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six sigma project
- 2. PROJECT AT GLANCE….. •Focus : Improve productivity of Compression Machine • Project ID : Six Sigma Project • Date : Dec.2011 • Green Belt : Mr. Yogesh Tripathi
- 3. SUMMARY OF PROJECT 0 10 20 30 40 50 60 BeforeAfter OEE • Project Name : Improvement of OEE of compression by 10%Improvement of OEE of compression by 10% Define | Project scope, team formation, project plan & charter. Measure | Use of C & E Diagram for route causes (Brainstorming conducted). OEE tool used. Analyze | Availability loss is mainly from changeovers & break down Performance loss is mainly due to machine setting and RPM Quality losses is mainly significant to individual negliance Improve | Interpretation & action plan for Product c/o, breakdown , m/c setting & RPM Control | Skill matrix / ownership applied OEE comparison (Before:-44.11%,After:-56.81%) Project benefits & financial calculations Monitor action steps & form system
- 4. Team Charter Project :Improve productivity of compression machine Business Case Opportunity Statement Improve availability of machine, Reduce machine downtime, Reduce Tab. wt.variation. Goal Statement Project Scope To increase Overall equipment efficiency by 10% Process : Compression Start point : Dispensing Granulation Compression End point : QC inspection Project Plan Team Members Task/Phase Start Date End Date Actual End Process Owner : AM prod'n Form team 20-Dec-11 20-Dec-11 20-Dec-11 Member : Maint Finalize Charter 22-Dec-11 22-Dec-11 22-Dec-11 Member : Maint Gather data 24-Dec-11 24-Dec-11 24-Dec-11 Member : Prod'n Analyse Data 29-Dec-11 29-Dec-11 29-Dec-11 Member : IPQA, Select Solution 05-Jan-12 05-Jan-12 05-Jan-12 Member : Mentor Implementation 06-Jan-12 06-Jan-12 06-Jan-12 Member : Prod'n Verify solution 08-Jan-12 08-Jan-12 08-Jan-12 Member : Operator 12-Jan-12 12-Jan-12 12-Jan-12 Member : Operator Member : Operator Close and Reco This project supports our Business objective of improving Plant performance thru' increasing productivity of compression m/c M CIAD M IAD Define
- 6. PROCESS FLOW CHART STARTDISPENSING SIFTING/ DRYING GRANULATION COMPRESSION BLENDING COATING SORTINGBLISTERINGPACKINGB.S.R.CHECK Dispatch Define Focus
- 7. ABOUT COMPRESSION MACHINE •Compression machine is used for producing oral dosage (tablets) by applying of required pressure. • Compression m/c consists of upper punches, lower punches & die cavity in which upper & lower punches are forced to form a tablet applying requisite pressure. Upper Punch Lower Punch Granules Die Define
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- 9. SIPOC Supplier Input Process Output Customer Stores Granulation Compression Dispensing Dept. - Change over process Compressed Primary packing Accuracy in weighing Granulation Tablets Department Cross check - Granulation end point - RPM Thickness -LOD - Line clearance scrap - Sieving - Friability - Bulk Density - Avg.wt. Defective Secondary -Hardness/Thicknes s Tab. scrap packing Blending - Disintegrity Department Lubrication - Batch Yield Left over Mixing time - Documentation scrap - QC Check Coating Define
- 10. • Highlight key suspected X’s for focus & analysis Measure Spare (M) Fine granules(L) Change over frequency (H) Prod’n plan (L) RPM (M) Room temp.high (L) Lab testing method (M) COMPRESSION M/C Machine start (H) Machine setting (M) Skill (H) Pully alignment (H) Vibration(H) Speed (H) Old/new M/c (H) R.M.quality (L) Loading plan (L) Noisy (L) Dusty (L) Moral(H) Discipline (M) Idle time(H) Tab.wt. (L) Granulation procedure (L) High moisture (L) Over dry granules (L) Training(H) Punches variation (M) Prev. Maint. (H) Break down (H) Compression m/c output Man
- 11. Productivity Quality wt.variation Y1Y2 Y3 Output indicator 1 2 3 importance Sr.No Input /Process indicator ------Total---- 1 Prev.maint./ Break down 9 3 0 114 2 M/c change over time 9 0 0 90 3 M/c setting 3 9 0 102 4 Granulation 3 9 0 102 5 Speed (RPM) 9 3 3 129 6 Training 3 3 0 54 7 Skill 3 3 3 69 8 Machine loading plan 9 0 0 90 9 Priority 3 0 0 30 None Low Moderate Strong 0 1 3 9 Scale : ------Correlation of input to output---- Measure
- 12. 12 Overall Equipment Effectiveness •Metric: Measure of Utilization / Potential •Calculation: OEE:What is OEE ? •Process: Data Info Action QPAOEE ××= Availability (Downtime loss) Quality (Quality Loss) Performance (Speed Loss) Measure
- 13. 06/06/16 13 Measure OEE Factor World Class Availability90.00% Performance 95.00% Quality 99.90% Overall OEE 85.00% OEE: What is OEE ?
- 14. • Product out put – Compressed uncoated tablet • M/c set up loss – At the beginning of machine start tab. Parameter needs to set Hardness,avg.wt.etc •Batch changeover – Same product batch change over with same machine change part. • Product C/o – All sets of change part need’s to replace, clean wash of machine & m/c area • Line Clearance – IPQA inspection prior to machine start. • OEE Time Explanation • Total available time – 720 Min. (8.30 to 20.30) • Change room time – 15 Min. • Tea break Time – 15 Min. • Lunch break Time – 30 Min. • Machine cleaning – 20 Min. • Net available time – 640 Min. Measure OPERATIONAL DEFINITION
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- 19. Interpretation & Actionplan to increase machine output Owner Status 1) Machine Availability time A) Reduction of Product changeover time Apply skill matrix for operator skill improvement SSM DONE Change over steps analyzed & removed idle time SSM DONE M/c loading plan displayed on board for advance SSM DONE planning for c/o to operator B) Reduction of machine break down Monthly Plan Preventive Maint. schedule to be circulated to production (Display on Board) Bhumkar DONE Some of Plan preventive Maint. schedule revised Bhumkar DONE Spare list & MOL should maintain display on board ( kanban in proposal) Bhumkar DONE M/c break down history should maintain by prod'n & maint.(Autonomous Maint.) Bedre DONE 2) Machine Performance A) Improvement of m/c setting time & RPM Machine ownership system develop (kaizen approach) SSM DONE Track to increase m/c RPM daily, prepare guideline checklist Survanshi DONE product wise to set standard for RPM Apply skill matrix to reduce operator to operator variation. Sawarkar DONE Improve ACTION PLAN
- 20. Machine wise Ownership(KAIZEN) Sr.no M/c name owner 1 CMB-4 (35 Station) Wagh S.S Double Rotary "B" Tooling (Old) 2 Cip.(27 Station) Sarode A.G. Doule Roatary"D" Tooling (Old) 3 CMB-2 (45 station) M.A. Jagtap Double Roatary "D B" Tooling (Old) 4 CMB-5 (35 Station) Kapse M.D. Double Roatary "B" Tooling 5 SR-1 (16 Station) Wetal S.B. Single Rotary "D" Tooling (Old) 6 Rimek-( 45 station) Patil M.J. "B" Tooling 7 Rimek-( 37 station) Wetal S.B. "D" Tooling 8 Rimek-( 37 station) Sarode A.G. "D" Tooling 9 Process co-ordinater Survanshi Improve
- 21. Step no. ActivityActivity Description Time- 1 M/P Time- 2 M/P Actual Avg.Before Actual Avg.after 1 Machine & area cleaning Previous product powder removal 40 20 30 30 Machine area dedusting Area cleaning with air Nozzle Cubical area cleaning walls cleaning 2 Equipment cleaning Deduster cleaning 30 30 20 20Metal detector cleaning Dust collector cleaning 3 Dismantle of parts Punches 45 30 30 30 Hopper Feed Frame Channel 4 Washing & cleaning with IPA Hopper 30 15 30 30Feed Frame Channel 5 cleaning New c/o punches cleaning 30 15 15 15 6 Polishing Punches polishing if required 45 30 45 45 7 Fitting Punches fitting to machine 60 45 60 45 8 Part fitting Hopper 30 20 20 20Feed Frame Channel 9 IPQA I PQA LINE CLEARANCE 15 15 15 15 10 Material Batch movement 10 10 10 10 11 Unaccounted Tool/equipment unavailability 45 0 Total 280 210 320 260 Compression m/c (Product) change over process Improve
- 22. Operator Skill Matrix Nameof operator Sarode A.G. Survanshi Wagh S.S M.A. Jagtap Skill Matrix Trainee Trained Trainee Trained Trainee Trained Trainee Trained Skilled Expert Skilled Expert Skilled Expert Skilled Expert Name of operator Kapse M.D. Wetal S.B. Patil M.J. Sawarkar Skill Matrix Trainee Trained Trainee Trained Trainee Trained Trainee Trained Skilled Expert Skilled Expert Skilled Expert Skilled Expert Name of operator P V Deshpande Bhusare Jagdale Gorade Skill Matrix Trainee Trained Trainee Trained Trainee Trained Trainee Trained Skilled Expert Skilled Expert Skilled Expert Skilled Expert Notification : 1)Under Training : - Trainee 3)Can work without guidence :- Skilled Trainee Trained 2)Can work under guidence :- Trained 4)Train others :- Expert Skilled Expert The Skill matrix used for work allocation for machine set up & c/o Expert operator will train , guide to Trainee and trained operators for Machine RPM and parameter set up to optimize machine speed to reduce performance loss Improve
- 23. Sr.No. Product NameMachine Name RPM 1 N Remik 45 station m/c 35 2 N CMB-2 Dob.ROT. 24 3 C-1 SR-1 28 4 C-2 CMB-5 , 35 station m/c 25 5 C-3 CMB-5 , 35 station m/c 24 6 L-1 CMB-5 , 35 station m/c 24 7 T-1 CMB-5 , 35 station m/c 23 8 O-1 CMB-4 machine 22 9 L-2 CMB-4 machine 20 10 E-1 CMB-4 machine 20 11 P-2 CIP double roat m/c 22 12 E-2 Remik 37 station m/c 20 13 C-4 Remik 37 station m/c 24 14 C-5 CMB-5,35 station m/c 18 15 C-6 CMB - 4 20 Standardized Product wise checklist to set RPM Improve
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- 25. Project Comparison &financial gain calculation OEE Gains explanation m/c availability time 640 10% 64 Min.saved for 8 m/c 512 ave.rpm 20 Rotation ave. 50 Tab./min. 1000 Tab/day 512000 Tab/month 15360000 Tab.in million /M 15.36 Cost Minimum/M 2227200 Control
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- 28. …AND KEEP YOUR EYEON THE DASHBOARD.
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- 30. The journey continues… Learningof project Replicated, Initiated project on Blister machine