project proposal - optimizing litho printing process

7/28/2019 Project Proposal - Optimizing Litho Printing Process

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DOME Page 2 of4 ME4042/09/01

PROJECT TITLE

Optimizing litho printing sample making process Avery Dennison Lanka

BACKGROUND

Avery Dennison Lanka (Pvt) Ltd is a company, which is situated in Biyagama free trade zone. Avery

Dennison is a multinational company which is spread among 60 countries over the world. The company

ranked number 362 on the 2010 fortune 500 list of the largest U.S. industrial and service companies. The

CEO is Dean A. Scarborough. There are around 600 employees working in the company.

Avery Dennison develops, manufactures and sells products through four groups of businesses as Pressure-

sensitive Materials, Retail Information Services, Office and Consumer Products and other specialty

converting businesses.

This Company's products include pressure-sensitive labelling materials, graphics imaging media, retail

apparel ticketing and branding systems, RFID inlays and tags, office products, specialty tapes, and a variety

of specialized labels for automotive, industrial and durable goods applications.

In Sri Lanka, products are narrowed to labels and tags which give information about a specific garment

good. So the customer of this company is garment manufacturers.

OBJECTIVE(S)

For the production and operational management project, we mainly focus on the sample production

process in the company.

x To manage the both sample production and the mass production effectively within the limitedfacilities.

x To enhance the quality and the accuracy of the sample.x To minimize the lead time of sample making process.

SCOPE

x Among 5 different label production lines we selected lithography production method and we aremainly focusing on the sample making process of litho printing section.

METHODOLOGY

x Study the existing sample making process and identify weak points which increase the lead time ofsample making process.

x Analyse all the operations and technology involved in making samples in litho printing section.x Collecting required data on sample making process,

o How the front end handle with customerso How the design centre works on a designo How the current sample making process perform (flow process)o Number of main processes and sub processeso Number of workers and machineso Allocated spaceo Identifying the skills and experience of labourerso How they assess the quality of a sample

x Perform a time study to identify the time deployment for each process.x Research into more efficient options for sample making process which minimize the lead time and

enhance the quality.


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COST BENEFIT ANALYSIS

Data

Finished samples per month = 40

Number of pieces per sample = 6000

Sample avg. Cost per 1000 pcs = 12$ ( 12 115 Rupees)

= Rs. 1380.00Sample rejection rate = 30%

Lead time for a single sampling job = 12 days

For the current sampling process

Samples rejected per month = 40 0.3

= 12 samples

Total losses due to rejection = Rs. 12 6000

for a month = Rs. 99360.00

Lead time for a single sampling job = 12 days

Number of samples finished per =

Month without parallel operations = 2.5 samples

Number of parallel operations =

= 16 parallel operations

Number of successful samples = 40 0.7

= 28 samples

For the expected sampling process

According to our objectives we are hoping to improve quality control of the process and reduce the

rejection rate up to 20%. Then reduce the lead time up to 9 days.

Expected sample rejection in the current process = 40 0.2

due to improved quality control = 8 samples

Total losses due to rejection = Rs. 8 6000

for a month = Rs. 66240.00

Approximate reduction of losses = Rs. 33120.00

After reducing the lead time number of samples =

Finished per month without parallel operations = 3.33 samples


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Total number of finished samples per month = 16 3.33

with 16 parallel operations 53 samples

Number of successful samples = 53 0.8

42 samples

Improved rate of successful samples =

%

= 50 %

We are hoping to reduce the loss due to sample rejection approximately by Rs. 33120.00 .With improving

the sample processing rate by 50%, it increases the average number of orders the company gets from the

customer per month. So this increases the profit and the efficiency of the company.

OUTCOMES

x Identify the slowest sub operation in sample making process of litho printing section.x Suggest a plan to handle both mass production and sample production based on the time

requirement and reduce the amount of storage.

x Reduce the production cost for a sample unit by cutting down the lead time.x Achieve customer satisfaction and minimize the losses due to sample rejection by the customer.x Project report with set of solutions

SCHEDULE

Schedule is attached to end of the report.

CONTACT DETAILS OF THE ORGANISATION

Tenith KanishkaAvery Dennison Lanka (Pvt) Ltd

Block B, Export Processing Zone,

Biyagama,

Sri Lanka.

Tel: 0773795421

Fax: 0094 11 2465011

CONTACT DETAILS OF TEAM MEMBERS

NAME NIC MOBILE E-MAIL

D.W.N.M.Amarawardhana 890945015V 0712784284 [email protected]

K.D.Bandara 891750307V 0718068255 [email protected]

N.P.A. Gunasekera 893053883V 0776153375 [email protected]

V.H.Hapuarachchi 892540047V 0773510021 [email protected]

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project proposal - optimizing litho printing process

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