Kaizen Project: 4 % Finishing Loss Reduction by Process Optimization
4 % Finishing Loss Reduction by Process Optimization
Team – ARJUN (Mr Rakesh Saini (Leader), Mr Ashish Tripathi, Mr Manish Jaiswal, Mr Rajesh Singh, Mr Kamal Choubey, Mr Dharmendar Maurya and Mr Raghunath Pal)
Introduction
Case Study:
PM 03 team is continuously striving to increase the production and improve Quality; for the same team brainstormed and identified one major gap (Finishing loss%) which is resulting in ~ 4% losses which can be minimized without any major investment. For the same a Kaizen project was initiated to reduce the finishing losses from 9.31% to 5.0 %.
Team worked on the project by following the Kaizen Project methodology, Data collection brainstorming, Root Cause analysis, DOE and Planned implementation.
Background
Staggering Results
Managers are often in the dark without timely data that would enable their organization to make proactive decisions with regards to process optimization. Instead, legacy practices leave managers feeling reactive, as if they will never have a chance to get ahead of problems before they become costly losses.
Before Automation
Many paper mills operate with data that doesn’t paint the full picture: periodic grab samples can provide a snapshot of parameters including paper quality rejection and finishing loss, however they can’t accurately illustrate how conditions change over time.
These legacy management practices finishing loss and quality deviation is a good result, but they’re hard to maintain, and can suddenly turn to losses when mishaps occur due to insufficient insight into the contamination or mitigation possible as new practices are deployed.
After Automation
Automated finishing loss and B quality deviation with real-time data can be a game-changer with nearly unlimited potential to enhance every facet of production: operational efficiency, cost control, product output, safety of human health and the environment—not to mention the opportunities afforded in discovering and resolving issues that may have been concealed for years behind lagging data.
Better still, everyone in the organization wins by collaborating to implement solutions that maximize production efficiencies—and finishing loss calculation in manufacturing is the first step to that beneficial outcome.
Challenges:
Following issues majorly cause a sudden increase in rejection & finishing losses. Root Causes were identified and solutions of these we implemented.
- Holes issues
- Wrinkle crease
- Shade variation
Summary:
After identification of top causes, DOEs were also done to validate and then action plan were made and executed. With these actions the Finishing losses reduced from 9.31% to 5.0 %.
