This project aimed to improve the productivity of the compression machine by 10% through a Six Sigma project. Key issues identified were availability losses from changeovers and breakdowns, and performance losses from machine settings and RPM. The project team implemented actions like skill matrices for operators, standardized checklists for RPM settings, and preventative maintenance schedules to reduce downtime. As a result, OEE improved from 44.11% to 56.81%, saving over 500 minutes of availability time per day and increasing annual tablet production by over 15 million tablets.

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
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60
Before After
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
START DISPENSING 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

8. Define

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
Y1 Y2 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
Availability 90.00%
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

15. OEE TOOL IN MEASURE PHASE FOR DATA COLLECTION
Measure

16. Analyze

17. Analyze
Prioritization of root causes

18. Y
Analyze
PROJECT FOCUS

19. Interpretation & Action plan 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. Activity Activity 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
Name of 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 Name Machine 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

24. Improve

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

26. START WITH A
VISION….

27. ..BENCHMARK..

28. …AND KEEP YOUR
EYE ON THE
DASHBOARD.

29. ANY QUESTIONS…

30. The journey continues…
Learning of project Replicated, Initiated project on
Blister machine