2. 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
3. Objective of the study
• Understanding the operation of SFD
• Observing machine components &
mechanism
• Minor stoppage data collection
• Proposing solution for reduction of minor
stoppage
7. Observed Machine Model
• The factory visit was on soap finishing
department
• Detailed observation of line-2 (lux)
• Wrapping machine in operation was
ACMA 711
8. 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
17. 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
19. 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
20. 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
21. 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
22. 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
23. 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
