QIP Squeegee wrinkles

1. Project : Reduction of Fabric scrap
Pain Area : Squeegee wrinkles formation at
Squeegee calendar/ Bias cutters / TB
Location : CKITL PLANT
Plan Actual
Start May 2017 – W1
May 2017 – W2
End July 2017 – W4

2. CEAT
SRI
LANK
A
Prabala
TEAM NAME
(Strong)

3. OUR TEAM
Team facilitator : Upul Chandana
Team leader : Samantha Priyadarshana
Tem members : Vasantha Thirinagamage
Anjana Udayanga
Thusitha Dinesh
Ramal Perera
Anurahda Munasingha
Sanjeewa Samarasingha
Vijitha Aberathna

4. 1
2
3
4
5
6
7
No. Of meetings held - 06
Brain Storming / Voting
Sessions - 2
√ Present
x Absent
Group Members
Year 2017
May June July Aug
6 13 20 27 5 14 25 28 5 14 22 29
Upul Chandana
√ √ √ √ √ √ √
Samantha Priyadarshana √ √ √ √ √ √ √
Anjana Udayanga
√ √ √ √ √ √
Thushitha de alwis √ √ √ √ √
Ramal Jayawardhana √ √ √ √ √ √ √
Vasantha Thirinagamage √ √ √ √
Vijita Abeyarathana √ √ √ √
OUR ATTENDENCE AT
WEEKLY MEETING

5. Project Title Justification
Reduction of Fabric scrap in CKITL plant
Total scrap cost per 1 month Rs.1.32 MIO
Goal statement Project scope
Parameter
Current
Level
Goal / target Target date
Kelaniya Bias PlantTotal fabric
Scrap/Total Tyre
Ware house %
0.67 0.40
30th July
2017
Project Plan Team Members
Phase Start End Team Leader- Samantha Priyadarshana
Define May W1 May W2 Ramal Jayawardane
Current situation
/Observation
May W2 June W1 Vijitha Abeyarathana
Analysis May W2 June W4 Dinesha De Silva/ Anjana Udayanga
Counter measures June W1 July W2 Sanjeewa Samarathunga
Result check June W3 July W2 Vasantha Thiriniwagamage
Standardization July W2 July W4 Ramal Jayawardane
Conclusion / Future plan July W4 July W4 Kathika Anuradha
Project Charter
1

6. Step 1 –
Reason for improvement

7. Fabric Scrap
Avg/ Month
2.4 MT
Cost/Month
SLR
1.32 Million
Our Pain Area – High Fabric Scrap

8. Financial Effect of the Problem
Average Scrap kg for last months
= 2400 kg/month.
Avg. Cost (Rs/kg) = 550.00* 2400
Avg. Cost=1.32 Mil/ Month.
2

9. CEAT
SRI
LANK
A
OUR THEME
REDUCE FABRIC
SCRAP 0.40 %

10. BARE
PATCHES
PLY
WRINKLE
SQUEEGEE
WRINKLE
BAD EDGES
PLY PIECES
OVER
PRESSING
WHAT IS FABRIC SCRAP?

11. 01
SCRAP
GENERATING
AREAS

12. 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

13. 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 0.238
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 0.402
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 0.069
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

14. 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

15. Month wise Fabric scrap %
(Scrap qty/Curing Output)
Month
Nov
2016
Dec
2016
Jan
2017
Feb
2017
March
2017
Curing
Output (kg)
292,530 368,100 429,110 368,120 340,490
Scrap % 0.70 0.70 0.64 0.71 0.88
Step 2a. Observation- Understand the Current
situation
292,530
368,100
429,110
368,120 340,490
0.70% 0.70%
0.64%
0.71%
0.88%
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.60%
0.70%
0.80%
0.90%
1.00%
-
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
Nov-16 Dec-16 Jan-17 Feb-17 Mar-17
Curring Kg
Scrap %

16. Selection of problem-Defecwise Pareto Graph
0.15
0.11
0.08
0.07 0.07
0.04 0.04 0.03 0.02 0.01 0.01 0.02
0
10
20
30
40
50
60
70
80
90
100
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
SqueegeeWrinkles
AngleChange
OverPressing
BarePatches
Plywrinkles
PlyPieces
Joint
Badedges
LabTest
Chafer
Breaker
Others
Scrap%percalenderfabricproduction

17. Selection of problem-Defect wise Pareto Graph
– Month of March 2017
0.253
0.181
0.088
0.000
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

19. Gemba Observations-Bias Cutter
Cut ply off center winding due to misalignments of splicing tables.

20. Operating with less number of V belt causing Ply
Wrinkles ,

21. Carriage breaks not properly functioning

24. Gemba Observations-Finish off roll – 30 no

25. Wrinkle at the end & initial of Bias cut ply
Initial ply fold Misalignment of winder-01
Gemba Observations-2roll calender.

26. No proper Break system – wear and tear of the break

27. Feeding unit shafts are not straight at all

28. Visual indicators are not available at the panel board

29. Water leaking and no adequate water circulation

30. Ply pieces

31. Gemba Observations-Tyre Building.
Liner loose winding,ply pieces wound in & damaged bobbins.

32. Gemba Observations-Tyre Building.
Liner loose winding,ply pieces wound in & damaged bobbins.

33. Fabric misusage….

34. On the job training
Operator awareness programs

35. Culture & Mind set changing….

36. Facility Enhancement ..
PEEP , Home for Naphtha bottle

37. Awareness Through Display
Boards
Before
Present

38. 3. Analysis

41. 3. 1 Brainstorming

42. 4. Actions
Quick wins..

43. 5. Results check