¬¬Hence a brief introduction on the components of the cigarette production unit was studied and analyzed. With the brief information an attempt to solve a problem statement “Increasing productivity of LOGA 5” was undertaken. The steps taken were proved to be effective in their course of action. Further deep study into the machinery would aim to remove all the existing problems. During the course of internship, basic knowledge of management skills were learned. Also the importance of finely structured work and work distribution was felt.

1. 1
Tobacco is a product processed from the dried leaves of plants in the genus
Nicotiana. It can be used as a pesticide, and extracts form ingredients of some medicines
and is commonly consumed as a drug. The product manufactured from the leaf is used in
cigars and cigarettes, snuff, pipe tobacco, chewing tobacco and flavored shisha. Few
believe the word tobacco may have actually originated from India as tambākū; (तंबाकू )
India has 96,865 registered tobacco farmers and many more who are not registered. In
2010, there were 3,120 tobacco product manufacturing facilities in all of India. Around
0.25% of India’s cultivated land is used for tobacco production. Since 1947, the Indian
Government has supported growth in the tobacco industry. India has seven tobacco
research centers, located in Chennai, Andhra Pradesh, Punjab, Bihar, Mysore, West
Bengal, and Rajahmundry. The Indian Government and several states have taken multiple
1 Introduction to Tobacco
Fig 1. 1-Tobacco leaf
Fig 1. 2-Caffeine molecular structure

2. 2
measures to reduce Cigarette smoking. Smoking in public places is banned in many states,
it is not allowed to be portrayed in movies, and warnings are posted on cigarette packs.
Tobacco is cultivated annually, and can be harvested in several ways. In the oldest method
still used today, the entire plant is harvested at once by cutting off the stalk at the ground
with a tobacco knife. It is then speared onto sticks, four to six plants a stick and hung in a
curing barn. In modern times, large fields are harvested mechanically, although topping the
flower and in some cases the plucking of immature leaves is still done by hand.
Curing and subsequent aging allow for the slow oxidation and degradation of carotenoids
in tobacco leaf. This produces certain compounds in the tobacco leaves, and gives a sweet
hay, tea, rose oil, or fruity aromatic flavor that contributes to the "smoothness" of the
smoke. Tobacco can be cured through several methods, including:
o Air cured tobacco is hung in well-ventilated barns and allowed to dry over a
period of four to eight weeks.
o Fire cured tobacco is hung in large barns where fires of hardwoods are kept on
continuous or intermittent low smoulder.
o Flue cured tobacco was originally strung onto tobacco sticks, which were hung
from tier-poles in curing barns
o Sun-cured tobacco dries uncovered in the sun.
Fig 1. 3-Sun curing
Tobacco is consumed in many forms and through a number of different methods. Below
are examples including, but not limited to, such forms and usage.
o Bidi are thin, often flavored cigarettes from India made of tobacco wrapped in a
tendu leaf, and secured with colored thread at one end.
o Chewing tobacco is the oldest way of consuming tobacco leaves. It is consumed
orally.

3. 3
o Cigars are tightly rolled bundles of dried and fermented tobacco, which is ignited
so its smoke may be drawn into the smoker's mouth.
o Cigarettes are a product consumed through inhalation of smoke and manufactured
from cured and finely cut tobacco leaves and reconstituted tobacco, often combined
with other additives, then rolled or stuffed into a paper cylinder.
o Gutka is a preparation of crushed betel nut, tobacco, and sweet or savory flavorings.
o Hookah is a single or multi-stemmed (often glass-based) water pipe for smoking.
Originally from India, the hookah has gained immense popularity, especially in the
Middle East.
o Topical tobacco paste is sometimes recommended as a treatment for wasp, hornet,
fire ant, scorpion, and bee stings. An amount equivalent to the contents of a
cigarette is mashed in a cup with about a 0.5 to 1 teaspoon of water to make a paste
that is then applied to the affected area.
o Tobacco water is a traditional organic insecticide used in domestic gardening.
Tobacco dust can be used similarly. It is produced by boiling strong tobacco in
water, or by steeping the tobacco in water for a longer period. When cooled, the
mixture can be applied as a spray, or 'painted' on to the leaves of garden plants,
where it kills insects. Tobacco is however banned from use as pesticide in certified
organic production.
India ranks 4th in the total Tobacco consumption in the world. But India's cigarette
consumption ranks 11th in the world. Out of the total production, only 19% of the total
consumption of Tobacco is in the form of cigarette whereas 81% is in other forms like,

4. 4
chewing, bidi, snuff, Gutka paste, Jarda, hookah paste etc. The per capita consumption of
cigarette in India is one of the lowest in the world in comparison to major Tobacco
consuming countries like Zimbabwe, UK, Brazil, U.S.A and Pakistan. The annual level for
demand of cigarette in India remains the same at 96 billion sticks as it was 15 years ago,
despite the cumulative growth in population by nearly 35 percent during the same period.
However the consumption of Tobacco has been a matter of national debate in view of the
emerging anti-Tobacco drive in the country.
Tobacco is a traditional item of India's foreign trade. India is one of the leading Tobacco
exporting countries in the world. India accounts for 5.8% of the international trade and
ranks 5th after Brazil, U.S.A, Turkey and Zimbabwe. The principal markets for Indian
tobacco are U.S.S.R, U.K, Japan and the Middle East countries.
Fig1.5 Areas under Cultivation & Production

5. 5
Even though tobacco has been known in the Americas for over three thousand years and
was taken to Europe by the first explorers in 1492, it was initially consumed in pipes and
in a primitive form of cigar, as well as being sniffed as snuff. Cigarettes, as we know them
today, began being industrially produced in mid-19th century.
Even though they may look the same, cigarettes have differences in accordance with the
preferences of the consumers. Cigarettes are a product that is manufactured using these
basic ingredients: paper, filter, blend of tobaccos and flavoring agents that gives them their
distinct sensory characteristics.
The main component of cigarettes is tobacco, a plant of the family solanaceae and it
naturally contains nicotine as one of its components.
The ingredients are substances added to tobacco during cigarette manufacturing and they
have different functions. As shown on cigarette packs, the basic ingredients used are a
blend of tobaccos, sugars, cigarette paper, vegetable extracts and flavoring agents.
o Flavoring agents – Improve the characteristics of the cigarette smoke’s aroma,
promoting a particular identity for that brand. For example: menthol
o Sugars – Homogenize the levels of sugars of the different types of tobacco used in
cigarette production. Examples: sucrose, popularly known as sugar.
o Ameliorants – Improve the quality of the cigarette smoke’s aroma. Ex.: extract of
licorice, from the licorice plant (Glycyrrhiza spp).
o Agglutinants – Keep the tobacco particles agglutinated to each other. They are used
in the production of reconstituted tobacco. Example: starch, found in maize, rice
and cereals in general.
o Moisturizers – Minimize the exchange of moisture between the product and the
environment, besides facilitating processing the tobacco. Example: glycerin, found
in tobacco, beer, wines and chocolate.
Ingredients must not be confused with the substances known as components. Components
of smoke are generated during the combustion of cigarettes upon burning. Tar, nicotine
and carbon monoxide are examples of some components of cigarette smoke.
Before being used, tobacco needs to be cured. The curing stage consists basically of drying
the tobacco leaves. In the curing process, besides losing water and changing color, the
2 Overview of Cigarette

6. 6
leaves go through a series of biochemical transformations that define the specific flavor of
each type of tobacco. Virginia tobacco is flue-cured in brick barns using firewood from
forests planted for fuel as the source of heat. After curing, this tobacco turns orange. Burley
tobacco is air-cured in ventilated barns that allow air to circulate naturally, removing
moisture from the leaves. This tobacco turns brown. After curing, the tobacco is stored in
storehouses where it awaits sale. The curing associated with different varieties produces
the characteristics of aroma and flavor typical of each type of tobacco.
The combination of different types of tobacco in different proportions, associated with
ingredients, is the tobacco blend that produces the flavor and aroma characteristic of each
brand. Cigarettes vary as a function of the tobacco used and their design (length,
circumference, type of filter, ventilation, etc.).
Cigarettes account for 85 %of the country's total tobacco exports. The per capita
consumption of cigarettes in India is a tenth of the world average. India is exporting tobacco
today to 80 nations which is over all the continents in the world. At present the Indian
Tobacco Industry is providing livelihood to more than 25 million people in the country. In
the unmanufactured tobacco exports, Flue Cured Virginia tobacco accounts nearly 75 % to
80 % export. The other varieties are- Burley, HDBRG, Natu, DWFC, Top leaf and Jutty
are also exported which are used in making cigarettes. Non cigarette tobacco exported
worldwide is Lalchopadia, Judi, and Rustica are used for chewing and making bidis.
Around 8 % to 10 % non- cigarette tobacco is exported in throughout the world. According
to the international trends, non-cigarette tobaccos are the dominating item in the national
export. According to the current situation in the international tobacco market India is
proved to emerge out as the favorable market for the Indian tobacco export. The prices of
Brazilian export have almost equalized the most expensive American tobacco cost.
Zimbabwean farm prices have also seen an upward trend. There are several advantages
which can be put forth for favoring the Indian tobacco. Like low unit production cost,
average export prices of tobacco in India, which are found more competitive than that of
the prices of Brazil, USA, Zimbabwe.
Fig2. 1-Dried tobacco

7. 7
VST Industries Ltd. is a public conglomerate company headquartered in Hyderabad, India.
The company manufactures and distributes cigarettes. Its Market Capitalization is 844.49,
PE Value: 15.70 and Dividend: 5.49.The company has its registered office in Hyderabad.
It started off as the formerly Vazir Sultan Tobacco Company, commonly known as VST
and shares collaboration with British American Tobacco group of the United Kingdom. It
is fully independent and registered as VST Industries Ltd in the year 1983.
Vazir Sultan Tobacco was started by Mr. Late Vazir Sultan in (1916 -1923). During the
rule of Mir Osman Ali Khan in Hyderabad State the Vazir Sultan Tobacco Company
Limited was incorporated on 10 November 1930, under the Hyderabad Companies Act
No.IV of 1320 Fasli and now governed under the Indian Companies Act 1956. The name
of the Company was subsequently changed to VST Industries Limited on 30 April 1983.
The VST has its registered office at Azamabad, Hyderabad, India
Vazir Sultan Tobacco Company is more commonly known as VST. The company
manufactures and distributes cigarettes under the brands names of Charms, Charminar,
Gold, Dark Knight, Knights, and Kingston Etc. The company is headquartered in
Hyderabad, India. It is 3rd largest cigarette manufacturing company in India. The company
declared a dividend of 450% in 2011 making it one of the highest dividend yielding stocks
in the Bombay Stock Exchange.
3 Review of Industry
Fig3. 1-VST logo

8. 8
4 Production Tree Diagram
Primary
Manufacturing
Department
Auto feed
Cigarette Production
Unit
Delphi-
Tobacco Recycling
Cigarette Packaging
Unit
Shipping Department
Retailers

9. 9

10. 10
5.1 Cigarette Manufacturing Units
Manufacturer Hauni-Decoufle
Model 3D-85
Origin French-Germany
Year 2008
Alternate name LOGA-4
Cigarette
production / min
8000/9000
Manufacturer Hauni-Decoufle
Model DX-85
Origin French-Germany
Year 2010
Alternate name LOGA-5
Cigarette
production / min
8000/9000
Manufacturer Molins
Model 6180
Origin Germany
Year 2009
Alternate name MAX 2
Cigarette
production / min
4000/5000
Manufacturer Molmax
Model 6013
Origin Germany
Year 2004
Alternate name MAX 1
Cigarette
production / min
4500/5000
Manufacturer G.D
Model 121A
Origin Italy
Year 2007
Alternate name 121
Cigarette
production / min
9500/12000
5 Secondary Manufacturing Department Details

11. 11
5.2 Cigarette Packaging Units
Manufacturer G.D
Origin Italy
Model X-2
Year 2001
Alternate Name GD-1
Packs produced / min 320
Manufacturer G.D
Origin Italy
Model X-2
Year 2002
Alternate Name GD-3
Packs produced / min 320
Manufacturer G.D
Origin Italy
Model X-2
Year 2001
Alternate Name GD-2
Packs produced / min 300
Manufacturer G.D
Origin Italy
Model X-2
Year 2007
Alternate Name GD-4
Packs produced / min 300
Manufacturer G.D
Origin Italy
Model X-2
Year 2005
Alternate Name GD-5
Packs produced / min 300
Manufacturer G.D
Origin Italy
Model X-2
Year 2003
Alternate Name GD-8
Packs produced / min 300
Manufacturer G.D
Origin Italy
Model C800
Year 2012
Alternate Name GD-6
Packs produced / min 600
Manufacturer G.D
Origin Italy
Model X-2
Year 2011
Alternate Name GD-9
Packs produced / min 320
Manufacturer G.D
Origin Italy
Model X-2
Year 2010
Alternate Name GD-7
Packs produced / min 300
Manufacturer G.D
Origin Italy
Model X-2
Year 2010
Alternate Name GD-10
Packs produced / min 300

12. 12
6.1 HOPPER
A cigarette starts its life cycle from Primary Manufacturing Department, where the tobacco
is cured and dried. The raw tobacco consists of
1. Stem
2. Leaf
Which has to be first separated before packing into a cigarette. This is achieved in Suction
unit of Cigarette manufacturing unit. The raw material is bought in to auto feed of the unit.
This is achieved by automatic suction pump which is centralized. The valve is triggered by
an electronic sensor which measures the level of tobacco in the hopper and fills the brink
up. The tobacco then falls on the lower chamber of the tower which is then picked up by
the spiked drum. It then places in to a slow moving belt which conveyers it to jimmy door.
6 Components of the unit
Fig 6. 2-Hopper
Fig 6. 1-Spiker drum

13. 13
6.2 THE JIMMY DOOR:
It is a pocketed door which houses the section of collection of stem, which is filtered out
and leaf proceeded forward for production. It contains a suction in the upper nylon belt
also called as fast carrier belt. This is specially made conveyor belt of 10 mm thickness
which is perforated for suction and it usually interchangeable. A suction pressure of 9.2
KPa is created by the squirrel cage electric motor affixed in the rear vicinity of the unit.
This pressure is so set up that it lifts up only leaf component of tobacco leaving behind the
stem part. Nylon belt under suction pushes it to the pocket disks.
The section has houses 1 main pulley operated by pulley mounted on door and 8-10 idler
pulleys for providing a proper tension.
6.3 POCKET ANDTRIMMING DISK:
After separation the nylon belt carries the tobacco to the pocket disk. This disks have a
small 4 pocket and so the name. The pocket is half on one and rest on other, which in
motion forms pocket. It is customary for a smoker to have his cigarette of slightly higher
filled at the front edge, which counteracts the frustration of early cigarette ash descend. To
encounter that the plain cutter disk followed by pocket disk is employed. The former one
separates any come over stem while the later one accumulates a bit higher tobacco to be
Fig 6. 3-Jimmy door
Fig 6. 5-Nylon belt chamber
Fig 6. 8-Disks assembly

14. 14
formed the tip of cigarette. This pocket hold the tobacco till the rod goes from front to end.
Pocket disk rotates at 2650 rpm while trimming at 1050.
6.4 ROD BOBBIN ASSEMBLY
The bobbin provides the thin paper of the cigarette. This special paper is made under stick
supervision has most of the time are imported details of supplier has kept confidential. The
bobbin assembly has two free spindle. This dual bobbin arrangement provides
uninterrupted supply of cigarette paper. At the end of spindle at an appropriate diameter a
fill sensor, which senses as soon as one spindle begins to runs out of bobbin. An extension
of the fresh bobbin is attached to the knife mechanism. The end of the new bobbin paper
is stuck on the knife with a tape. As soon as the sensor sends the run out signal. This knife
strikes the existing paper such that the new bobbin paper is attached to the flowing paper
inflow. The exhausted bobbin is replaced and an extended end of the replaced paper is
stuck on to the knife ready for next replacement. During this change over of cigarette paper
Fig 6. 6-Trimmin disk
Fig 6. 7-Pocket Disk
Fig 6. 9-Rod bobbin

15. 15
machine speed (8000 cpm) is automatically brought down to half (4000 cpm). Also an
alarm goes on during this change over to alert the operator to change the bobbin.
The spindle is free to rotate so to control the speed, auto breaks on the spindle drums is
employed. These get activated in response to level over which the paper runs. When the
paper starts running at higher speed it pushes down the bell crank level, the other side to
which is the brake pad which is pressed on the external spindle drum. Thereby reducing
the speed, as soon as the speed reduced the force of bell crank reduces and breaks are
released. This breaking and releasing actions engages so frequently such that it ends up
providing the same speed of paper to machine on which the unit is set to. The unit is spun
by the motor at the rear of the spindle mounting plate while the bobbin change over. The
bobbins are keyed to the spindle by a push and lock mechanism which is computer
controlled. In the event of removal the locks are pushed in by the computer and on the
pressing of the button on near the knife area releases those locks outwards thus holding the
bobbin to spindle. Bobbin is supplied in bulk from Asian countries. They are 6km long
with 26.5mm width. Each weighing 3.975 Kgs.
6.5 SHOE AND GLUE SECTION
Tobacco after separation is put on to the flat running cigarette paper by the shoe. The paper
undergoes though a die with progressively closes to form a circular envelope encapsulating
the tobacco to form a cigarette. It has in line glue section, an air blower section and a heater
section.
Fig 6. 10-Bobbin motor
Fig 6. 11-Glue section

16. 16
Fast moving tobacco falls on the dynamic paper rod. Tape is being moved at 100 rpm
pulley. At the start of the pathway its flat, which gradually is closed up by the progressive
continuous long narrow die. Before the total closer the upper lip of the paper gets glue resin
from the glue pump. Glue is pumped at pressure of 800mBar.This lip forms the overlap.
To make it dry a heater is incorporated between which heats the rod to 180 C. This
temperature is required because it has to transfer heat to very fast moving rod. Generally a
2mm overlap is kept.
This assembly envelops and sticks the cigarette rod.
For setting up the overlap width an adjusting nob is put into use. This is done to reduce or
increase the perimeter of the cigarette rod. In case of any defect or failure due to many
reasons the machine is stopped where breakage of rod is indispensable. The rod assembly
area is always cleaned so that it moves without tiny hindrances. A small air through a
nozzle is always directed towards the shoe in order that any steam is not entered into the
rod, the diameter and pressure being very small.
To stop the break rod from going into the cutting chamber an director is place in between,
which in event of stoppage moves up causing the rod to divert to bin, the tobacco of
which is again recycled for reuse.
Fig 6. 12-Heater section
Fig 6. 13-Overlap knob
Fig 6. 14-No go Fig 6. 15-Go

17. 17
The total rod assembly is 2m in length. It is kept uncovered for easy inspection.
6.6 CUT-OFF UNIT
This is where the continuous rod is sliced. The rod is set to cut the rod into 106 mm division
each the tolerance being kept +0.06 to -0.06 mm.
There are two methods by which the rod is cut.
a) Ledger
b) Inclined Drum
The first being the undated method inclined drum is being explained. The drum is powered
by the separate motor. On the outer casing of drum, two wafer knifes are placed which
slices the rod. The runway are grooved for the cutting so that there is no hindrance in the
motion of rods. The drum is placed inclined to a set angle so that the wafer knifes lie on
same line of drum but cut at distance of 106mm of the rod. This angle is achieved with a
huge trial and error method.
Fig 6. 16-Rod Conveyor
Fig 6. 17-Ledger

18. 18
It has humidity and density sensors attached to it, any discrepancy found with respect to
same will have the machine stopped at the very instance. The density depends on the type
of brand. It is usually around 257 g/cc.
6.7 SPIDER
Not present in the old model the spider drum is to lift the sliced rod and place in onto the
drum. Because the individual rods has to be picked up. It has 8 elliptical shaped arms with
suction on the pickers for lifting the rods. The arrangement is such that the arm at the same
orientation at the particular position. Suction is such that it exists only at the left three
positions. The arm picks the individual rods up and drops at the inlet drum. The length of
the pickers is 83mm each. This peculiar mechanism is achieved by cams. The boots are
always pointed
downwards.
Fig 6. 18-Inclined cylinder
Fig 6. 19-Sensors
Fig 6. 20-Spider
Fig 6. 21-Boot

19. 19
6.8 CIG LENGTH CUTTING DRUM
This is where the 106 mm rod is cut into 53 and 53 mm lengths. The round cutter is
employed for this cutting. The abrasive disk in kept in contact with the lower knife which
frequently sharpens the cutter. The adjustment of the contact force on cutter is done by the
hex nut. The grinding wheel and cutter both are replaced when worn out of service. The
cutter wheel is of 95 mm diameter and is made up of stainless steel. And the grinding wheel
is of 4 inch in diameter and 2mm in thickness.
Fig 6. 22-Round Cutter
Fig 6. 23-Cig length cutting drum

20. 20
6.9 SEPERATING DRUM
This is the heaviest drum of all due to its mechanism. It has two halves which take the cut
rods and separate them by 22 mm for the placement of filter. This is done by the two
attached cylinders on the drums which gets separated at the end of half a revolutions. It has
the big counter drum to support the dynamic movement of drums.
A 66mm filter rod of diameter 8mm is separated in three equal division by two round knifes
in the Filter stagnation chamber. The divided filters are then passed on to the grading drum.
This grading drum passes the filters to the Filter Alignment Drum.
6.10 FILTER ALIGNMENT DRUM
Its purpose is to separate the three filters by a distance. It’s of diameter 14.5 cm. Rotates
anticlockwise. This drum runs only when the rod is inserted. The filter are placed into three
sections namely inner, central and outer groves. These groves are not in line
Fig 6. 24-Separating drum
Fig 6. 25-Filter Alignment drum

21. 21
6.11 PLUG ALLIGNMENT DRUM
It aligns the three plugs into a line for fixing between the two rods. It too has three sections.
The non-aligned groves of the filter alignment drum places the three plugs into three
sections of plug alignment drums. The central one remains in central position. While the
end one are sucked to the center by the central suction hole on the groves. By this all the
plugs lie in the same circumferential lines ready to be joined with the rods. The central
groves are open in the end while the inner and outer are closed at the ends to provide
efficient suction. Each is of 11mm length to support the plugs. Plugs are received at 45
degree while they leave at 270 degree angle to plug guiding drum. It is of 15 cm diameter.
6.12 PLUG GUIDING DRUM & CIG-PLUG ALIGNMENT DRUM
It receives the two separated rods from the Separating drum and the plug from the Plug
Guiding Drum on it. It also has the guide plates for the plug from the guiding drum on to
the alignment drum. It has 20 rows on to which 15 are given the suction. This drum is
simply supported on to the two ends. It has the diameter of 19.5 cm and width of 18.5 cm.
Fig 6. 26-Plug alignment drum

22. 22
6.13 SWASH DRUM
It addition to regular drum it has the swash plate attached to both the ends. Swash plate has
a concentric plate that is held to the base/core plate by tension springs. When in motion,
swash plate expands due to centrifugal force. The main objective of the swash plate is to
squeeze the incoming cig+plug+cig elements to properly so as to avoid any gaps in the
assembly.
6.14 PENCIL PASTE ASSEMBLY
This unit has the PCT bobbin, Glue section and the tapered drum. The glue is applied only
to the ends of the PCT passed on to the rolling drum. PCT is of width 42 mm. For which a
10 mm overlap is on the rod while the rest is on the plug. The PCT has two spindles for
continuity of the process while run outs. The Pickering drum controls the speed of PCT
paper. The friction drums pulls the paper from the spindle The PCT glue section has a glue
holder which puts the exact amount of glue into the glue chamber which is controlled by a
level sensor. The flat section of 35mm at center and taper at ends such that it sticks to the
center portion.
Fig 6. 27- Swash drum
Fig 6. 28-PPA

23. 23
6.15 ROLLING DRUM
This is where the elements and PCT paper meets. It has 10 pins on each row. These pins
are provided so as to take up PCTpaper, which is then rolled up onto the cigarette at rolling
plate affixed at bottom. The rolling plate area has no suction which helps in rolling of PCT
around the elements. Ribs are provided to help achieve the proper roll. The suction is
directed by the sleeves. These sleeves doesn’t rotate the drum is placed on them by steel
ball bearing.
6.16 FINAL CUTTING DRUM
The final cut of Cig (52mm) +Plug (22mm) +Cig (52mm) into half is done here. A round
cutter with the grinding wheel is attached at the bottom of the cylinder to achieve the cut.
6.17 TURNING DRUM
The final cut divided the two final cigarettes. But these are head to head which to be packed
have to be in the same orientation. This is done in this drum by turning the inner row
cigarettes to the same as the outer.
Fig 6. 29-Rolling drum
Fig 6. 30-Turning drum

24. 24
6.18 INSPECTIONDRUM
It inspects each cigarette for through sensors. If loose ends or filter missing or less dense
cigarette are found, the sensor sends the signal to the sensor at rejection drum. It notes the
position of the defective cigarette and rejects by blowing air. The direction of air is so
adjusted it faintly disturbs the rest of the cigarette in the drums.
Fig 6. 31-Inspection drum
Fig 6. 32-LOGA unit

25. 25
The quality control of the production and packagin is very strict and falls to stern norms.
Quality check can be :
I. Brand
i. PCT
ii. Filter
a.220 PD
b.300 PD
II. PCT wavering
III. Rough Cutting
IV. Slant Cutting
V. Seam
VI. Body marks
VII. Black rings
VIII. Long and Short
IX. PCT Flaging
i. Improper
ii. Anchorage
X. Die smug
XI. Loose Ends
XII. Length Checks
XIII. Weight Checks
A cigarette R&D machine which basically measure almost all the above check, however
sometimes the naked eye inspection is also done on regular basis.
Company code is printed on each packet which is 4-5 digit number, which helps in
identfing the mistake done by the operator
X YYY ZZZZZZ
X= Shift
Y=Machine number
Z=Date
7 Quality Control

26. 26
8. Troubleshooting of unit
PCT Wandering Bobbin cross position
Improper glue adhesion
Defective Bobbin
Idler gum roller gets corroded
Remedies Clean Idler glue roller
Adjust T guide
Rough Cutting Blunt Knife
Corroded grinding wheel
Reduced diameter of knife
Glue on knife
Remedies Change Knife
Slant Cutting Ledger angle improper
Remedies Change ledger settings
Seam
Thick/Thin
Seam less or more than 2mm
Improper holder knob setting
Remedies Adjust till achieved

27. 27
Black Rings Improper filter rod conjuction
Remedies Check the plug allignment drum
adjust swash plate
Black Rings Improper filter rod conjuction
Remedies Check the plug allignment drum
adjust swash plate
Long and Short Plug guide improper
Swash plant inaccuracy
Cig plug allignment drum ineffective
Ledger misallignment
Remedies Adjust T guide
Redo ledger settings

28. 28
As it was stated earlier that LOGA 4 and LOGA 5 were the production units in VST.
Both of the machines belonged to same manufacturer i.e. Hauni, however LOGA 5 was
purchased 2 years later than LOGA 4. Due recently the production of LOGA 5 has been
dropped down due to frequent machine repairs. Also machine had to run at 80%
maximum speed to decrease the frequency of problem.
The following is the Downtime analysis taken on the LOGA 5 during a 3 day survey
Average traysproducedperhour= 68
Total cigarettesproducedinthathour= 68 * 4200
= 0.285 M
Ideal Expectedcigarette production=0.45 M
Generationefficiency=63.47%
Nettime wastage = 14 min
Percentage time wastage =17 to 20 %
9 Comparison of LOGA 4 & LOGA 5 units
0
5
10
15
20
25
15-Jun
18-Jun
19-Jun
Chart 8. 1-Problem Occurrence of LOGA 5

29. 29
A through servicing was carried out on the unit which is didn’t solve the problem. It was
found that replacement of Roller Drum has yielded the positive result.
Conclusion on the result was reached by carrying out step by step inspection
 Sensors were tested for possible malfunction, by the sensor board. It was found
out that the display output was faulty. This didn’t solve the manufacturing
problem though.
 The rod conveyor belt was changed along with the nylon belt to ensure if the rod
has any conflicting hindrances between the run. The belts seems to work fine
though.
 The suction pressure in the hopper was changed but it was found to be of negative
impact on the unit
 Brands with no requirement of garniture was inserted, so the garniture assembly
was put off.
 All the drums were rigorously cleaned
 The manual control stopped working, which was replaced
 Rolling drum pins were found to be missing which indicted possible rough
contact with the guiding plate, the plate was adjusted and the rolling drum was
replaced completely
Long run achieved (mins):
I. 55
II. 45
III. 52
IV. 53.5
Average long run =51 minutes which was considerable increases before the troubleshoot
Machine was now run at 7800 cpm
To compare the efficiency down time analysis comparison of a perfectly working LOGA
4 was done as follows.

30. 30
Chart 8. 2-Problem Occurrence of LOGA 4
0
1
2
3
4
5
6
7
8
9
Week 1
Week 2

31. 31
10. CONCLUSION
Hence a brief introduction on the components of the cigarette production unit was
studied and analyzed. With the brief information an attempt to solve a problem statement
“Increasing productivity of LOGA 5” was undertaken. The steps taken were proved to be
effective in their course of action. Further deep study into the machinery would aim to
remove all the existing problems. During the course of internship, basic knowledge of
management skills were learned. Also the importance of finely structured work and work
distribution was felt.

32. 32
11. References
[1] “Facts and Figure” Hauni, The Körber Foundation
[2] “Economic History Of Tobacco Production In India” Professor S K Goyal,
Institute for Studies in Industrial Development, New Delhi, June 2004
[3] Annual Survey of Industries, 1997–98, Central Statistical Organization, New
Delhi.
[4] Tobacco Board, Ministry of Commerce, Government of India. The Tobacco Atlas
(3rd Edition). “Global cigarette consumption.” p. 33.
www.cancer.org/downloads/AA/TobaccoAtlas3Revised/TA3_Chapter_7.pdf.
[5] TOBACCO Production Guide”, Kentucky & Tennessee, 2011-2012
[6] Description of the tobacco market, manufacturing of cigarettes and the market of
related non-tobacco products” European commission, SWD(2012) 453 final
[7] Additives, Cigarette Design AND Tobacco Product Regulation, Kobe, Japan ,28
June-2 July 2006
[8] Tobacco Products Processing Detailed Study” U.S. Environmental Protection
Agency Engineering and Analysis Division, Washington, D.C, November 2006