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Case study on Rapidinnovation (shampoo pouch packaging m/c)
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a case studyin Rapidinnovation
INNOVATION
R A P I DCase Study – Rapid Innovation
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• production not more than 60 packet a min• vibration between 50 to 60 microns• variation of quantity in packets – 6 to 8 ml• rat tailing – wastage of material• horizontal sealing problem• vertical sealing problem• new German machine = 1Cr• workers’ problem!
INNOVATION
R A P I DThe pain ….
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• Don’t attempt to solve each problem separately • Observe the System & Interactions within the
system as a whole • Find the imperfections (use Chaos Design
Principles)• Innovate to negate or eliminate the
imperfections• A new system evolves• Gives on going benefit for years!
INNOVATION
R A P I DThe pain ….
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• Observe that the machine is like a tall column pitching effect.
• The width at the base (c to c of cushy foot) = 0.7 m. Length is 1 m
• Note the sensitive directions shown by the red arrows.
0.7 m
INNOVATION
R A P I DPrinciples of Sensitive Direction, Proportions & Structures
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• The paper reel unit, the stair case are attached to the main unit. (Left hand side of the red line)
• It shifts the centre of mass and induces vibration which is amplified by the low stiffness of the staircase
• The yellow line more-or-less shows the centre of mass
• Note that the machine has two regions of stiffness. One the left hand side of the red line it is the region of low stiffness and on the right is the region of high stiffness.
1 M
Low Stiff region
High Stiff region
INNOVATION
R A P I DPrinciples of Centre of Mass & Stiffness
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• This is an important centre of friction.
• Moreover, this place requires accuracy. The metering of the flow of shampoo would depend on the accuracy of the backlash.
INNOVATION
R A P I DPrinciple of Centre of Friction
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• This slider mechanism is critical for the operation.
• Here the linear bearing can’t be lubricated by any means.
• Moreover, the L/D ratio of the bearing is also not ideal. This would lead to accelerated wear & misalignment
Linear Bearings
INNOVATION
R A P I DPrinciple of centre of friction & proportion
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• Imperfection: Is the height required? It only adds to the height of the column -> leads to pitching effect.
• Moreover concentricity may induce air entrapment. Feed hopper
INNOVATION
R A P I D
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Principle of Symmetry & Height
• Imperfection: the temperature of the heaters are not equal. So a steady state temperature can’t be reached.
INNOVATION
R A P I DPrinciple of Centre of Temperature
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• The tension of the spring is important for proper horizontal sealing. But the spring can lose its tension due to temperature effects.
Spring
INNOVATION
R A P I DPrinciple of linkages & springs
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• This portion is subjected to fatigue wear under higher temperature. The roundness and smoothness of the surface is important and the S and P % in material is also important
INNOVATION
R A P I DPrinciple of centre of wear
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• Imperfection: Bearing width. Narrow width would lead to cocking and frequent failures
Bearings
INNOVATION
R A P I DBEARINGS
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• Imperfection: play if v belt is used leading to improper metering of the material at the end.
INNOVATION
R A P I DPrinciple of tolerances & Stacking
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• Imperfection: an additional bearing just before the chain coupling. This is not required. This is an additional constraint (unbalanced moment)
Additional bearing
INNOVATION
R A P I DPrinciple of Bearing
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• The shampoo feed pipe is attached to the machine. Hence pipe vibrations are easily transferred to the machine.
• Pipes supported symmetrically
INNOVATION
R A P I DPrinciple of Pipes
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• Imperfection: Heat gets trapped because of the safety enclosure
INNOVATION
R A P I DPrinciple of Heat Distribution
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• Imperfection: Heat is trapped because of the stainless steel cover. This heats up other elements in the working zone and reduces life.
Stainless Steel cover
INNOVATION
R A P I DPrinciple of Heat Transfer
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• Imperfection: The fitting may induce air entrapment which leads to “rat tailing”.
INNOVATION
R A P I DPrinciple of Nozzle fitting
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INNOVATION
R A P I DThe new machine - Redesigned
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• Sensitive direction• Basic proportion machine• Basic proportion of foundation & structure• Center of mass• Regions of stiffness• Center of Friction• Center of Temperature.• Hanger/support symmetry.• Tolerance Staking • Structural loop
INNOVATION
R A P I D
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Application of the principles
the pains……… the gains• < 60 packets a min• 60 microns vibration• 6 to 8 ml per packet• rat tailing• horiz seal problem• vertical seal problem• foreign mac > 1 Cr• workers’ problem
• 80 packets a min• < 5 microns vibration• 8 ml per packet• no rat tailing• no problem• no problem• new machine = 7.5L• workers’ cooperation
INNOVATION
R A P I DPain to Gains
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learning to live by system & design thinking & natural principles
spreading innovation – the ultimate competitive advantage!
INNOVATION
R A P I DPersonal Mastery – 6th Principle
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