Reduction of rejection in 4UP HF welding in blood bag manufacturing unit

1. INTERNSHIP REPORT
DONE BY GUIDED BY
ANIL VISHNU B K N SREENIVASAN
NIT CALICUT MANAGER (BB),HLL AKKULAM

2. AFT TRIVANDRUM
 Akkulam factory (AFT) is the 2 largest manufacturing plant of HLL in
Trivandrum district.
 Which is set up in October 1992.
 In which the main production in this unit are Blood bags, Needles,
Tubes, Suture implants, Copper T.

3. PROBLEM STATEMENT
 Reduce the rejection in 4UP HF Welding by finding out the root causes of
the rejection in blood bag manufacturing unit of Akkulam factory of HLL
Life care Ltd

4. Importance of the project
 Company now facing around 4.5% rejection per annum
 Total loss 66 lakhs per annum
 Reducing 1% will save around 13 lakhs per annum

5. OBJECTIVES
 Find out the total rejection in 4UP HF welding
 List out the various reason for the rejection
 Find the root causes for the rejection
 Implement the remedies to reduce the rejection
 Reduce the rejection percentage within the range of 1-2%

6. RESEARCH APPROACH
 Collection of Historical data on 4UP HF welding rejection.
 Detailed study about working of the machine.
 Comparison of historical data with online study on the machine.
 Finding out the problems in working of the machine.
 Searching for the root causes of the problem.
 Listing out the root causes of the problem.
 Taking Details about the input material for the machine.
 Detailed study about the requirement of input sheet for the machine.

7.  Take samples from Sheet extruding machine.
 Take all readings as well as parameters of the sample sheet taken.
 Run the sample sheets in 4UP HF welding machine.
 Calculate the rejection percentage for the population from the sample.
 Compare it with Historical data collected.
 Implement the remedies for the reason for rejection
 Compare the pre implementation and post implementation data.

8. DATA SOURCES
 Primary:
Primary data were collected through direct observation by sampling method.
And also by discussion which have been held with various official employees
and workers of the company.
 Secondary:
Secondary data were collected through the historical data saved in the sorting
register of the 4UP HF welding machine and also from various books,
websites, company database etc.

10. Uniform thick
sheet after
extrusion
Production of blood bags
Material flow diagram
Raw material PVC
granules
Blood bags after
4UP machine
operation
Manually
sorted bags
Packed
bags

12. Process flow diagram
Sheet
Extrusion
HF
Welding
Sorting Labelling
Anti-coagulant
filling
Coiling
SealingSterilizationDrying
Visual Check Packing
Tube
Extrusion
Needle
Production

13. Hypothesis
Ho1 : Rejection occurs in the m/c are because of the design imperfections in 4UP HF Welding
Ha1 : Rejections occurs in the m/c are not because of the design imperfections in 4UP HF Welding
Ho4 : Excessive punching rejection in 4UP is due to thickness variation and there by bumps on input sheet
Ha4 : Excessive punching rejection in 4up is not due to thickness variation and there by bumps on input sheet
Ho5 : Rejection because of the feeding problem in the 4UP m/c
Ha5 : Rejection is not because of the feeding problem in the 4UP m/c
Ho6 : Rejection in sheet mainly because of the dust particle present in the bag
Ha6 : Rejection in sheet mainly not because of the dust particle present in the bag
Ho7 : Punching problem is because of the sticking of input sheet
Ha7 : Punching problem is not because of the sticking of input sheet
Ho8 : Punching rejection occurs mainly because of the mis-alignment of the m/c parts
Ha8 : Punching rejection occurs not because of the mis-alignment of the m/c parts

14. Ho9 : Punching rejection is mainly because of the bumps in the two ends of the sheet
Ha9 : Punching rejection is not because of the bumps in the two ends of the sheet
Ho10 : Punching rejection is due to variation of temperature using in the operation of sheet extrusion
Ha10 : Punching rejection is not because of the variation of temperature using in the operation of sheet extrusion
Ho13 : Sheet thickness variation is because of quality of pellet using.
Ha13 : Sheet thickness variation is not because of quality of pellet using.

15. Protocol

16. Method of study
1
 Collect the data from sorting department under various rejection
 Classify the rejection under various category and find out which rejection
is excessive.

17. 2 (A)
 Mark specific sheet from sheet extruder
 Draw chart for movement of the input sheet to the 4UP m/c
 Note down which roll is on the left & right side of the m/c roller
 Mark the movement of sheet in the 4UP m/c centres
2 (B)
 Observe the 2 pickup station process
 Observe kind of sheet that both pick up station accept & Reject from the
samples
 Note down the specific values of thickness
 Point out the sheet which is with more acceptable specific values

18. 2 (C)
 Find out the amount of rejection by both plates
 Take sample from the both accepted & rejected sheet.
2 (D)
 Collect 4 samples of imported sheet
 Divide sheet with length of 0.5 cm
 Find the thickness of each strip
 Draw the graph for thickness with length on x axis and thickness on y axis
 Collect the sealed sheet from the 4UP machine
 Find the thickness variation of the sheet along the length by cutting into strip
of length 0.5cm and to plot it on the graph
 From a sample of 100 find out the total number of rejection in 4UP machine
 So as to find the total percentage of rejection

19. 3 (A)
 Detailed study on how die is setting and the study on the parameters for
the perfect sheet
 Study on how to adjust the lip screws.
3 (B).
 Take a set of sheet rolls which is in the accepted groups
 Take samples from the taken sheet rolls
 Determine the thickness from each sample
 Make a trial run on the 4UP machine check whether the accepted sheets
are running Properly on the machine
 Note down the sheet details with minimum acceptance level.

20. 3 (C).
 Take two sealed sheet samples from the 4UP machine which is not
properly placed and the other is properly placed
 Compare the sheet parameters with the parameters of the imported sheet
and the Sheets that are successfully running on the 4UP machine
 Formulate set of sheet parameters that are in region of acceptance for the
4UPmachine

21. Historical data collection
1. DATE- 12/5/2016
SHIFT TARGET ACTUAL REJECT DEVIATION
A 12,500 11,000 124 150
B 12,500 10,000 100 2500
C 12,500 11,000 180 1500
37,500 32,000 404 5500
0
10,000
20,000
TARGET ACTUAL REJECT DEVIATION
REJECTION REPORT- 12/5/2016
A B C

22. 1. DATE 17/5/2016
SHIFT TARGET ACTUAL REJECT DEVIATION
A 12,500 2200 60 10,300
B 12,500 8700 100 3800
C 12,500 8200 68 4300
37,500 19100 228 18400
0
20,000
TARGET ACTUAL REJECT DEVIATION
REJECTION REPORT-17/5/2016
A B C

23. 1. DATE 19/5/2016
SHIFT TARGET ACTUAL REJECT DEVIATION
A 12,500 6500 96 6000
B 12,500 3400 100 9100
C 12,500 5000 100 7500
37,500 14,900 296 22600
0
12,500
6500
96
6000
0
12,500
3400
100
9100
0
12,500
5000
100
7500
0
5000
10000
15000
SHIFT TARGET ACTUAL REJECT DEVIATION
REJECTION REPORT -19/5/2016

24.  SORTING DATED FROM 13/05/2016 TO 20/05/2016
CARD
O/P
M/C
REJ/DUST
BAG WITHOUT
TP STOPPER CONNECTOR
143854 1478 304 3 153
WELDING COMPLAINT
2WELD PUNCHING OTHERS SORTEDTP STOPPER CONNECTOR % OF REJ
676 556 74 2706 501 141091 4.5
0
500
1000
1500
2000
2500
3000
M/C REJ/DUST BAG WITHOUT WELDING
COMPLAINT
2WELD PUNCHING OTHERS
Sorting

25. 61 13 12 6 5 2 1 100
61%
74%
86%
92%
97%
99% 100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
20
40
60
80
100
120
Punching
problem
Connector comp
ins pro
TP comp
insertion pro
Others Bag w/out TP Bag w/out
connector
2nd weld
problem
Total N
Percentage
Number
Item
Defects in 4UP HF-350 ml transfer bag
Thisbarrepresentsthetotal(N)ofyourpareto.
Caption box.
Month of MAY 2016

26. 4 UP WELDING MONTH WISE
REJECTION REPORT
MONTH TARGET ACTUAL % M/C REJ % SORTING % TOTAL %
OCT 8,75,000 8,60,618 98.3 1.05 2.72 3.74
NOV 8,75,000 7,90,049 90.2 1.07 2.17 3.21
DEC 8,75,000 7,99,608 91.3 1.57 4.33 5.83
JAN 8,75,000 8,36,319 95.5 1.32 3.21 4.49

27. SORTING DETAILS KOREAN (1)
PRODUCTION DATE 26/06/2016
BAG TYPE 350 ml TRANSFER BAG KOR
MASTER BATCH NO A126066KOR
SHIFT A
CAR
D
O/P
M/C
REJ/DU
ST
BAG WITHOUT
TP STOPPER
CONNECT
OR
9976 10 2 3
WELDING COMPLAINT
2WELD
PUNCH
ING
OTHER
S
SORTE
D
T
P STOPPER CONNECTOR
% OF
REJ
1 6 5 3 9976 0.3

28. 4UP Roll Loading diagram

29. Sample sheet thickness calculation
from sheet extruder
BATCH : W7624056B1-B
SHIFT : B
DATE : 24/05/16
PELLET NO : 154730
0.34
0.35
0.36
0.37
0.38
0.39
0.4
0.41
0.5 2.5 4.5 6.5 8.5 10.512.514.516.518.520.522.524.526.528.530.532.534.536.538.540.542.544.546.548.550.5
SHEET THICKNESS
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06
Distance
Thickness

30. Sealed sheet sample
BATCH : W7625056C1-B
SHIFT : C
DATE : 25/05/2016
OPERATORS : CKJ/GSM
PELLET NO : 154976-K76
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.5 2 3.5 5 6.5 8 9.5 11 12.5 14 15.5 17 18.5 20 21.5 23 24.5 26
SEALED SHEET THICKNESS VARIATION
TOP BOTTOM
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06
Distance in cm
Thicknessinmm

31. Sample data collection

33. CAR
DO/P
M/C/
DUST
BAG WITHOUT
TP
STOPPE
R
CONNECTO
R
6108 116 0 0 0
WELD COMPLAINT
2
WELD
PUNCHIN
G
OTHER
S
T
P STOPPER CONNECTOR
0 0 129 8 560 0
14%
0% 0%
0%
0%
0%
16%
1%
69%
0%
CONCLUSION
M/C/DUST BAG WITHOUT TP BAG WITHOUT STOPPER
BAG WITHOUT CONNECTOR WELD COMPLAINT TP WELD COMPLAINT STOPPER
WELD COMPLAINT CONNECTOR 2 WELD PUNCHING
OTHERS

34. Sheet specification with more acceptable level
BATCH : W7623056C1-B
SHIFT : B
DATE : 23/05/2016
PELLET NO : 154730-K76
0.37
0.375
0.38
0.385
0.39
0.395
0.4
0.405
0.5 3.5 6.5 9.5 12.515.518.521.524.527.530.533.536.539.542.545.548.551.554.5
SHEET THICKNESS
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06

35. DATE : 25-02-2016
TIME : 04:31
PVC SHEET
DIMENSION : .35*260
QTY : 20KG
LOT NO : 92131186-13
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.5 2 3.5 5 6.5 8 9.5 11 12.5 14 15.5 17 18.5 20 21.5 23 24.5 26 27.5
KOREAN SAMPLE 2 THICKNESS

36. BATCH : W7624056A1-F
SHIFT : A
DATE : 24/05/16
PELLET NO : 154730
0.35
0.36
0.37
0.38
0.39
0.4
0.41
0.42
0.5 3.5 6.5 9.5 12.515.518.521.524.527.530.533.536.539.542.545.548.551.5
THICKNESSI
DISTANCE
SHEET THICKNESSRIGHT LEFT
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06

37. Sheets that need to be avoided
BATCH : W7625056A1-A
SHIFT : A
DATE : 25/05/16
PELLET NO : 154730K76
0.32
0.34
0.36
0.38
0.4
0.42
0.44
0.5 3 5.5 8 10.5 13 15.5 18 20.5 23 25.5 28 30.5 33 35.5 38 40.5 43 45.5 48 50.5 53 55.5
SHEET THICKNESS
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06

38. BATCH : W7628056A1-G
SHIFT : A
DATE : 28/05/2016
PELLET NO : 154976-K76
0.33
0.34
0.35
0.36
0.37
0.38
0.39
0.4
0.41
0.42
0.43
0.5 3.5 6.5 9.5 12.515.518.521.524.527.530.533.536.539.542.545.548.551.5
SHEET THICKNESS
PARAMETERS
TEMPERATURE - C1 C2 C3 H D1 D2 D3
IN OC 175 179 182 185 185 185 185
TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL
M/MIN 3.15 3.12 3.06

39. Conclusion
 Lion share of the rejection is constituted by punching rejection which can be
reduced by maintaining the thickness of input sheet in between 0.38 to 0.42 mm
 M/c or dust rejection can be reduced by reducing the rate of degradation in the
extrusion die and also by controlling the floor waste.
 Proper maintenance in TP, CONNECTOR and BOV feeding section.
 Resorting of the rejected bags.