KT PSDM Process Application

LEONY Y. SINGSON JUNE ,2010

KT PSDM Process Application

ISO 14001:2004CI/3414I/03/12/361

CIP/3414I/03/12/361

ISO 9001:2000

KT PSDM Process Application

Universal Robina Corporation

Packaging Division - BOPP Films

KT PSDM Process Application

COMPANY PROFILECOMPANY PROFILEPackaging Division

UNIVERSAL ROBINA CORPORATION – PACKAGING DIVISIONIS AN ISO 9001:2008 & 14001:2004 CERTIFIED PLANT CAPABLE OF PRODUCING MORE THAN 30,000 MT OF

BI-AXIALLY ORIENTED POLYPROPYLENE (BOPP) FILMS PER YEAR.

• APPLICATIONS

- PLAIN FILM for Printing, Lamination & flower packaging

- TAPE FILM for Pressure sensitive adhesive tape application

- HEATSEALABLE FILM for printing, lamination and over wrap

- CIGARETTE FILM for Tobacco Industries

- WHITE FILM for soap, chocolate wrapping & labels

- MATT FILM FOR Printing & lamination for brochures & poster.

- METALLIZABLE FILM for Vacuum Metallizing

KT PSDM Process Application

Packaging Division

OVERVIEW OF THE PROCESSOVERVIEW OF THE PROCESS

Two Station TurretMain line

Ageing Rack Main Slitter

KT PSDM Process Application

PROBLEM STATEMENTPROBLEM STATEMENT

On time and in full (OTIF) delivery commitment On time and in full (OTIF) delivery commitment

below the target below the target

INSTRUCTIONS

KT PSDM Process Application

Date Schedule of Item

Actual Delivery

On Time % OTIF %Oct-09 227 221 97.36% 191 84.10%Nov-09 395 394 99.75% 217 54.90%Dec-09 374 374 100.00% 273 73.00%Jan-10 289 287 99.31% 181 62.63%Feb-10 460 458 99.57% 328 71.30%Mar-10 331 301 90.94% 231 69.79%Apr-10 305 305 100.00% 245 80.33%May-10 327 323 98.78% 262 80.12%Average 338.50 332.88 98.21 241 72.02

DELIVERY COMMITMENT MONITORING OCT2009 – MAY2010

KT PSDM Process Application

BACKGROUND OF THE PROBLEMBACKGROUND OF THE PROBLEM (What is the current scenario and assumptions regarding the problem? What was the situation or concern that had developed prior to the application of KT process? How were you dealing with this issue prior to the application of KT process?)

•Perceived unreliable supplier

•Projected opportunity loss per month = Php5.18M

CHALLENGE

KT PSDM Process Application

APPLICATION OF KT PROCESSAPPLICATION OF KT PROCESS (How was the challenge addressed? What KT processes and supporting methodologies were used? How were they implemented by KT and by you? How has KT made a difference or changed the way issues are resolved?)

After the problem analysis, we established a method that keep analysis visible to everybody. Then we identify Possible

Causes using DA.

RESPONSE TO THE CHALLENGE

KT PSDM Process Application

Line Component

Reason for downtime

No. of Occurrences

No. of Hours lost Remarks

Jan Feb Mar Apr Jan Feb Mar Apr

Edge trim grinder

Grinder overloadEdge trim grinder motor drive fuses blows

0 9 10 21 0 30.

546.7

63.8

Fixed on April 18 – no recurrence since

Pre-dosing system

System faultSystem shows negative weight then stops fill/refill cycle and eventually shuts down the line

0 0 2 11 0 0 7 16

Still a recurring problem – we have asked for Bruckner's help to improve cooling in the area and improving cooling of electronics

Main dosing system

Valve MalfunctionMain dosing slide valve goes out of position due to mechanical blockage in the slide guides mainly due to PP powder accumulation

10 0 1 2 45.2

0 7.4 9.2

Fixed in January by reshaping slide valve

Chiller #3

Chiller #3 was not workingThis cause high temperature of Chill roll and water bath

3 0 0 0 10 0 0 0

Fixed in February after rehabilitation work of chiller #3

Chill rolling walker displacing motor

Motor based detachedThis caused wrong position of water bath vs Chill roll

4 0 0 0 18.8

0 0 0 Fixed

MAJOR / CHRONIC DOWNTIME FOR LINE 2 FROM JANUARY TO APRIL 2010

KT PSDM Process Application

Line Component

Reason for downtime

No. of Occurrences

No. of Hours lost Remarks

Jan Feb Mar Apr Jan Feb Mar Apr

Pull rolling walker system

Loose drive belt of pull rolling walker systemBelt was already worn out

0 3 0 0 0 11 0 0Fixed, replaced belt and adjusted tension

Hot Oil burner Burner faultFound defective relay for the burner firing sequence

0 0 5 0 0 0 14.4

0Fixed

WATER REMOVAL BLOWER

Stuck up blowerUpon inspection; it was found that the blower was running above the rated speed – leading to frequent failures

0 0 1 0 0 0 8 0

FixedWe ran slow speed in March while the blower was out

COMPUTER SERVERHard disk for server defective

1 0 0 0 352

0 0 0

FixedServer and disk drive imported from Germany

KT PSDM Process Application

Risk Probability Weight

Plant Unscheduled Shutdown

10 10 100

In House Rejects above target of 5%

5 5 25

Realistic and Workable Mainline Scheduling

5 4 20

No Sales Order due to Credit Concerns

10 5 50

KT PSDM Process Application

Risk Probability Weight

Hold Delivery 10 4 40

Truck Availability

10 2 20

Conclusion:

Plant unscheduled shutdown is the main root cause of OTIF delivery commitment lower than target

KT PSDM Process Application

List of possible causes

POSSIBLE CAUSES RISK PROBABILITY WEIGHT

1. Ageing Machineries 7 6 42

2 Lack of dedicated personnel to handle Maintenance

Planning5 5 25

3. No established Preventive Program 8 8 64

KT PSDM Process Application

ACTION PLANS

Corrective ActionsRESPONSIBLE

PERSONTIME FRAME

1. Complete audit of Machines performance

RPM July 2010

2. Rehabilitation of machines RPM 6

months to 1 year

3. Assign a dedicated maintenance planner

HPCJune 2010

4. Implementation of comprehensive preventive maintenance program

Planning Engineer

ongoing

KT PSDM Process Application

Potential Problem Analysis

Potential Problem Contingent Action Triggers

1. Incomplete Audit of Machines Performance

Hire competent Consultant

No accomplishment

2. No available Spare Parts

Consult for Parts modification

Failure to comply

KT PSDM Process Application

FINAL RESULTS (What solution was chosen? What results were achieved? What were some key learnings from the experience?)

Audit and evaluate machine condition, continuously implement comprehensive maintenance program that

will eventually lead to minimum unscheduled downtime and optimize plant operations.

Action plans that make good score and produced results were generated and implemented within define

time frame.

RESULTS

KT PSDM Process Application

THANK YOU