maarg final report
TRANSCRIPT
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A
Consultancy Report to
“Camlin India Limited”
Submitted by,
MAARG CONSULTANCY AND SOLUTIONS
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About Camlin:
With our 50,000 strong retailer network, prestigious foreign collaborations, large consumer
base, regular interaction with consumers by the sales force and participation in international
trade fairs like Paperworld in Frankfurt, Camlin is now a trusted household name all over
India. Camlin was the first company in India to adhere to Art & Creative Materials Institute’s
world standards in toxicity certifications. All India Camel Colour Contest too has been well-
received, holding the record of the highest entries ever and has been registered in the Limca
Book of World Records. Camlin has been encouraging and promoting fine art, which is why
Camlin Art Foundation was set up.
From a company manufacturing ink powders in 1931 to a company manufacturing over
2000 products, operating in diverse fields, Camlin has come a long way.
Ideal for painting or drawing quick sketches in colour. They are also for superimposing as
they spread evenly on paper without smudging or smearing. Painting done with Camel Oil
Pastels can be protected by Camel Pas-O-Fix, a special fixer for Oil Pastels. They are
available in various pack sizes and shades assortments upto 50 shadesShades are Set of 50 Assorted Colours (1004 - 50) RD 60mm length x 10mm dia, Set of 25
Assorted Colours (1004 - 25) RD 60mm length x 10mm dia, Set of 15 Assorted Colours
(1004 - 15) RD 60mm length x 10mm dia.
Set of 12 Assorted Colours (1004 - 12) RD 60mm length x 10mm dia.
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1.2 Scope of the Study:
The Study included the Productivity Improvement for Oil Pastels Line in Camlin India at
Tarapur Plant, Thane District. The major focus area was the final stage of Oil Pastel line
as it had maximum number of problems causing decrease in the productivity.
The focus area of the study was the man and machine utilization at the final stage of oil
pastel line.
Study focused on the Oil Pastels Manufacturing Activities in the following areas:-
1) Three Stages are there for Manufacturing of the Oil Pastels which is the highest selling
Product of Camlin India. Detailed Study of Man, Machine and Inventory in Preliminary,
Tripple Rolling and Final Stage(Mixing) of Oil Pastels Line.
2) Multiple Activity Chart Plotting for Final Stage of Oil Pastels Line.
3) Overall Equipment Effectiveness
4) Design of Experiment by Taguchi’s Method to Improve Productivity of Oil Pastels
Line.
The Scope of the Work included the review of Systems and Procedures to achieve the
Maximum Productivity of Oil Pastels Line as per the Machine Standards.i.e upto 350kg
of o/p per shift and also to streamline the Processes to utilize the Man and Machine
efficiently.
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1.3 Methodology:
The Study was conducted using the following methodology:
1) Review of Systems and Procedures followed in the Manufacturing of existing Oil
Pastels Line.
2) Detailed Study and Critical Analysis of Present Practices at each stage of man,
machine, inventory, quality and productivity.
3) Interaction with different in-house departments like Quality, Stores, Shop floor to get
the cross functional view of the problem. Quality Department was visited to study the
nature of colors and which constituents of the colors undergo quality check. Stores
department was visited to review whether the raw materials of the color pastels are
weighed according to the standards.
4) Identification of Productivity Problems in oil Pastel Line related to man and machine
utilization with the help of multiple activity chart plotting.
5) Identification of Standard Parameters affecting machine performance with the help of
design of experiment using Taguchi method.
6) Suitable recommendations were made along with operational improvement
opportunities. The recommendations were discussed with the senior management.
However, the actual implementation of the recommendation will be the
responsibility of Camlin India, Tarapur plant.
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1.4 Consultancy Team:
The consultancy team included the members from “MAARG Consultancy and
Solutions”. The following members were involved in the project:
Paresh Gugale Ashif Tadvi
Abhinav Gupta Radha Krishna Mothadaka
Kasam Srinath Kiran Dhamapur k ar
D
k1.5 Scheme of Report
Chapter II deals with the study of the most critical stage of oil pastel line using Multiple
activity chart to identify the utilization of man, machine, time and inventory and
includes the recommendations to utilize the resources properly to increase productivity of
oil pastel line.
Chapter III Highlights the Overall equipment effectiveness of the machine
Chapter IV deals with the Design of Experiment (Taguchi Method) to identi
fy the
standard parameters affecting machine performance and suitable recommendations were
given using the above principles.
Summary of recommendations are presented in Chapter V
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Chapter II:-Multiple activity chart
Introduction:
It is these charts which give the idle time and the utilization times of the machines and
workers.
A Multiple activity chart is a chart on which the activities of more than one subject
(worker, machine or item of equipment) are each recorded on a common time scale to
show their interrelationship.
By using separate vertical columns or bars to represent the activities of different
operatives or machines against a common time scale, the chart would clearly showidleness on the machines of oil pastels.
The Multiple activity charts is useful in organizing teams of operatives on the mass-
production work i.e. Oil-pastels work and also on maintenance work as it is not
feasible to remain idle longer than the necessity.
In making the chart, the activities of the machines and the operators are being recorded
in terms of working time and the idle time. These times are being recorded by ordinarywrist-watch or a stop-watch.
Methodology adopted:
RECORD:
In this stage all the desired inputs of the workers (worker 1 and worker 2), machines
(rotating table) are being noted and then once in 20 minutes the operations of the
workers, machines are being recorded and is shown in the tabulated form as below for
the 3 different Oil-Pastel machines with different colors to get the more accurate results
so as to address more discrepancies.
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EXAMINE CRITICALLY
All the critical activities are being noted from time to time with the change of
operations, with the change of the speed, with the effect of the external parameters like
chilling, the temperature of the rotating table and its speed, the movements of the
workers, the location and flow of the input material and all the activities are being noted
in the chart for the calculation of the Utilization and the Idle times of the Oil-Pastel
machine.
DEVELOP THE METHOD
After the total observations are being recorded and then critically examined for the Oil-
Pastel machines and the workers operating, this stage is the final stage involving the
development of the multiple activity chart with the inputs being recorded with the
IDLE TIME being shown as the RED COLOR and the WORKING TIME being
shown as the YELLOW COLOR in the experiments being carried out and is being
shown below.
Once the RED ZONE and the YELLOW ZONES are obtained it is quite easy to note
the working time i.e. UTILIZATION TIME and then the IDLE TIME of both the
workers and also the machines.
The UTILIZATION TIME and IDLE TIMES would help in addressing many issues
discussed after the experiment section.
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EXPERIMENT NO: 1
MAARG CONSULTANCY & SOLUTIONS
MAN MACHINE CHART - OIL PASTEL LINE FINAL STAGE
Date:6thAugust 2008
Method:
Present/Proposed
MANMACHI
NE
Shift:Second
Shift
Idle
Time% 0.4516 0.225806
Analyst:Ashif Tadvi Utilizatio
n % 0.5484 0.774194
Remarks
Time W1 W2 W1 W2 S1 S2 RT
4:10 Counting & stacking Idle
4:20 Counting & stacking Idle
4:30
Counting & stacking Adjustingstroke
4:40
Idle Manualstroking
4:50
Idle Manualstroking
5:00 Idle Adjustingstroke
5:10 Idle Idle
5:20 Idle Idle
5:30 Counting & stacking Idle
5:40
Counting & stacking Gone for rawmaterial
5:50
Counting & stacking Gone for raw
material
6:00
Counting & stacking Gone for
rawmaterial
6:10
Idle Gone for rawmaterial
6:20 Counting & stacking Idle
6:30 Idle Idle
6:40 Counting & stacking Inspecting
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EXPERIMENT NO: 2
MAARG CONSULTANCY & SOLUTIONS
MAN MACHINE CHART - OIL PASTEL LINE FINAL STAGE
MAN MACHINE
Date: 6th
august 2008
Method:
Present/ProposedW1 W2
S1 s2
Shift:First shift Idle Time 0.14 0.62 0.29 0.29
Analyst: Kasam
Srinath Utilization % 0.86 0.38 0.71 0.71
NOTE: Continued work from the previous Shift of white color
Remarks
Time W1 W2 W1 W2 S1 S2 RT
7.00IDLE FOR CHALKS
Adjustingstroke
7.10
Counting &stacking
Gone for rawmaterial
7.20Counting &stacking
Idle
7.30Counting &stacking
Idle
7.40Counting &stacking
Idle
7.50 Counting &stacking
Materialpouring
8.00
Make ready
next box Inspecting
8.10Counting &stacking
Handlingscrap
8.20
Counting &stacking
Gone for raw
material
8.30Counting &stacking
Idle
8.40Counting &stacking
Idle
8.50
Counting &
stacking
Idle
9.00
Break for Break-Fast9.10
9.20
9.30
9.40 IdleAdjustingstroke
9.50Idle to getCHALKS
MakingStable
10.00 Counting & Idle
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stacking
10.10Counting &stacking Idle
10.20Counting &stacking Idle
10.30
Counting &
stacking Idle
10.40Counting &stacking Idle
10.50Counting &stacking Inspection
11.00
Counting &
stacking
Material
pouring
11.10
Counting &
stacking Idle
11.20
Counting &
stacking Idle
11.30
Counting &
stacking Idle
11.40Counting &stacking Idle
11.50Counting &stacking Idle
12.00
Chilling Stopped12.10
12.20
12.30
12.40
LUNCH BREAK
12.50
1.001.10
1.20
CHILLING STOPPED1.30
1.40 Idle
Adjusting
stroke
1.50
Counting &
stacking Idle
2.00Counting &stacking Idle
2.10
TEA BREAK
2.20
2.302.40 STOPPED WORKING AND STARTED
CALCULATIONS OF THE SHIFT2.50
3.00
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comments:
1 Between 12.00 to 3.00 only 40 minutes was being output and worked
2 Chilling Problem is a prime Concern as it stopped one-third of the work per shift
3 Adjusting the rotating speed and putting down the chalks produced as scrapeats away 1 hour time as they do it for 4 times.
It is a form of Reworking -- waste of labour hours, machine hours of time as well.
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EXPERIMENT-3
MAARG CONSULTANCY & SOLUTIONS
MAN MACHINE CHART - OIL PASTEL LINE FINAL STAGE
Date: 06
/ 08 / 08
Method:
Present/Pro
posed
MAN
MACHINE
Shift:
2nd Shift Idle Time
Analyst:
Radha K Mothada
ka
Utilizatio
n %
Remarks
Time W1 W2 W1 W2 S1 S2 RT
3:10 Bring Material Bring Material
3:20 Bring Material Bring Material
3:30Wait for mixing Wait for
mixing
3:40Wait for mixing Wait for
mixing
3:50 Doing Collection Removingscrap4:00 Doing Collection Helping to W1
4:10 Doing Collection Helping to W1
4:20 Doing Collection Helping to W1
4:30 Doing CollectionMaintenanceWork
4:40 Doing CollectionMaintenanceWork
4:50 Doing CollectionMaintenanceWork
5:00
TEA BRAKE5:10
5:20 Doing CollectionMaintenanceWork
5:30 Doing CollectionMaintenanceWork
5:40 Doing Collection Not available
5:50 Doing CollectionMaintenanceWork
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6:00 Doing CollectionMaintenanceWork
6:10 Doing Collection Not available6:20
Doing CollectionMaintenanceWork
6:30 Doing Collection
Maintenance
Work
6:40 Doing CollectionMaintenanceWork
6:50 Doing CollectionMaintenanceWork
7:00 Doing Collection
Maintenance
Work
7:10 Doing Collection
Maintenance
Work
7:20 Doing Collection
Maintenance
Work 7:30
Doing Collection
Maintenance
Work
7:40 Doing CollectionMaintenanceWork
7:50
DINNER / LUNCH
TIME
8:00
8:10
8:20
8:308:40 Doing Collection Helping to W1
8:50 Doing Collection Helping to W1
9:00 Doing Collection Helping to W1
9:10 Doing Collection Helping to W19:20 Doing Collection Helping to W1
9:30 Doing Collection Helping to W1
9:40 Doing Collection Helping to W19:50 Doing Collection Helping to W1
10:00 Doing Collection Helping to W1
10:10 Doing Collection Helping to W110:20 Doing Collection Helping to W1
10:30 Doing Collection Helping to W1
REMARKS
Mix problem , Viscousity problem
Worker 2 is in maintenace work most of the time because of mixture
problem
The Output lot is almost defective
Chilling failure and improper liquid temp problems
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5. From the entire 3 experiments one can infer an observation that the idle time of the
worker 2 (Maintenance worker) is having or spending most of the time idle
ranging from 45 -65%.
Worker 1 who is allocated the work of counting sticks is doing his activity withjust 10-`15% of idle time (as the sticks have to get accumulated in order to start
his operation).
6. It is one of the feasible and advisable to allocate 2 machines to operate for the
worker 2 which helps in the reduction of one worker.
7. The allowance time that the company has allotted and the times the workers are
really taking for allowance has a difference of 20 minutes per shift(1 hour per 3
shifts --- loss of close to 40 kg output)
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Chapter III:-
Overall Equipment Effectiveness (OEE)
Introduction:
Overall Equipment Effectiveness (OEE) is a total measure of performance that relates the
availability of the process to the productivity and quality. The OEE measure shows how
well the company is utilizing resources, which include the equipment, the labor and the
ability to satisfy the customer in terms of delivering the quality specified by the customer.
This approach provides focus and simplicity to decision making with respect to
controlling unplanned downtime, the cycle time of the process and the quality rate.
OEE is directly related to the six big losses, which are as follows: -
Breakdown and Changeover form the Availability measure.
Minor stoppages and reduced speed form the productivity/performance measure.
Non-Conforming items and changeover scrap form the quality measure.
Where appropriate
OEE measure is suitable for any process within a manufacturing environment and
provides a means of prioritizing improvements.
Requirements when implementing
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When undertaking an OEE on a process the following issues need to be addressed: -
Availability of the process
The productivity/performance of the process
The quality of the process
The Overall Equipment Effectiveness is now calculated by taking all three factors into
consideration using the metric listed below: -
In world-class terms an OEE of 85% is a good performance and maybe used as a
benchmark.
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OEE Calculation SHEET
(Example is given)
Maximizing Equipment Effectiveness
Breakdowns and minor stoppages impede automation
Stop accelerating the deterioration of equipment
Preventive maintenance alone cannot eliminate breakdowns
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IN CAMLIN:
The project work is carried out in Oil Pastels production line of Tarapur plant. The
production process is analyzed and it is identified that the final stage viz. the mixing &
molding stage is very critical for the line efficiency as well as productivity.
A brief about the Mixing Stage:
The necessary quantities of raw materials are taken as prescribed by the R & D dept. and
are used in lots to load in to the machines. The Mixing machine has two tanks, one is
main tank in which the raw materials are mixed thoroughly and the other tank is in which
the ready to mold liquid is available. From this second tank, the hot liquid is circulated in
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to a molding table which rotates at a certain adjusted speed. The liquid is mad cool to
solidify while the table is rotating, by passing a child water circulation. Once the liquid is
solidified in the molds of the table, a set of plunging sticks will eject the sticks finishing
the process of production.
Sticks are collected in trays and sent for labeling and then for packaging.
OEE of the machines in Mixing Stage:
As per the above description of the machine, the different chances / causes that can affect
the OEE of the Mixing machine are:
• Molding table speed (has affect on productivity).
• Plunger sticks action (has affect on productivity).
• Viscosity of the liquid (has affect on quality).
• Hot & Cold temps (has affect on quality).
• Machine running time (has affect on availability).
• Color changing time (has affect on availability).
OEE Improvement Measures:
• Experiments are conducted on the machine at different table speeds to increase the
output which can increase the production efficiency of the machine. An optimal
machine setting parameters are found for max. Output.
Machine Setting parameters include:
1. Molding table speed.
2. Valve angle.
3. Hot & Cold Temps.
• Proper mixing of raw materials to maintain the necessary viscosity of the liquid is
suggested as per the R & D dept. recommendations. Proper viscosity ensures the
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better quality of the pastel sticks. Similarly, Hot and Cold temps. are properly
regulated to maintain the proper viscosity of the liquid for better quality output.
• To increase the machine availability, Man machine charts are drawn and analyzed.
Measures to reduce the worker idle time and machine time are suggested. Color changing time is very considerable and has a greater affect on machine
availability. Hence, a proper color changing sequence is suggested to minimize the
color changing time.
All the above measures, address to increase the OEE of the machine.
COLOR
Production
PerformanceAvailability Quality OEE
RED 86.28% 85% 92.78% 68.0%
YELLOW 90.75% 85% 92.69% 71.5%
PURPLE96.38% 85% 91.66% 75.0%
NOTE:
• Availability is taken as 85% only because of the worker behavior and additional
allowances he is taking in the shift time.
• Production performance is calculated based on the assumptions that max. output
per shift (i.e. planned run time) is 350Kg.
Increase in Availability can directly increase the OEE of the machine
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Chapter IV:-
Design of experiment
What is it?
DOE is a systematic approach to investigation of a system or process. A series of
structured tests are designed in which planned changes ar e made to the input variables of
a process or system. The effects of these changes on a pre-defined output are then
assessed.
Why is it important?
DOE is important as a formal way of maximizing information gained while resources
required. It has more to offer than 'one change at a time' experimental methods ,
because it allows a judgment on the significance to the output of input variables acting
alone, as well input variables acting in combination with one another.
'One change at a time' testing always carries the risk that the experimenter may find one
input variable to have a significant effect on the response (output) while failing to
discover that changing another variable may alter the effect of the first (i.e. some kind of
dependency or interaction). This is because the temptation is to stop the test when this
first significant effect has been found. In order to reveal an interaction or dependency,
'one change at a time' testing relies on the experimenter carrying the tests in the
appropriate direction. However, DOE plans for all possible dependencies in the first
place, and then prescribes exactly what data are needed to assess them i.e. whether input
variables change the response on their own, when combined, or not at all. In terms of
resource the exact length and size of the experiment are set by the design (i.e. before
testing begins).
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When to use it?
DOE can be used to find answers in situations such as "what is the main contributing
factor to a problem?", "how well does the system/process perform in the presence of
noise?", "what is the best configuration of factor values to minimize variation in a
response?" etc. In each case, DOE is used to find the answer , the only thing that marks
them different is which factors would be used in the experiment.
How to use it?
The order of tasks to using this tool starts with identifying the input variables and the
response (output) that is to be measured. For each input variable, a number of levels are
defined that represent the range for which the effect of that variable is desired to beknown. An experimental plan is produced which tells the experimenter where to set each
test parameter for each run of the test. The response is then measured for each run. The
method of analysis is to look for differences between response (output) readings for
different groups of the input changes. These differences are then attributed to the input
variables acting alone (called a single effect) or in combination with another input
variable (called an interaction).
DOE is team oriented and variety backgrounds (e.g. design, manufacturing, statistics etc.)
should be involved. Moreover, as this tool is used to answer specific questions, the team
should have a clear understanding of the difference between control and noise factors.
In order to draw the maximum amount of information a full matrix is needed which
contains all possible combinations of factors and levels. If this requires too many
experimental runs to be practical, fractions of the matrix can be taken dependent onwhich effects are of particular interest. The fewer the runs in the experiment the less
information is available.
Design of experiment at Camlin
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We have identified following process parameters at oil pastel line:
1. Table speed
2. Valve opening
3. Boiling temperature
4. Chilling temperature
The design of experiment at camlin has been performed in two stages
In the first stage we have changed only one parameter at one time called “a single
effect”. Here the change of table speed and valve opening has been observed
while keeping other process parameters (Boiling temperature & Chilling
temperature) constant. The rationale behind doing so is that we were not in a
position to change the chilling temperature because only one chilling unit is used
to supply chilling water to whole unit. Same is the case with boiling temperature
(same unit supplies water to all oil pastel line).
In the second stage we have changed more than one
parameter at a single time. It is called “an interaction effect”. Here the valve
setting and table speed both have been changed and the result was investigated.
“A single effect design of experiment”
The experiment was done for three oil pastel lines. Here we have changed the
table speed keeping all parameters constant. Following graphs illustrates the effect
of table speed on the output.
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Table
Speed
(volts)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
18 9.65 0.75 82 8.8 12.87 257.33
At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Red Color is –Table Speed is 18 and the
Output Obtained is 257 kg/shift.
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At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Pale Yellow Color is –Table Speed is 19.2
and the Output Obtained is 270 kg/shift.
Table
Speed
(volts)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
19.2 10.15 0.8 82 8 12.69 270.67
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Table
Speed
(volts)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
10 12.65 1.15 76 9.8 11.00 337.33
At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Purple Color is –Table Speed is 10 and the
Output Obtained is 337 kg/shift.
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“An interaction effect design of experiment”
In the second stage we have changed more than one parameter at a single time. It is called
“an interaction effect”. Here the valve setting and table speed both have been changed
and the result was investigated
At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Pale Yellow Color is –Table Speed is
19.2,Coolant Opening is 90 degees and the Output Obtained is 270 kg/shift.
Table
Speed
(volts)
Flow
in
Angle
(Deg)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
19.2 90 10.15 0.8 82 8 12.69 270.67
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At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Red Color is –Table Speed is 18,Coolant
Opening is 85 degees and the Output Obtained is 257.33 kg/shift.
Table
Speed
(volts)
Flow
in
Angle
(Deg)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
18 90 9.65 0.75 82 8.8 12.87 257.33
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At the moment when maximum output was reported the process parameters are shown
in the above table.
Conclusion:- The Optimal Condition for Purple Colour is –Table Speed is 10,Coolant
Opening is 90 degees and the Output Obtained is 337.33 kg/shift.
Table
Speed
(volts)
Flow
in
Angle
(Deg)
Sticks
Accepted
(Kg)
Sticks
Rejected
(Kg)
Boiling
Temp
(Deg
C)
Chilling
Temp
(Deg C)
Accepted/RejectedShift
Prod(Kg)
10 90 12.65 1.15 76 9.8 11.00 337.33
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Chapter IV
Summary of MAARG Recommendations to Camlin India Limited:
For Manpower:
1. Strict following of Scheduled breaks by labour by improving discipline among
workers. It was observed that there was little following of scheduled break timings
by workers.
2. Tea and snacks can be brought to the workstations instead of workers going to
canteen which adds to the non-productive time due to delays. This would make the
worker stay at the workplace for maximum time and the tolerances provided for
walking to the canteen and back can be eliminated.
3. Siren or Bell can be blown for all breaks to intimate the shift workers about all the
breaks. This would standardize the time of the breaks for all workers so that they
all follow the same breaks.
4. Shop floor should have a big display board showing the shift output for the week,
output given by different workers and other similar details. This will help in
developing healthy internal competition among the workers and also help in
segregating performers and under performers.
5. Performance Linked (e.g. according to kgs produced) can be started in the shop
with the help of matrix performance tables. This will give positive reinforcement
to the workers for their good performance.
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6. In current situation it can be observed from the man machine chart that instead of
having 4 workers for 2 machines we can have 3 workers managing two machines.
7. Attitude of labour can be improved by making them aware about the actual gap in
demand and supply in the market and about future effect on the company due to
economic downturn in the market and corresponding layoffs by organizing
motivational workshops by top management.
8. Reward strategy can be used for workers and supervisors in the form of “Camlin
Man of the Plant” Award and bonus system based on monthly performance the
sample calculation of which is shown below:
Average performance per day = 180 kgs/shift (assumed)
After introducing bonus system suppose it is raised to 250 kgs/shift
Then improvement = 70kgs X 25 days = 1750 kgs and similarly increment in other
workers output due to internal competition.
For Machines:
1. Machine should be fully controlled by maintenance people and not by
production people. Giving controls to production people only gives them a
chance of manipulation.
2. All machine control parameters like table speed, valve opening, chilling
temperature, boiling temperature, etc. should be under the control of
maintenance people through locked machine panels.
3. The boiling temperature should be greater than 75 deg Celsius and chilling
temperature should be between 8 and 10 deg Celsius.
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4. Pneumatic Circuits can be used to control the speed of the table and flow rate
of liquid pastel independently and not by the same mechanical linkages as seen
in the present situation.
5.
Separate hot water and cold water system should be used for all machinesbecause there is loss of heat if the same pipe is used for circulation to all
machines.
6. The stick holding unit should be fabricated with as close tolerances as the
circular table because if it is not so the sticks break and there is loss of time in
fixing this problem.
7. TPM ( Total Productive Maintenance) can be employed in a phased manner by
starting off with a pilot machine.
For Methods:
1. Methods at all stages should be standardized using work station standardization
methods like method study and time study.
2. Standardized operation sheets should be displayed at all stages.
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Future Projects For Camlin India Limited
1)ISO Implementation in the Tarapur Plant.
2)TPM Implementation in the Tarapur Plant.
3)Development of Excel –Based Softwares for Inventory Management, Forecasting
Techniques etc.
4)Implementation of Six Sigma.
5)5 S Implementation in the Plant.
6)Training on various topics like “JIT,Poka Yoke,Kaizen,PMTS etc.