Leonardus

DefineBackground Information Unilever is a Fast Moving Consumer Goods (FMCG) company. Its core business is classified into four sectors: Food, Refreshments, Home Care and Personal Care. This project focuses on Unilever’s Ice Cream business under the Refreshments sector.

Problem DefinitionUnilever Indonesia uses a production machine with eight lanes running in parallel for Cornetto production. This project investigates two types of product concepts : product A – without inclusion inside ice cream mix and product B – with inclusion inside ice cream mix. Both production process encompasses multiple stages, in which the cream dosing stage contributes to the majority of fluctuation. There exists severe fluctuation in cream dosing mass across eight lanes, and the fluctuation has greatly reduced process capability in meeting the user specification limits.

ObjectiveTo improve process capability through reducing the fluctuation of dosing mass across lanes while keeping dosing mass within product specifications.

3. Under same setting, mean dosing mass is inconsistent across lanes.

2.Fraction non-conforming is high (53%). Cp is low (0.21)

Different Pipe Configuration

Different Pressure Drops across Four Lanes

Different Pressure at Four Pipes

Dosing Mass Fluctuation

Old Manifold New Manifold

Control Plan

Proposed solutionsMechanical Approach: To Tackle Pipe Pressure Discrepancy • Change new manifold with equal pipe length and curvature• Install dynamic distributor• Change the Filler from time based to volumetric based

Statistical Approach: To Configure Best Parameter Settings on Current Machine• Use Design of Experiments to identify significant factors causing fluctuation • Use Response Surface Methodology to investigate relationship between dosing mass and factors• Optimize machine settings that minimize fluctuation

Process Monitoring Validation of Machine Performance Consistency over TimeCheck if pressure change at the filler corresponds to valve opening duration: High-precision measuring instruments including:• Stroboscope• High-speed camera • Strain gauge can be used to capture pressure variation with respect to valve changes during dosing process.

Purpose:• To diagnose any faulty machine part when the dosing mass is out-of-control. • To check the competency of the machine, i.e. machine input parameters are accurately translated to machine output during production.

When incompetent machine performance is observed: maintainance/upgrade of machine should be performed rather than using Response Surface Methodology to calibrate the incompetent machine

Documentation of Experimental ApproachProper documentation enables this approach to be used to find satisfactory settings for other products fabricated by the machine and to verify whether the machine performance is consistent over time.

Future projects1. Central Composite Design A full Central Composite Design can be used to accurately identify the relationship between dosing mass and all machine parameters. Cons: • Very resource intensive and time consuming• Should be conducted when the production schedule is not hectic.

2. Robust Parameter DesignTo locate the best set of parameters where the effect of noise factors (such as ambient temperature and humidity, etc) is least significant.

Measure

Analyze

Control

ImproveFactors Contributing to Fluctuation

Root Cause Analysis

Data Collection 180 consecutive samples, taken in three batches of 60 samples, are collected in each of the eight lanes to investigate dosing mass fluctuation under base case machine settings.

Preliminary Findings

1. Process is in control most of the time, but is obviously not capable to meet the specification limits.

Proposed Mechanical Approach was chosen. Use new manifold with dynamic distributor and volumetric filler to replace the old one.

Calibration of New Manifold

Comparison between New and Old Manifold for Product A

Financial Implication

Steps:

1. Establish relationship between Total Dosing Mass and Flow Rate.

2. Use Hill Climber Heuristics to fine tune valve open duration.

Three replications of 30 samples each are used to validate dosing mass is consistent under new settings.

New manifold design reduced Fraction Non-conforming for product A from 60.1% to 41.2%, this translates to savings of 109K SGD annually.

The following plan should be executed to verify machine performance over time:

InputParameters

RootCause

Output

Comparison between New and Old Filler for Product BNew filler increased dosing process capability (Cp) from 0.40 to 0.66.