DO O D!

Theme: Capacity Creation of Ketchup Glass Bottle through utilisation of Existing Monogamy Line.

Migration

Monogamy

Glass

Selection of Theme Setting up of a make shift manual machine

Morale Very High. Safety. Throughput 60TP . !uality" Concern of Hygiene. #oreign Bo$y Contamination.

%n$er %tili&ation of 'sset. () *%P 's Bottle line +as not running. CC#)T ,rop in Glass Bottle $ue to Capacity Crunch. *o+ Morale in (e+ #actory $ue to

Capacity Creation for Glass Bottle

Data Collection
CC"OT& C'D
G O O D

CC"OT Tren# $ Loss %nalysis

Mar(et Deman# tren# analysis

Glass Bottle

'lastic Bottle

Deman# )s 'ro#uction Tren#

G O O D

G O O D

Data Analysis

Mar(et

esearch

Deman# )s Capacity "or 'lastic Bottle

G O O D

Glass Bottle Deman# )s Capacity

G O O D

Mismatch Bet*een !nstalle# capacity $ Mar(et #eman#

Options

Option + 'urchase $ !nstall complete ne* line Option , !ncrease 'ro#ucti-ity of manual line Option .
Con-ert i#le plastic /ottle line on glass /ottle line.

SWOT ANALYSIS Strengths

Capa.le / 01perience$ Manpo+er Strong +ill to accept challenges / $eli4er *ocal Ven$or Support

Weaknesses
Sta.ili&ation time can .e 4ery high. Glass .ottle Capping Pro.lem

2n3house Technical 01pertise an$ 01perience High Glass Bottle Breakage

Opportunities
Meeting Business 5e6uirement. Capacity creation of Glass Bottle. 5e$uction of Con4ersion Cost.. 2ncrease BB)00 an$ )00. Manpo+er Sa4ing. 5e$uction in Gi4e '+ay. 0nhance$ Safety Better Hygiene an$ 7iel$ Control.

Threats
Machine may fail to deliver results. Switching back to Monogamy may be difficult.

Options

Option + 'urchase $ !nstall complete ne* line Option , !ncrease 'ro#ucti-ity of manual line Option .
0afety $ 1ygiene !ssue Cost $ Time Constraint

Con-ert i#le plastic /ottle line on glass /ottle line.

Target Setting
Production (Ton/Week)

200% Conversion Cost (Rs/Ton)

Targ et
50%

%ctu al

Team: Arro

Team

S 7a$a4

, Sa.har+al

B Singh

8 Singh

G Singh

8 Singh

# Singh

G Singh

, 9umar

S Singh

Meher$een

,9 8ain

Policy Act & Review

!aster "lan
Check

Continual Improvement Do

Plan

Actual Target

Challenge s

Challenge +

To con-ert

inser Machine

Challenge ,

To con-ert "illing Machine

Challenge .

To #e-elop cro*ning machine

#rainstorming Directly implemente # i#eas & .4

,4 i#ea implemente# through 55%

Total #rain Storming I$eas I$entifie$: %&

Cro*ning 2 CT

,3 i#eas #roppe#

#ottle fee$ing to 'inser()illing !(c

516 & +

55%& +
BE"O E

Chances of Bottle Breakage. Profile of lass and Plastic Bottle is different. lass Bottle Profile.

516 & ,

516 & .

!esign Problem" Star to be modified for

0tar 0tar*heel *heelprofile profilefor for monogamy monogamy/ottles. /ottles.

Hori&ontal replication on all star +heels of 5inser / #illing machines. Total 6 Star +heel Mo$ifie$.

%"TE

Challenge + $ ,

Mo#ifie# Mo#ifie#star star*heel *heel profile profilefor forglass glass /ottles. /ottles.

*limination of gripping pro+lem ,Creati-e .ai/en0

516 & +

55%& ,
BE"O E

Bottle

ri##ing issues can come.

516 & ,

ri##er Tension not ade%uate for heavier glass bottle. !esign" $igid ri##er to be designed for heavier glass bottle. "lexi/le "lexi/le00 00 gripper gripper *ith *ithspring spring tension. tension.
Hori&ontal replication on all Gripper of 5inser / filling machine Total 6: Grippers Mo$ifie$

516 & .

%"TE

Challenge + $ ,

igi# igi#Teflon Teflon gripper. gripper.

Smooth #ottle Tra-erse in )illing !(c

516 & +

55%& .
BE"O E

Bottle &olding 'ssues can come. Profile of Bottle Su##ort not suitable for lass Bottle.

516 & ,

516 & .

lass Bottle Profile different from Plastic Bottle. !esign" Bottle Su##ort design to be modified for lass Bottle.
Bottle Bottlesupport support"or "orMonogamy Monogamy /ottle /ottle

516 & .

%"TE
Hori&ontal replication on all Bottle Support Total ;: Supports Mo$ifie$

Challenge ,

Mo#ifie# Mo#ifie#profile profileof ofglass glass/ottle /ottle support support

#ottle )illing "ro+lem

516 & +

55%& 9
?A< mm

lass Bottle length more than Plastic Bottle. !esign" (illing )o**le length to be reduced by +, mm to suit lass Bottle length.

516 & ,

;@< mm

;A0 mm

<0 mm >0 mm

"illing "illing7o88le 7o88le"or "orMonogamy Monogamy /ottle /ottle Hori&ontal 5eplication on 5inser / #illing Machine (o&&les Total 6: (o&&les Mo$ifie$
??< mm

;;< mm

;=0 mm

;0 mm >0 mm

Challenge ,
Mo#ifie# Mo#ifie#Length Length

Challenge .

Cro ning "ro+lem 1 Chain of .ai/ens

Sa4ing of 5s:=lakh -cro+ner +ith ?00B)T2# Capping Cappingmachine machinefor formonogamy monogamy /ottles /ottles

Cro*ner Cro*nermachine machinepro-i#e# pro-i#e#for forglass glass /ottle. /ottle.

Capping Machine for

ater Bottle CBeforeD

Challenge .

Creati-e .ai/ens 1 Con-ersion of capping !achine into Cro ner

K+ & Gear emo-e# to eliminate otary Motion of 1ea#: K, &Key 5ay 'ro-i#e# to restrict otary Motion During Crimping: K. & Capping 1ea# eplace# /y Crimping 1ea#
Cro+ning Machine

Challenge +:,:.

Check ,Interim 'esults0

0till 5ay /ehin# the Target: achie-e# 4;< against ,;;< Target 'ro#uction Tonnage:=;T25ee( against Target of +>; T25ee(.
Production (Ton/Week)

esulte# esulte# in in Consi#ering Consi#ering of of Loss Loss Tree Tree %nalysis %nalysis

G O O D
Targe t

'ctual

BM

Data Analysis

Loss 'areto

Focus areas

Targets

Target + Eliminate e?uipment /rea(#o*ns. Target , Eliminate spee# loss of filling machine. Target .
Eliminate Minor 0toppage.

516 & + 516 & , 516 & .

#reak$o n of filling machine interme$iate gear ,#reakthrough .ai/en0 !amage of intermediate gear of filling machine.
ear unable to take re%uired load for glass bottle. ear not designed for lass Bottle-M.C to be changed to un Metal.

Target +
55%&4
BE"O E

Gear Gearma#e ma#eof of Teflon Teflon Eero Break$o+n )f interme$iate gear

%"TE

Bottle #illing Machine CBeforeD Bottle #illing Machine C'fterD

Gear Gearma#e ma#eof ofGun Gun

WWA :,#reakthrough .ai/en0

Bottle Lifter Bush Breakdo n

55%& @ $ 3

Target +

516 & + 516 & , 516 & . 516 & 9

/orn out Bush. Point load on the Bush. Circular Bush. !esign " Circular Bush to be re#laced with S%uare Bush. BE"O E %"TE

Bottle Lifter !ollo er Breakdo n

516 & + 516 & , 516 & .

Bearing (ailure. Bearing unable to take heavy load. !esign" Bearing to be re#laced with Bush.

BE"O E

%"TE

.ai/en: Capacity De+ottlenecking

BE"O E %"TE

Target ,

#illing machine spee$ increase$ .y ?00B.

Sa4ing of 5s:=lakh -cro+ner +ith ?00B)T2# One machine. Onecro*ning cro*ning machine. MP Sheets 2mplemente$ of ?st Cro+ner T*o T*oparallel parallelcro*ner cro*nerpro-i#e#. pro-i#e#.
:< A0 ;0 ?< 0 M-c Spee$FBPM :0

G O O D

;n$ cro+ner resulte$ in ,ou.le spee$ of filler spee$

G(o4?0 ;0

G,ec?0 :0

# il lin g M -c ) u tf e e $

?00.0

;<.0

<0.0

@<.0

0.0

C h o ki n g

C ro + ne r s to p p a g e

+0.,

B o tt l e B re ak ag e

1,.,

Data Analysis ,!inor Stoppages0

M at e ri a

2.,

l o 4 e rf l o+ fr o in g T im

2n fe e $

3.,

m h o p p er

4.,

ig h t 4 ar ia ti o n

B o

1.,

tt l e 8a m m in g

Target .

B o tt l e * e ak a

5.+

C yl in $ e r B o

#ocus 'reas

ge * ea k ag

Minor 0toppage Loss 'areto

5.,
e tt l e S ta r4 a ti G ui $ e

,.+
on S

,.4
e tt i B o tt l n g e

,.1
ti lt i n g

,.1

"ro+lem2 )re3uent Stoppage of )illing !achine ,!inor Stoppage 0 'dentified reasons for fre%uent sto##age of (illing Machine.
Frequent Breaking / Jamming of bottle in crowner Frequent Stoppage of Crowner Material overflow from hopper Weight variation Filling machine In feed warm timing out in!er in feed belt conve"or !lip / not carr"ing bottle# Bottle tilting at tran!fer plate#

Consi#ering all these aspects *e #eci#e# to #o 55BL%

!echanism Worksheet
5inser #iller

: > @ ; 6 =

?0

Cro+ner ?A

A ?

?; ?:

<

??

WW#LA Worksheet

Go A 9> 7o GoA + Kai8enA+@

K1

Bottle Jamming / Breakage in crowner

$ilting of Bottle in crowner

Bottle not in completel" !tatic during crimping

%ue to inertia

%e!ign weakne!!

K! K3, K"

'dditional Bottle (olding Mechani!m to be &rovided

K#,$ K% Frequent !toppage of crowner $iming &roblem of !tar wheel Star wheel not able to take crimping load %e!ign weakne!! K& K1',11 K1! K13 K1 K1" K1#

Single piece !tar wheel without !lot provided#

4erification Sheet

WW#LA .ai/en :2 )re3uent Time out of cro ner star heel BE"O E %"TE

0ingle piece 0tar 0ingle piecestar star*heel *heel*ithout *ithout 0tar*heel *heelin int*o t*opiece piece*ith *itha#Bustment a#Bustment Eero Timing out of a#Bustment slots. a#Bustmentslot. slot. slots. %"TE BE"O E Cro+ner star +heel ?=mm =mm

0tar 0tar*heel *heel

Mo#ifie# Mo#ifie#star star*heel *heel

WW#LA .ai/en: #ottle tilting pro+lem in cro ner ,Inno-ati-e .ai/en0

BE"O E 7ec( 7ec( 0upport 0upport %"TE

T*o T*ostar star*heel. *heel.

7ec( 7ec(0upport 0upport0tar 0tar*heel *heelpro-i#e#. pro-i#e#.

Tilting of .ottle eliminate$.

WW#LA .ai/en 2 *limination of #ottle 5amming in Crimping hea$

BE"O E %"TE

Bottle 0Hection shaft after crimping ;<mm ;@mm

Crimping Crimpinghea# hea#of ofcro*ner cro*ner

Crimping Crimping1ea# 1ea#of ofcro*ner cro*ner

Eero Bottle 8amming in Crimping Hea$.

WW#LA .ai/en: )re3uent cro ner +reak$o n ,#reakthrough .ai/en0

BE"O E %"TE

;E ;EBall Ball.earing .earing+hich +hichfollo+s follo+s the thecam camto torotate rotatethe thestar star

5oller 5ollerI Ipin pinassem.ly assem.lypro4i$e$. pro4i$e$.

Eero failure of roller .earing

'esult: !inor stoppage re$uce$ +y 6%7 o-er No- 89

Target .

;:0 ;00 ?60 ?;0 =0 :0 0 Minor StoppageFhr

;0=
K1,K!,K3,K , K",K#,K%,K&, K1',13 K1 ,K1#

Minor 0toppage e#uce# /y 9>< o-er 7o-+;.C

?0@
K1!,1"

;<
8H / PM

;: k; ;:

;0 kA ;0

?> k: ?>

G(o4 G,ec?0 ;0= ?0@

k? ;<

Summary
(um.er of 9ai&en implemente$ I :; CTotal (um.er of Mo$ifications inclu$ing Hori&ontal 5eplications"A6;D Pro$ucti4ity !uality Cost Safety (um.er of analytical tools use$ I < (o. of a$4ance$ analytical TPM Tools use$ I ? )n 8o. Trainings I ;< man $ays " A: "6 "< " ?0

'esults 1 " ,#est in Class0

Production (Ton/Week)

G O O D

BM

'ctual

Target

'esults 1 C
Conversion Cost (Rs/Ton)

"#%

G O O D

BM

Target

'ctual

'esults 1 D an$ !
%eliver&
=00 Ton-Month 9etchup glass .ottle ?9g re6uirement in 2n$ia3 5aHpura #actory ,eli4ering @00Tons. Contri.ute$ in a .ig +ay in increasing 9etchup CC#)T thru. I Volume ,eli4ery. Bran$ ,e4elopment )pportunity .y pro4i$ing fle1i.ility to pro$uce $ifferent Variants an$ S9%Js at )ther sites.

$orale
2ncrease in pro$ucti4ity. Safe +orking en4ironment K impro4e$ safety. Very High Morale

Stan$ar$i/atio n

S)P re4ie+e$ an$ stan$ar$i&e$. C*2T Check sheets re4ise$. 2$entifie$ type of maintenance through e6uip. rating. PM check sheets re4ie+e$. 2mparte$ trg. to all the +orkmen for mo$ifie$ S)PJs.

)uture "lan
2ncrease the Tonnage to ;<0 Ton - eek .y commissioning Ar$ Cro+ner. 5e$uce further Con4ersion Cost .y A0B. *earningGs to .e replicate$ in other manufacturing areas. 2mpro4e technical efficiency o4er yr ;0?0. )00 impro4ement proHect.

A REWARDING WORK STYLE