This document describes a project to reduce fabric scrap from squeegee wrinkles at a tire plant in Sri Lanka. The team aims to reduce the scrap rate from 0.15% to 0.098% by July 30, 2017. Current sources of squeegee wrinkles were analyzed through gemba observations and brainstorming sessions. Key causes identified include misalignments at winding tables, operator skills, and maintenance issues. A cause-effect matrix was developed to validate the top causes through a why-why analysis.

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 – W1
End July 2017 – W4

2. 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

3. 1
2
3
4
5
6
7
No. Of meetings held - 07
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

4. Project Title Justification
Reduction of Fabric scrap due to squeegee wrinkles created
before and after Squeegee layer applied in CKITL plant
Total scrap cost per 1 month Rs. 0.4 MIO
Goal statement Project scope
Parameter
Current
Level
Goal / target Target date
Kelaniya Bias Plant, Bias cutters, Squeegee
Calendar, Tyre Building and Material handlingTotal fabric
Scrap/Total Tyre
Ware house %
0.15 0.098
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

5. Step 1 –
Reason for improvement

6. Fabric Scrap
Avg/ Month
0.7 MT
Cost/Month
SLR
0.4 Million
Our Pain Area – High Fabric Scrap due to squeegee wrinkles

7. Financial Effect of the Problem
Average Scrap kg for last months
= 700 kg/month.
Avg. Cost (Rs/kg) = 550.00* 700
Avg. Cost= 0.4 Mil/ Month.
2

8. CEAT
SRI
LANK
A
OUR THEME
REDUCE FABRIC due to
Squeegee Wrinkles
SCRAP 0.098 %

9. Step II Current Situation

10. 01
SCRAP
GENERATING
AREAS

11. 0.16
0.14
0.15
0.10
0.10 0.10 0.10 0.10
0.18
0.19
0.15
0.20
0.67
0.16
0.13 0.13 0.13
0.12
0.16
0.15
0.160
0.169
-
0.05
0.10
0.15
0.20
0.25
YTD 14/15 YTD 15/16 YEAR 16/172 YEAR 15/16 YEAR 16/17 YEAR 17/18
TOTAL FABRIC SCRAP –MONTHLY TREND

12. 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

13. 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 0.149
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

14. Selection of problem-Defect wise 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

15. Selection of problem-Defect wise Pareto Graph
0.253
0.181
0.088
0.000
0
10
20
30
40
50
60
70
80
90
100
0
0.1
0.2
0.3
0.4
0.5
Sq.Wrinkle
Angle
PlyWrinkle
MD&OM
Data Analysis

17. Step II : Current Situation
• Specific Problem Statement
– Reduction of Squeegee wrinkles generated before and
after squeegee layer applied form 0.15 % to 0.098 %
by August 30.ple:

18. BRAINSTORMIN
G-01
Possible causes
112
BRAINSTORMIN
G-02
Possible causes
50
CAUSE EFFECT
MATRIX
Probable
causes 21
CAUSE
VALIDATION

19. Squeegee
Wrinkles
2 roller operator
skill level
High width ply does not
center at 2 roll
Bias cutter
compensat
or issues
Over aged
calender
fabric
ply manually
centering
Material
Man
Off center squeegee
Cut ply joint not equal
Cold compound feeding
Initial wrinkle in calendar winding
Open splicing joints
Ply roll unloading to the
ground in 2 roll
High number of ply unloading
due to drum change at TB
Liner pieces usage
wrinkle in calendar liner
Machine
Method
Let off shaft bending
issues at squeegee 2
roller
Servicer liner
damage at TB
Winding conveyer belt
speed variation in 2 roll
Damage liners - Bias
Off centre booking
Empty liner
dumping on ply
Operator
height
Wrong
squeegee apply
Bend bobbin
Bobbin
length
variation
Bobbins
end
damages
Poor cooling in two
roller Colling drums
No alignment in winding table
wrinkle formation at
Bias cutter
Not having proper liner
rewinding process
Cut ply rotating on
the ground
ply pieces
hanging on the
machine
Manual compound
feeding at 3 roller
Liner width
variation
Liner wrinkles
Not having a proper BD
and PM maintenance
unavailability of the
cotton liner in the end
BRAINSTORMING-02
Different
diameter of the
rubberized
bobbin
loose liners
Liner damage
ply wrinkles not remove
before the squeegee
applied
Initial ply folding at 2
roller
Not removing the
1st ply squeegee
layer

20. Cause Effect Matrix

21. Squeegee
Wrinkles
2 roller operator
skill level
Bias cutter
compensat
or issues
Over aged
calendar
fabric
Material
Man
Off center squeegee
Initial wrinkle in
calendar winding
Ply roll unloading to the
ground in 2 roll
High number of ply
unloading due to drum
change at TB
Machine
Method
Winding conveyer belt
speed variation in 2 roll
Damage liners - Bias
Wrong
squeegee apply
No alignment in winding table
wrinkle formation at
Bias cutter
Not having proper liner
rewinding processCut ply rotating on
the ground
ply pieces
hanging on the
machine
Liner width
variation
Liner wrinkles
unavailability of the
cotton liner in the end
BRAINSTORMING-02
ply wrinkles not remove
before the squeegee
applied
Initial ply folding at 2
roller
Not removing the
1st ply squeegee
layer

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

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

24. Carriage breaks not properly functioning

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

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

29. Feeding unit shafts are not straight at all

30. Visual indicators are not available at the panel board

31. Water leaking and no adequate water circulation

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

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

34. Fabric misusage….

35. Step III Analysis

36. Step III Analysis – Why –Why Example
Validated Cause WHY WHY WHY
2 Roller operator skill level High labour turnover Salary issue
No alignment in winding
table
Wear and tear of the
machine
No proper maintance
process
No proper PM
system
Wrinkle formation at Bias
cutter
Wear and tear of the
machine
No proper maintance
process
No proper PM
system
Poking not as per spec Lake of knowledge No training & no
visual Display
Training need and
schedule not
identified well

37. Step IV : Counter Measures
Root Causes Action Plan
(action to be
taken)
Target
Completion
Date
Responsibility
(person)
Status
Damage liners -
Bias
Repairing and
removing the badly
damage liners
2017.08.15 Dinesh
Liner width
variation
Liner
standardization
2017.08.15 Dinesh 78 roll
completed.
Initial ply folding
at 2 roller
Operator training 2017.08.15 Dinesh Operator training
going on
Bias cutter 1
compensator
issues
Correct the
compensators
2017.06.25 Ramal
unavalability of the
cotton liner in the
end
Sewing of end liners 2017.08.15 Dinesh 78 Roll
completed. 502
pending
Over aged
calendar fabric
Daily monitoring 2017.06.30 Dinesh
ply pieces haging
on the machine
Daily monitoring Udayanga / Kathika
Kusal
Let off shaft
bending issues at
squeegee 2 roller
Replace the bending
shafts
Sanjeewa

38. Root Causes Action Plan
(action to be
taken)
Target
Completion
Date
Responsibility
(person)
Status
No alignment in
winding table
Replacement of the
old table with new
table
2017.06.25 Ramal
Wrinkles
formation at Bias
cutters
Replacement of the
old table with new
table
2017.06.25 Ramal
No break system
to tight the liners
at 2 roller
Repair the existing
break system and a
develop a new
system
2017.07.05 Sanjeewa
Cut ply rotating
on the ground
Develop a OPL and
train the material
handling carder
Vasantha
Not having proper
liner rewinding
process
To standardize the
liner length and the
width and liner
numbering
2017.08.15 Dinesh

39. Quick Wins action…

40. On the job training
Operator awareness programs

41. Culture & Mind set changing….

42. Awareness Through Display
Boards
Before
Present

43. Step V Result Check
4326th May 2017

44. 0.16
0.14
0.15
0.10
0.10 0.10 0.10 0.10
0.18
0.19
0.15
0.20
0.67
0.16
0.13 0.13 0.13
0.12
0.16
0.15
0.160
0.197
0.169
0.179
0.169
0.217
0.191
0.169
0.179
0.206
0.137
-
0.05
0.10
0.15
0.20
0.25
YTD 14/15 YTD 15/16 YEAR 16/172 YEAR 15/16 YEAR 16/17 YEAR 17/18
TOTAL FABRIC SCRAP –MONTHLY TREND

45. Step V : Result Check
• Tangible Benefits
• Intangible Benefits
4526th May 2017

46. Step VI : Standardisation
• Update existing SOP or Create new SOP
– Standards / Work Instructions / Manuals etc.
– Provide names/ snapshots of documents created or
updated
• CMS No. Internal Doc Number
• Pic of Document with Revision No highlighted
4626th May 2017

47. Step VII Future Plan
• Any Scope for Horizontal Deployment
– Within plant
– Across plant
AND / OR
• Taking the next QIP with redefined specific problem
statement
– Identification of new problem from the ‘After-Pareto’

48. Thank You