Minor Stoppage Data Collection,Analysis & Proposal

for Imrovement

CONTENTS

• Objectives of the study• Planned & activated training schedule.• Minor stoppage data collection for ACMA, VAT &

Case packer• Pareto analysis & identification of major problems• Suggestions for improvement

Objective of the study• Understanding the operation of SFD• Observing machine components &

mechanism• Minor stoppage data collection• Proposing solution for reduction of minor

stoppage

Activity Plan

Packaging System

• Envelop Wrapping Machine• VAT Machine• Case Packaging Machine

Envelope Wrapping Machine(ACMA)

• A packaging machine• Finished Goods are packaged for

distribution• Totally automated machine

Observed Machine Model

• The factory visit was on soap finishing department

• Detailed observation of line-2 (lux)• Wrapping machine in operation was

ACMA 711

ACMA 711• Serial Number : 0951174501• Manufacturing Year : 1995• Reconditioning Year : 2009• Customer : Unilever Bangladesh LTD.• Order N. : our Proforma Invoice N. 174/08

dated 22/12/2008

ACMA 711

Different Regions

• Pick & Place Unit• Paper Feeding Group• Main Body

Pick & Place

Suction Cups

Pockted Belt

No Soap No Wrapper

Bad Position Sensor

Paper Feeding Group

Stiffener

Wrapping Paper

Switch

Text Stamper

Main Body of ACMA

Main BodyTop Elevator

Roller

Cutter

Bottom Elevator

Gripper

Leaving ACMA to Metal Detector

Active Working time & Stoppage Time(s)

Mean Time Between Failure• Total stoppage time=1314 sec• Total working hour observation=11284 sec• Number of stoppages=21 times

• MTBF= = 537.42 sec•

12600-1314

21

Pareto Analysis

Main Causes for Stoppage & Proposal for Improvement

• Main two sources : Wrapper reel change & stiffener reel change

• Both can be optimized to run out at the same time to stop the machine once for both reel changing

Data & Calculation• Collected data : 1. Wrapper needed for one soap : 170mm 2. Weight of 170 mm wrapper : 1.78g 3. Stiffener needed for one soap : 154mm 4. Weight of 154 mm wrapper : 2.48 g

Data & Calculation• Wrapper: 1.78 g 170 mm 10 kg 955.056 m• Stiffener: 170 mm wrapper 154 mm stiffener 955.056 m wrapper 865.168 m 13.93 kg

Stiffener

Proposal for Improvement• If 10 kg wrapper & 13.9 kg stiffener are

employed at the same time, minor stoppage can be reduced to a great extent

• Currently around 9.1 kg wrapper & 14.9 kg stiffener are employed for packaging

• Better empirical relation can be established by working with more data

Proposal for Improvement• A color sensor can also be set at near the

end of stiffener wheel which will sense a specific color & activate an alarm to make operator alert

Other non-frequent phenomena responsible for minor stoppage

Miswrapping Defect in Soap

Other non-frequent phenomena responsible for minor stoppage

Bad position of soap

Thank You