The document summarizes an internship at Surya Nepal where various projects were completed to improve operations. The intern worked on an Admoist protocol to reduce moisture variation, increased the filling value of cut tobacco by 3% on average by adjusting machine settings, analyzed the Cp and Cpk of the CRS dryer, reduced spillage at the CTS bin by 5-8 kg/day, maintained uniform feed at the CRS cutter, designed a pan for sampling and a stand for a trap, and established standard blend change times for lines while decreasing tail out time for the CRS dryer.

1. OJT AT SURYA NEPAL
Bikram Dahal
Thapathali Campus
PMD
Supervisor
Ayush Raj Aryal
I/C PMD

2. Projects
Objective
Increase productivity, quality and profitability through keen data analysis and process
design; significantly improve operations and provide efficient resolution of process issues.
• Admoist protocol
• Increase filling value of Surya
Main
projects
• Spillage reduction in CTS bin
• GFP feed maintenance at CRS Cutter
• Cp & Cpk of CRS Dryer
• Optimization of blend change time (CRS line)
Side Project
Design • Design of pan for Sampling at HT and stand for Serrico Trap
OJT at Surya Nepal

3. Methodology
1
2
Asking question (understanding problem)
Labeling patterns in data
Modeling conceptually
Decomposing
Experimenting
implementation
3
4
5
6
7
Continual monitoring and communicating
OJT at Surya Nepal

4. Moisture Content
variation in cutter above
0.5
Admoist protocol and Data Analysis
Method Mother Nature Raw material
Moisture Content
Intrinsic Property
Size distribution
Bulking time
Type
(cold or Hot)
Humidity
Temperature
Power failure
Hand feel
Moisture
Uniformity of water, raw material
and steam flow
Measuring Instrument Least count
Setting of machine
Uniformity of filling
Machine
Man
Finding
Fig 1: Fish bone Diagram of causes for moisture variation

5. Result and Discussion
40.00
39.50
39.00
38.50
38.00
37.50
37.00
36.50
36.00
35.50
Moisture Mean Ex-cutter
0 5 10 15 20 25 30 35
0.60
0.50
0.40
0.30
0.20
0.10
0.00
S.D Chart
0 5 10 15 20 25 30 35
Admoist protocol and Data Analysis

6. Result and Discussion
• Weight deviation
for HVM/VSN5
stem is high
because stem of
this Grade are
longer and have
non-uniform
thickness
Admoist protocol and Data Analysis
6.00%
5.00%
4.00%
3.00%
2.00%
1.00%
0.00%
Coefficient of Variation of weight
0 5 10 15 20 25 30

7. Due to low filling value of CRS from regular interval in QUAS daily report after 17 aswin.
Temperature of product at 1 meter distance from outlet of admoist was checked. It was
found that temperature was above SOP i.e. 76.
Cause Solution Result
• Failure of PRV to
maintain set pressure of
0.3-0.4 bar. Line
pressure was changing
as per main pressure
variation.
• Main line pressure was
decrease to 5bar from
maximum pressure of
boiler i.e. 7- 8 bar.
• Temperature of 3 samples
of 3 operation was tracked
average value was found
71 C
Further Step
Admoist protocol and Data Analysis

8. Finding (Research)
Increasing filling Value of Surya
• Virginia Tobacco have less filling Value due to high sugar Content
• Lamina Cutter is optimum at 32CPI other argue its best at 25 CPI
• F.V varies among different part of same leaf, between different year crops
• FV is very sensitive to moisture
• Main control able factor effecting filling value
• HT steam pressure
• CPI of cutter
• Storage time and temperature
• Cheese pressure of cutter
• Type of dryer

9. Finding(Data analysis)
Increasing filling Value of Surya
• F.V after Ex-cutter was below average
• Expansion from cutter to H.T of both
lamina and CRS was with in speciation limit
• CPI of Cutter was below average and
not uniform
• Steam pressure of CRS H.T could be increase
• Order of operation had no effect on
filling value
• Filling value jump from ex-cutter
and ex-dryer
13.62
8.11
16%
14%
12%
10%
8%
6%
4%
2%
0%
Ex-cutter to Ex-bin Ex-cutter to Ex-Dryer
CRS Lamina

10. Step taken to improve F.V
Increasing filling Value of Surya
• Maintenance and Calibration of Cutter was carried out
• Steam pressure of CRS H.T was increased from 4bar to 5bar
• Cheese pressure of lamina cutter was reduce for NG to 15KN
• Temperature of lamina dryer was reduced from 66 C to 62 C

11. Increasing filling Value of Surya
CPI of Cutter Result
139
166
180
160
140
120
100
80
60
40
20
0
Before After
CPI
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
Wax Thickness (before)
0 10 20 30 40 50
0.25
0.2
0.15
0.1
0.05
0
Wax Thickness (after)
0 10 20 30 40 50

12. Result
Increasing filling Value of Surya
Filling Value Cut Tobacco
47.78
49.15
49.50
49.00
48.50
48.00
47.50
47.00
Before After
After Before
Mean 49.16 47.78
Observa
tions 32 36
p-value 2.91E-06
• Continuous
monitoring was
carried till end of
project
* FV value for before batch (NG1-42) and after (NG-43-78) was taken form QUAS daily report

13. Scope of Further Improvement
Increasing filling Value of Surya
• Increase tobacco and steam ratio to find optimum ratio in H.T
• Changing rate and temperature of airflow in dryer
• Experimenting with CPI of both cutter under control environment

14. Result
3.5
3
2.5
2
1.5
1
0.5
0
Cp and Cpk of CRS dryer
1 2 3 4 5 6 7 8 9 10
Old Boiler | | New boiler
Cpk
Cp
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
SD chart of Steam pressure at HT
0 1 2 3 4 5 6 7 8 9 10
Old Boiler | | New Boiler
Cp and Cpk of CRS Dryer

15. In order to maintain uniform flow of product at CRS cutter, product level at GFP should always
be visible. But some of the time, product at GFP of CRS cutter is empty.
Cause Solution Result
• Large tart time
difference between
VOV(2) and bin belt
conveyer(1) i.e. 5 sec
• High speed of Belt
conveyer(6)
• Start time difference
between 2 and 1 was
reduce to 1 sec
• Speed of 6 was reduce to
12+0.5 all other blend
except VSY from which it
was reduce to 15+ 0.5
• No single gap between
stem in conveyer from bin
to cutter
• Product at GFP was visible
most of the time
Introduction
Feed maintenance at CRS cutter GFP

16. Feed maintenance at CRS cutter GFP

17. Spillage reduction CTS Area

18. • Inter-operational
time 8 minutes
• 90sec gap
• 390sec time
difference
between start
and finish
Stem Conditioning
WEIGHCON
Optimization of Blend Change Time
SC
ADMOIST
AIR LIFT
40 sec 65 sec 165sec
45 sec 510 sec
60 sec
Inter-operational time
sec
30 sec
35 sec
OP 1 390 sec 90 Sec OP 2
Start:
Finish:
Diff. start to finish Gap

19. HT
• Speed cylinder
rpm at tail out
was increase
from 16 to 18
• Decrease In 1
minutes tail
out time
• Inter-operation
time is 360sec
after sensor in
GFP Detects no
Tobacco
CRS Dryer
VC
WEYCON
KLS
Optimization of Blend Change Time
55 sec 70 sec 390 sec 45 sec
Variable 40 -240 sec 90 sec 705 sec 50 sec
Start:
Finish:
Inter-operational time
Diff. start to finish Gap
sec
OP 1 280 sec 80 Sec OP 2

20. Design
Design of Pan for Sampling at HT

21. Summary
OJT at Surya Nepal
• Admoist protocol was passed
• Filling value of NG was increased by 3% on average
• Cp and Cpk of CRS dryer were calculated
• Spillage of CTS was reduce by 5-8 kg/day
• Uniform feed at CRS cutter was maintained
• Pan and stand were designed
• Standard blend change time was established for CRS conditioning and CRS
Dryer line. Along with decrease in tail out time of CRS dryer.