Feasibility study of installing

Automatic loaders in Bagging Plant

Kaizen Team- Tamanna

Members:
1. Mr. S K Panda (TL)
2. Mr. S K Parida
3. Mr. B K Pattanaik
Introduction

PPL dispatches its products in the following modes

1. Railway Wagons
2. Trucks
We aim to partially automate the loading procedures
of the above two modes by introducing wagon loaders
and Truck loaders.
This will improve TAT and will prove beneficial
considering the head load issues.
 PRESENT SCENARIO
We are loading 4.5 wagons using 1 slat and 12 nos of labours in 1
shift of 8 hours. This means in a platform of 9 wagons, 24 labours are
utilized to complete the job in 8 hours.

In this way we have a Turn Around Time of around 14-16 hours per
rake.

The labours are also carrying 50 Kg load on their backs and heads
which is also a concern of safety.
 TARGET
We want to reduce the loading time of a rake to 8 hours and reduce
the head load of labours by 30 %.

Head load of labours is mainly involved in the process of stacking, de-

stacking and direct loading. Hence we aim at reducing the head load
for direct loading and de-stacking.
 DATA ANALYSIS
Monthly Labour Use Loading Time/Rake ( January)
14000 18.00
12000 16.00

10000 14.00
12.00
8000
10.00
6000
8.00
4000 6.00

2000 4.00
2.00
0
ri l ay ne Ju
ly st er er er er ar
y 0.00
Ap M Ju gu m
b
to
b b b u
Au te Oc em em Ja
n 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41
ep N ov ec
S D

No of Rakes La bour TAT

 STEPS TAKEN

For formulating a suitable wagon loader and truck loader, we have

visited PICT of Paradeep Port. We made the following observations: