scarp

1. 2017.04.20

2. 0.47
0.57
0.67
0.40
0.49
0.40 0.40
0.85
0.62
0.74
0.67
0.72
0.67
0.63 0.61
0.70 0.70
0.64
0.71
0.88
0.40 0.40 0.40
-
0.20
0.40
0.60
0.80
1.00
1.20
YTD 14/15 YTD 15/16 YEAR 16/172 YEAR 15/16 YEAR 16/17 YEAR 17/18
TOTAL FABRIC SCRAP –MONTHLY TREND

3. Fabric scrap Analysis
Calendar YTD 15-16 Target April May June July August Sep Oct Nov Dec Jan Feb Mar YTD
joint 0.04 0.028 0.036 0.039 0.036 0.039 0.046 0.04
0.039
0.049 0.050 0.045 0.034 0.045
Over pressing 0.05 0.035 0.044 0.102 0.063 0.054 0.045 0.029 0.029 0.034 0 .059 0.043 0.032 0.069
Bare patches 0.04 0.028 0.062 0.079 0.05 0.033 0.031 0.039 0.031 0.042 0 .054 0.031 0.029 0.037
Bad Edges 0.03 0.021 0.014 0.033 0.018 0.019 0.052 0.034 0.023 0.031 0.047 0.021 0.028 0.047
Lab 0.02 0.014 0.025 0.023 0.025 0.025 0.029 0.025 0.022 0.031 0.029 0.027 0.027 0.040
Total 0.18 0.13 0.181 0.276 0.192 0.17 0.214 0.171 0.156 0.186 0.247 0.168 0.150
Sq/Bias
Angle 0.08 0.056 0.122 0.112 0.103 0.106 0.13 0.119 0.121 0.148 0.1306 0.115 0.120 0.130
ply wrinkle 0.08 0.056 0.064 0.065 0.049 0.077 0.104 0.078 0.067 0.066 0.078 0.055 0.047 0.071
Sq.wrinkle 0.14 0.098 0.176 0.194 0.154 0.198 0.129 0.13 0.127 0.159 0.130 0.118 0.163 0.147
MD and Others 0.054
Total 0.3 0.21 0.362 0.371 0.306 0.381 0.373 0.34 0.318 0.372 0.349 0.288 0.329
Assembly
Ply pieces 0.04 .0.028 0.042 0.043 0.035 0.039 0.047 0.042 0.026 0.028 0.040 0.045 0.056 0.043
Chafer 0.01 0.007 0.01 0.011 0.011 0.017 0.014 0.013 0.007 0.010 0.015 0.012 0.015 0.012
flipper 0 0.001 0.004 0 0.007 0.002 0.003 0.005 0.002 0.004 0.009 0.007 0.009 0.003
Breaker 0.01 0.007 0.008 0.009 0.01 0.009 0.012 0.011 0.006 0.010 0.011 0.006 0.022 0.016
Total 0.06 0.042 0.064 0.063 0.063 0.067 0.083 0.071 0.038 0.051 0.077 0.071 0.099
Others 0.37 0.020 0.044 0.000 0.029 0.024 0.147
M/defect&
others 0.03 0.02 0.02 0.03 0.019 0.105 0.011 0.069 0.047 0.070 0.081 0.102 0.021
Total 0.57 0.4 0.62 0.74 0.67 0.72 0.67 0.63 0.61 0.70 0.75 0.64 0.71 0.88

4. Fabric scrap Analysis – Section B
Calendar YTD 15-16 Target April May June July August Sep Oct Nov Dec Jan Feb Mar YTD
Sq/Bias
Angle 0.08 0.056 0.122 0.112 0.103 0.106 0.13 0.119 0.121 0.148 0.1306 0.115 0.120 0.130
ply wrinkle 0.08 0.056 0.064 0.065 0.049 0.077 0.104 0.078 0.067 0.066 0.078 0.055 0.047 0.071
Sq.wrinkle 0.14 0.098 0.176 0.194 0.154 0.198 0.129 0.13 0.127 0.159 0.130 0.118 0.163 0.146
MD & Operator
mistake 0.054
Total 0.3 0.21 0.362 0.371 0.306 0.381 0.373 0.34 0.318 0.372 0.349 0.288 0.329 0.401
Assembly
Ply pieces 0.04 .0.028 0.042 0.043 0.035 0.039 0.047 0.042 0.026 0.028 0.040 0.045 0.056 0.043
Chafer 0.01 0.007 0.01 0.011 0.011 0.017 0.014 0.013 0.007 0.010 0.015 0.012 0.015 0.012
flipper 0 0.001 0.004 0 0.007 0.002 0.003 0.005 0.002 0.004 0.009 0.007 0.0086 0.147
Breaker 0.01 0.007 0.008 0.009 0.01 0.009 0.012 0.011 0.006 0.010 0.011 0.006 0.022 0.016
Wet & Finish off 0.147
Total 0.06 0.042 0.064 0.063 0.063 0.067 0.083 0.071 0.038 0.051 0.077 0.071 0.099 0.221

5. Fabric scrap Analysis
Calendar YTD 15-16 Target April May June July August Sep Oct Nov Dec Jan Feb Mar YTD
Sq/Bias
Angle 450 473 495 333 444
ply wrinkle 150 270 231 121
Sq.wrinkle 575 451 507 457
Total 1175 1213 1237 911
Assembly
Ply pieces 125 139 194 161
Chafer 25 53 52 52
flipper 12.5 31 31 21
Breaker 12.5 38 27 62
Total 175 268 233 296
Others 8 124 52

6. Selection of problem-Defect wise Pareto Graph
0.147
0.043
0.016
0.012
0.003
67
86
93
99 100
0
10
20
30
40
50
60
70
80
90
100
0
0.05
0.1
0.15
0.2
Oldply&Finished
off
Plypieces
Breaker
Chafer
Flipper
Data Analysis

7. PROBLEM Root cause ACTION RES. TARGET
DATE
Accumulation of NCR rolls,
aging ply and finished off
ply
Gaps in FIFO ,
Discipline
Clearing of accumulation lot of 52 rolls
32 numbers clear
Clearing of all NCR roll
Samantha 2017.02.20
2017.02.24
Chafer and Breaker high
damage due to slittering
machine operator / TB
machine operators bad
practice
New operator create
high damage rate
Skill Development Training on new
operators – Sanjeewa
Samantha 2017.03.31
Chaper , Breaker and
flipper high % of waste
Slittering machine
rollers alignment and
vibration of the
cutters
2 shaft completed , machine
alignment and vibration is to be
repaired
Ramal 2016.10.23
2016.10.30
2016.11.06
2017.01.15
Breaker high % of waste Breaker high % of
waste due to current
practice of cutting
the breaker in to
pieces without using
as the bobbins
Elimination of using pieces &
converting to a bobbin usage
Samantha 2017.02.27
High % of PP waste Helper tare the plys
near the ply joint ,
then the operator
remove the
considerable amount
Helper training on not to tare the plys
near the joint and always try within
the ply joints
Udayanga 2017.02.20
Pending actions - Action Plan

8.  Flipper waste reduction

9.  Breaker waste reduction
Kaluthara Benchmark

10. Selection of problem-Defect wise Pareto Graph
0.146
0.130
0.071
0.054
0
10
20
30
40
50
60
70
80
90
100
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Sq.Wrinkle
Angle
PlyWrinkle
MD&OM
Data Analysis

11. PROBLEM Root cause ACTION RES. TARGET DATE
Squeegee and Ply
wrinkles due to
bobbin issues
Damage bobbins Repairing of 110 bobbins
PR raised for 100 nos
First 50 no’s receiving on 2017.02.27
Samantha 2016.11.20
2017.01.30
2017.03.15
Squeegee wrinkles
defects high
Implementation of data collection of
machine wise , shift wise , and the type
of the wrinkle
Samantha 2017.03.16
Bias cutter table numbers recording on
the transport card to monitor the table
conditions
Samantha 2017.02.15
Wrinkle not
removing with
existing machine
No spiral roll and
tension
Placing of spiral roll to the liner re roller
machine
Ramal
Wrinkle
generation due to
the spiral roll of
the 2 roller
calendar
Spiral roller creating the
issues.
Removal of the spiral roll Sanjeewa
Ply wrinkle
generation
Let off area design issue
of the 2 roller calendar
Removal of the existing practice and
fabricating the let off area as the radial
Sanjeewa
Pending actions - Action Plan