3. Introduction
Nestle is the world's
leading nutrition, health
and wellness company.
"Good Food, Good Life" is
the promise we commit to
everyday, everywhere.
Mission
Nestlé’s mission is to
enhance the quality
of life of people.
Brands
8,000 brands
Cereals
Juices
Milk
Water
Cream
Nescafe
Chocolates
11. • We calibrate the sensor, by applying the
pressure 25%, 50%, 75%, 100% of the
working pressure. of transmitter. First
check at 0 bar, reading should be 4 mA
on ammeter. Then for 25% reading
should be 8mA, for 50% reading should
be 12mA, for 75% reading should be
16mA, and for 100% reading should be
20mA. if it is in the above sequence in
both increasing and decreasing order,
then senor is correct, otherwise it is
adjusted.
Pressure Sensor
• In this method we calibrate the
sensor, by setting the temperature
of the oil bath to 25%, 50%, 75%,
100% of the working temp. of
sensor. Then measure the temp of
oil bath using same sensor, if the
reading is matching (+- 0.5'C) with
the set value , then sensor is
correct, otherwise it is adjusted.
Temperature
Sensor
1st Project
Instrumentation And
Calibration
12.
13. Pumps
Centrifugal Pumps
• All the Pumps used in
Nestle are Centrifugal
Pumps.
• Transport fluids by the
conversion of rotational
kinetic energy to the
hydrodynamic energy of
the fluid flow.
Positive-displacement
pumps
• Used in Fluidor.
• Operate by forcing a
fixed volume of fluid
from the inlet pressure
section of the pump
into the discharge
zone of the pump.
Peristaltic pump
• Used for Pulp
Transfer
• It has pinch Tube
and transfer material
by pinching effect.
14. Abnormality
Identification (AI)
Center lining (C/L)
PM Elements
Standard Work
Jidoka
Tools of
Create
Stability
Tools to Create Stability
LEAN Value Stream Pillar – Create Stability Tools
Help Chain
15. What is Center lining?
Fixed position adjustments based upon individual
products
Ensure the equipment is “set-up” for optimal operation
Indicate precise machine adjustments eliminating ALL
guesswork
2rd Project
Centre lining
16. TECHNICAL –SHRINK MACHINES
Initiative: Center lining on Gauges.
Issue
- If machine stops then operator
have to see the OM Book of
every sensor.
- Time consuming.
Achievement
- Time saving.
- Visually see the problem.
- Quantity of product
increases.
- Machine cant stop for long
time.
Solution
- Color indications displayed
on Hot melting unit
pressure gauge to guide the
operators.
Team: Zunaira Khan, Internee Date:July.2014
17. TECHNICAL –TAPPING MACHINE-PRISMA LINE R
Initiative: Centerline Implementation on Mandrel of Filling Machine.
Issue
Nut can attach to any
hole.
Alignment of reel is
inaccurate.
Time consuming.
Machine stops if nut is
attached to wrong
hole.
Solution Achievement
Alignment of reel is
right.
No wastage of paper.
Splicing is proper.
Time saving.
Visual Control
We can fill the extra holes. Only Centre hole is
left while the others right and left holes are
filled so that operators fix the nut to the desired
hole that is Centre Hole.
Zunaira Khan, Internee Date: July.2014
18. TECHNICAL –TAPPING MACHINE-PRISMA LINE R
Initiative: Centerline Implementation on Printer- Prisma line R
Issue
Operator can change
the printer position.
Printer can’t fix so
maintenance
department come.
Wastage of time.
Irregular printing.
Solution Achievement
Fixed position of printer.
Quality of printing is good.
Machine can’t stop due to
printer position.
Time saving.
Visual Control
We can implement centerline on the Printer by
fixing its position .
Zunaira Khan, Internee
Date:
July.2014
19. To reduce the Unplanned stoppages and printing
misalignment complaints coming from printer of
line R through Center lining till end July 2014
20. Team Members:
Zunaira Khan, Mehmood ul Hassan, Haji Zafar Iqbal, Saqlain Raza
LEAN VS Project Charter
: To reduce the Unplanned stoppages and printing misalignment
Complaints coming from printer of line R through center lining till End of July 2014.
Problem Statement
QA complaints are high regarding Expiry code misalignment and
misprinting issues on lines R.
Printer frequency is 18% of total number of stoppages on filler R
1 SCOPE
Printer-1000 ml Prisma R
Deliverables
Zero Quality Complaints of Expiry on Packs Reduced No of
Unplanned Stoppages OPLs, Help Chains Competence
Building of Team on Tools.
Measures
SHO=Printing Quality, No of Stoppages
DOR=Consumer complaints , Unplanned planned
Stoppages
Business Case
Consumer complaints for Expiry compliance tie directly to
our consumer value proposition of “Brand Image”.
Number of stoppages have strong link with “Availability”
2
4
3
5
Document Owner:- Zeeshan Khaliq3rd Project
21. Schedule for Printer Center lining Project
Till 15th
July Till end of July
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
2
6
27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
PhaseI.
EquipmentSelection
1. Identify Key Equipment For Centerline (Based on
Consumer Values)
Define
2. Create an “All Adjustment Points List” (Go to
Gemba)
Measure
PhaseII.
DefineAdjustment
Points
3. Identify and Eliminate Unnecessary Adjustments
4 Create and set Metrics for 1st and 2nd Level
Parameters
Analyses
PhaseIII.
Implement&Control
5. Establish/Adjust centerline positions
6. Implement Centerlines
Improve
7. Ensure Adherence
Control
8. Centerline Continuous Improvement
Project Timeline
25. Elimination of Unnecessary Adjustments
Head Delay and
Horizontal adjustments
Adjustments Eliminated
Head Delay and Horizontal position was
unnecessarily adjustable, Now its Eliminated
I mprove
26. Elimination of Unnecessary Adjustments
Head Delay and
Horizontal adjustments
Adjustments Eliminated
Head Delay and Horizontal position was
unnecessarily adjustable, Now its Eliminated
I mprove
27. Elimination of Unnecessary Adjustments
Printer Head Vertical position was unnecessarily
adjustable, Now its Eliminated
Adjustments EliminatedPrinter Head Vertical
adjustments
I mprove
28. Time Lost-1 40 31 28 25 20 16 15
Percent 22.9 17.7 16.0 14.3 11.4 9.1 8.6
Cum % 22.9 40.6 56.6 70.9 82.3 91.4 100.0
Stoppage
FFU
+
Processing
Printer
Super
Structure
A
SU
H2O
2
Bath
Jaw
U
nit
200
150
100
50
0
100
80
60
40
20
0
TimeLost-1
Percent
Pareto Chart of Stoppage
Before and After
30. TECHNICAL –TETRA FILLERS
Initiative: Jidoka on Mandrel for its direction.
Issue
- Operators can fix mandrel to
any direction.
- Wastage of time in
correcting its direction.
- Not proper splicing.
Achievement
Proper Alignment of paper.
Time saving.
No problem of ASU joint Unit.
Solution
We can fix the direction
of mandrel by attaching
a key to it so that it only
fixes to its right
direction.
Team: Zunaira Khan, Internee Date:July.2014
31. TECHNICAL –SHRINK MACHINES
Initiative: Jidoka to prevent FFU packets bursting on Prisma Line R by fixing
spacer.
Issue
- Operators tight the screw
more and less.
- Packet DE shape
- Bursting of packets.
- Wastage of packets and
time.
Achievement
- Time saving .
- Efficiency loss due to packet
issue have been controlled.
- Quality of packet increases.
- Money consumption.
Solution
We can fix the screw.
Team: Zunaira Khan, Internee Date:July.2014
32. Nível 3
Acionado
Nível 1
Acionado
Nível 2
Acionado
1st Level
triggered
2nd Level
triggered
3rd Level
triggered A structured way to react
to abnormalities
(deviations or
unexpected events)
during the execution of a
task. Help chain includes
trigger limits or criteria
definitions to
communicate and to
request for help.
33.
34. Standardized work
defines the safest,
easiest, and most
effective way of doing
the job, that people
currently know, using
available equipment,
people, and material.
TAKT Time
The best Sequence
Standard Work in
Progress
To increase
productivity
To increase production
To solve botlenecks
To improve operators
morale and motivation
What is???
It consists of
Benefits
6th Project
Standard Work
35. Push Button that can stop the whole machine should be covered
properly.
The workers suffering from diseases like Asthma, t.b. etc. should not work near the
suffocating regions I-e boilers.
CHECK for leakages and that all unions are tightened.
CHECK that all covers are mounted correctly.
Never clean the floors or the equipment in the process room when
the equipment is in process.
The sensors in high temperature areas should be properly covered so
that hot air n steam can’t effect its efficiency.
The plate on motors should be clearly seen so that operators know their rpms
and other desired specifications.
Opportunity Ideas
