Six Sigma Approach for Industrial Quality Improvement and Defect EliminationMd. Injamamul Haque
This slide contains information about a case study of six sigma methodology, DMAIC approach. How to do an analysis, find the root cause and area to be improved through DMAIC methodology, just covered in this slide.
Six Sigma Approach for Industrial Quality Improvement and Defect EliminationMd. Injamamul Haque
This slide contains information about a case study of six sigma methodology, DMAIC approach. How to do an analysis, find the root cause and area to be improved through DMAIC methodology, just covered in this slide.
Celcon® m90 Material Certificates of Quick Connect FittingsAquafittings
Wisnex Aqua Fittings Co., Ltd, is a professional manufacturer of the plastic push fittings. All the materials are food rank, certificated by NSF, FDA, NSF etc, nontoxic, suitable for all kinds of drinking water systems.
Final results of the beams made of glued laminated timber (glulam) in the EU CELLUWOOD Project. These results were presented by AIDIMA at the CELLUWOOD Final Workshop on 4th September 2014.
During the workshop comprehensive outcomes of the CELLUWOOD project were presented and the future exploitation of the project results was discussed. The project outcomes were presented to the industry stakeholders and the research community. Some valuable feedback on project developed products and technology were obtained by the external workshop participants. The useful contacts were established with potential resin manufacture with an interest for further commercial exploitation of the CELLUWOOD technology, in particular lignin-based and nanocellulose-based gluing systems.
CELLUWOOD ( “Laminated Strong Eco-Material for Building Construction Made of Cellulose-Strengthened Wood - Final Outcomes”) was a four years EU project, funded under the Eco Innovation research initiative. The project aims to develop a new range of structural elements made of wood by introducing innovative production elements and includes the use of cellulose instead of petroleum-based glue in the lamination of the timber products. The main results will be the strong eco-beams and eco-columns and their most sustainable manufacturing technologies, in addition to significant environmental and cost benefits of the innovation. These are achieved by the introduction of the (new) technologies from other sectors (e.g. cellulose velvet, biocomposite reinforcement and bio-resin) for innovative uses in the defect removal and repairing, facilitating innovation in the use of nanocellulose and bio-resin technologies in timber reengineering, and the development, testing and demonstration of the new products.
The CELLUWOOD products include strong glulam Eco-beams and columns manufactured by using bio-based lignin resins and nanocellulose enhanced glue systems. Both innovative building products provide significant environmental benefits.
Coordinator and responsible of the project at AIDIMA: Miguel Ángel Abián
In the case of AIDIMA, this project is co-funded by IVACE (Instituto Valenciano de Competitividad Empresarial) and by the European Regional Development Fund (ERDF).
Celcon® m90 Material Certificates of Quick Connect FittingsAquafittings
Wisnex Aqua Fittings Co., Ltd, is a professional manufacturer of the plastic push fittings. All the materials are food rank, certificated by NSF, FDA, NSF etc, nontoxic, suitable for all kinds of drinking water systems.
Final results of the beams made of glued laminated timber (glulam) in the EU CELLUWOOD Project. These results were presented by AIDIMA at the CELLUWOOD Final Workshop on 4th September 2014.
During the workshop comprehensive outcomes of the CELLUWOOD project were presented and the future exploitation of the project results was discussed. The project outcomes were presented to the industry stakeholders and the research community. Some valuable feedback on project developed products and technology were obtained by the external workshop participants. The useful contacts were established with potential resin manufacture with an interest for further commercial exploitation of the CELLUWOOD technology, in particular lignin-based and nanocellulose-based gluing systems.
CELLUWOOD ( “Laminated Strong Eco-Material for Building Construction Made of Cellulose-Strengthened Wood - Final Outcomes”) was a four years EU project, funded under the Eco Innovation research initiative. The project aims to develop a new range of structural elements made of wood by introducing innovative production elements and includes the use of cellulose instead of petroleum-based glue in the lamination of the timber products. The main results will be the strong eco-beams and eco-columns and their most sustainable manufacturing technologies, in addition to significant environmental and cost benefits of the innovation. These are achieved by the introduction of the (new) technologies from other sectors (e.g. cellulose velvet, biocomposite reinforcement and bio-resin) for innovative uses in the defect removal and repairing, facilitating innovation in the use of nanocellulose and bio-resin technologies in timber reengineering, and the development, testing and demonstration of the new products.
The CELLUWOOD products include strong glulam Eco-beams and columns manufactured by using bio-based lignin resins and nanocellulose enhanced glue systems. Both innovative building products provide significant environmental benefits.
Coordinator and responsible of the project at AIDIMA: Miguel Ángel Abián
In the case of AIDIMA, this project is co-funded by IVACE (Instituto Valenciano de Competitividad Empresarial) and by the European Regional Development Fund (ERDF).
Indian Dental Academy: will be one of the most relevant and exciting training center with best faculty and flexible training programs for dental professionals who wish to advance in their dental practice,Offers certified courses in Dental implants,Orthodontics,Endodontics,Cosmetic Dentistry, Prosthetic Dentistry, Periodontics and General Dentistry.
Machinability Study Of 3D printed Ti-6Al-4VSajjadAhmad214
The objective of the research is to study the machinability of 3D printed materials and provide fundamental insight into the material removal mechanism. Specifically, this study aims to investigate how the porosity in 3D printed materials can affect its machinability in terms of cutting force, surface quality, and tool wear. It is believed that machining response during the subtractive cycle of the process could be used to provide feedback on printing quality for the upcoming addictive cycle to improve the quality of the parts. This could be achieved by the machinability studies of 3D printed parts with varying degrees of defects such as porosity to obtain a one-to-one correlation between the machining response, e.g., cutting forces and vibrations, and the defect concentration e,g, porosity.
The present study is limited to the most extensively used Titanium alloy-6Al-4V which is 3D printed by the Selective Laser Sintering process. Micro-end milling is used as the machining process to conduct the machining experiments.
Cam gear process improvement shifter assembly manufacturingQuan Nguyen
Design and manufacture shifter assemblies
Implement Six Sigma and Lean to address quality issues
Use expenses only where necessary
Save company over $50,000/year in key areas of production
The intent of this study is to evaluate three step stencil technologies and measure their effectiveness in applying different volumes of paste on the same board during the printing process.
Norton Vitrium3 combines a patent-pending bond technology with abrasive grain developed by Saint-Gobain Abrasives’ R&D division. The new bond features exclusive chemistry that promotes grain adhesion and allows for increased porosity resulting in greater product versatility across a number of applications.
2. UNDER THE SUPERVISION OF
MR. KAPIL SINGH
PRODUCTION INCHARGE
CARTON LINE
ITC (PPD) HARIDWAR
SUMMER TRAINING PROJECT ON
WASTAGE & DOWNTIME DUE TO LAMINATION MACHINE
ITC,HARIDWAR
PACKAGING AND PRINTING DIVISION
SUBMITTED BY
Shailesh Chauhan
B.Tech (Printing Technology)
Guru Jambheshwar University of
Science & Technology, Hisar (Haryana)
email: shaileshchauhan231@gmail.com
UNDER THE GUIDENCE OF
MR. VIPUL ARORA
PRODUCTION MANAGER
ITC
5. Lotus 102 SFITC
side lay problem
12%
Glue dam setting
6%
Infeed
12%
Outfeed
9%
Piling
2%
Paper arrangement from
Storage area
3%
Knife error
3%
Feeder Problem
3%
Sheet alignment problem
3%
Sheet block
1%
Cleaning
2%
Maintainance
19%
Film Reel Change
6%
Film Setting
0%
Waiting for M/c part
9%
Misc.
8%
Double sheet
1%
Pile
position
setting
1%
Halt(min)
6. ITC
side lay problem
35%
Glue dam setting
14%Knife error
10%
Feeder Problem
2%
Sheet alignment problem
8%
Sheet block
6%
Cleaning
0%
Film Reel Change
11%
Misc.
2%
Start
10%
Double sheet
2%
Waste
7. Sunflower 102 PURITC
side lay problem
0%
Glue dam setting
2%
Infeed
13%
Outfeed
7%
Piling
6%
Paper arrangement from
Storage area
9%
Knife error
4%
Feeder Problem
11%
Sheet alignment problem
10%
Sheet block
1%
Cleaning
21%
Film Reel Change
10%
Film Setting
2%
Double sheet
1%
Pile position setting
1%
m/c trip
2% Halt(min)
8. ITC side lay problem
1%
Glue dam setting
10%
Knife error
21%
Feeder Problem
11%
Sheet alignment problem
18%
Sheet block
8%
Cleaning
3%
Film Reel
Change
6%
Film Setting
2%
Misc.
1%
Start
15%
Double sheet
2%
Pile position setting
1%
m/c trip
1% Waste
9. Main Problems In M/cITC
Side Lay (vacuum problem)
Feeder (forwarding sucker problem)
Glue dam (wiper issue & leakage problem)
Glue temp control problem
Clamps of Transfer Roller are damaged
Lotus 102 SF
10. Main Problems In M/cITC
Double Sheet sensor problem
Glue dam (wiper issue & leakage problem)
Clamps of Transfer Roller are damaged
Knife Problem (blocks are not aligned properly)
Knife cutting sensors not working properly.
Side lay reading Calibration is not correct.
Sunflower 102 PUR
11. Comparison b/w Sunflower & LotusITC
Sunflower 102 PURLotus 102 SF
0.48739607 %
19.7 min
51.86
Average waste percentage
Average Stoppage (Time/h)
Average speed(meter/min)
1.085707493 %
28.7 min
51.134
12. Comparison b/w Sunflower & LotusITC
Chart of Daily Downtime of Lotus 102 SF
0
50
100
150
200
250
300
350
400
450
Day 1 Day 2 Day 3 Day 4 Day 5
Machine Runtime(min)
Stop Time(min)
13. Comparison b/w Sunflower & LotusITC
Chart of Daily Downtime of Sunflower 102 PUR
0
50
100
150
200
250
300
350
400
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7
Machine Runtime(min)
Stop Time(min)
17. Wastage ResultITC
Total avg. waste percentage: 8.65%. (According to monthly samvad)
Target : less than 5%.
Wastage due to lamination: 3.36%.
Lamination share in waste: 29%.
18. Quality Related Problem
In Laminated Sheet
ITC
Sticky sheets- increases the chance of delamination and reduces machine
runnability
Wrinkles
Delamination
Patchy
Unlaminated Sheets
Orange Peel Effect
19. Causes & Solutions For
Quality Related Problems
ITC
Sticky sheets:
Cause 1: Film Protrudes over the sheet
Film comes out from sides or back of sheet
Reasons:
1) Sheet alignment is wrong
2) Side lay not working properly.
3) Variation in sheet length.(I observed 901mm length of sheet(Sidharth papers) in OC
Blue 750ml job,but required length is 903mm so film came out from back end).
4) Knife blocks must be aligned parallel to sheet.
Solutions:
1) Proper check for Sheet Alignment & cross sheet and if observed then corrected
immediately from feeder.
2) Enter the sheet length 1mm shorter than the actual sheet length.
3) Regular check at side lay.
20. Causes & Solutions For
Quality Related Problems
ITC
Sticky sheets:
Cause 1: Film Protrudes over the sheet
Film comes out from back of sheet (Knife Problem)
Film comes out
Film cut in from edge
21. Causes & Solutions For
Quality Related Problems
ITC
Sticky sheets:
Cause 2: Sides Escape of Adhesive
Adhesives comes out from sides of sheet in the pile of laminated sheets.
Reasons:
1) Glue solidify at the egdes of the transfer roller and hence increases the glue
application area.(Hrlx 500g Cmalt was run on machine with this problem,
required Transfer roller length=771mm but solidified glue is on egdes increases 3
mm length.)
2) Glue gsm is more than 3.8.
3) Improper Glue dam setting(wiper).
4) Leakage for glue dams.
5) Film and transfer roller does not have 5mm difference in length.
22. Causes & Solutions For
Quality Related Problems
ITC
Sticky sheets:
Glue solidify at the egdes of the transfer roller Glue dam Leakage
New
Old
Rubbed off portion
23. Causes & Solutions For
Quality Related Problems
ITC
Solutions:
1) Glue gsm must be b/w 3.0 to 3.8.
2) Transfer roller edges must be properly cleaned.
3) Increase the lateral adhesive freezone by setting wiper and glue dam properly
according to the keyline.
4) Regular checking of the freezones from both sides(minimum 1.5mm gap each side).
5) Smaller height of pallets after lamnation.
24. Causes & Solutions For
Quality Related Problems
ITC
Wrinkle:
Type 1: In direction of Process
Wrinkles occur in the direction of running m/c.
Reason 1: Excessive tension of film.
Reason 2: Excessive pressure b/w Laminating roller and counter roller.
Reason 3: Non parallel tension rollers.
Reason 4: Unsuitable film
Solutions:
1) Tension must be controlled b/w 5.5 kg to 8 kg. With reducing diameter of the film reel
roll the breaking system must be reduced.(For 350mm diameter-30% breaking system
& for below 150mm dia-10% breakage should be used.)
2) Parallelism of tension roller must be check after fil infeed.
25. Causes & Solutions For
Quality Related Problems
ITC
Solutions:
3) Pressure Control.
Observations Regarding
Pressures of different
rollers .
26. Causes & Solutions For
Quality Related Problems
ITC
• The Standard Pressure is .3 mpa.
• P3 can be achieved to .3 mpa by changing the clamp holders and correcting the
clamps of the Transfer roller to perfect 20.2mm square sides.
• P2 of lotus M/c can be operated at .3 bar.(New Film Pressure Roller) But
Sunflower has old film pressure roller so it must be operated b/w .35 to .42 mpa.
• P4 must be operated from .3 to .45 mpa.
Type 2:Perpendicular to Process Direction
Reason: Speed difference of laminating and counter pressure roller may be too high.
Solution: Increase the speed of counter pressure roller.
27. Causes & Solutions For
Quality Related Problems
ITC
Delamination:
Causes:
1)Adhesive free zone gets out from keyline.
2) Curing time given is less than 6 hrs.
3) Solidified glue dirt at glue dam rollers cause less glue application on the film hence
cause delamination.
Solutions:
1)Regular check of freezones with keyline.
2) Curing time given must be more than 8 hours.
3) Proper cleaning after m/c stop must be done.
28. Causes & Solutions For
Quality Related Problems
ITC
Patchy:
Causes:
1) Patterned Transfer roller.(Dried glue on transfer roller.)
2) Glue solidified at edges of film pressure roller.(Proper pressure on film not
applied).
3) Less pressure applied on transfer roller (due to damaged clamp holders).
4) Uneven Rotational motion of transfer roller due to damaged clamps and clamp
holders.
5) Dirty(due to solidified glue) glue Rollers.
Solutions:
1)Proper cleaning of glue transfer rollers(glue applicator roller)
2) Cleaning of edges of film pressure roller.
3) Pressure of transfer roller and film pressure roller must be from .3 to .4.
4) Uneven or patterned transfer rollers must be grinded before use.
29. Causes & Solutions For
Quality Related Problems
ITC
Unlaminated Sheets:
Causes:
1) Double sheet detector not working properly.
2) Board width variation is more than 2mm.
Solutions:
1)Proper setting of double sheet sensor
2) Board pallet having width variation more than 2mm must be removed and reported
to the vendor.
Orange Peel Effect:
Causes:
1) Glue more than 4.0 gsm.
Solutions: Glue gsm must be controlled b/w 3.0-3.8.
30. Suggestions…ITC
Standard Tags must be made for Transfer Rollers which
includes :
Roller Diameter-which can be entered in the system and hence proper
pressure of transfer roller must be controlled.(Standard roller
daimeter=110 mm)
Length
Job In which it is used.
31. Suggestions…ITC
Steel Wipers must
be used:
Produces sharp freezones at
the edges.
Its life & efficiency of
wiping glue is more than
the Plastic glue wipers.
