White Belt DMAIC Project Line G MTTR

White Belt DMAIC Project

Project Goal: To reduce MTTR of line G by 45% before 30 April 2015.

Sheikhupura Factory

Project Leader

Irfan Rasheed

Shift Engineer

Dairy and Juice Dept

Key Concepts Definitions:Failure & Minor Stops PPI’s

6 June 2015TPM - PM Pillar 2

TypeTechnical Operational, etc.

Time

10 min

Fail

ure

sM

ino

r S

top

s

MTBFT

MTTAT

MTTR

Owner: PM PillarSupport: FI Pillar

MTBFO, etc,

MTTAO, etc.

Owner: AM PillarSupport: FI Pillar

MTBF, MTTA

Bre

akd

ow

ns

MTBSm

Owner: AM Pillar

Support: PM Pillar Support: FI Pillar

MTBS

Notes:1. MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars. Priority for Phase zero is MTBSm for Autonomous Maintenance -which is tracked through the Index of Minor Stops, and MTBF(t) for Planned Maintenance in order to develop the competences while improving the Reliability of the Line.

2. MTBS, which considers all stops independent of its origin, will be tracked as a standard after Phase zero. Focus of AM Step 4 and PM Steps 3-5 are to eliminate un-planned stops. Tracking MTBS before Phase 1 is optional.

Notes:1. MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars. Priority for Phase zero is MTBSm for Autonomous Maintenance -which is tracked through the Index of Minor Stops, and MTBF(t) for Planned Maintenance in order to develop the competences while improving the Reliability of the Line.

2. MTBS, which considers all stops independent of its origin, will be tracked as a standard after Phase zero. Focus of AM Step 4 and PM Steps 3-5 are to eliminate un-planned stops. Tracking MTBS before Phase 1 is optional.

MTBF

Mean Time Between Failures

MTTA

Mean Time To Action requirements

MTTR

Mean Time To Repair

MTBS

Mean Time Between Stops

Note:MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars. MTBFT and MTBFo, etc, can be used as internal departmental KPI.

Note:MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars. MTBFT and MTBFo, etc, can be used as internal departmental KPI.

Pro

ce

ss

Fa

ilu

res

PMStep 1

PMStep 2

PMStep 3

MTTR Drivers Target per

step.

NA

+ 25%

+ 60 %

Definition: Indicates the mean time for a production Line to start operating again under normal conditions, after the occurrence of a Breakdown. (Excluding startup cleaning time etc).

Frequency: Monthly.

When: Start measuring from Step 2. This is an OPTIONAL indicator that can help to understand skill gaps or preparation for intervention gapsPPI’s Influenced: Productivity, Quality, Cost, Delivery. And Morale.

6/6/2015TPM - PM Pillar 3

.CalculationInputs:

MTTR = Total Duration of Breakdowns (1)

Total Number of Breakdowns (2)

Calculation:

Description Unit Data Source:

1. Time allocated to corrective maintenance activities > 10 min).

2. # of Corrective Maintenance Orders in Breakdown > 10 min.

Hrs AMM

# AMM

Considerations:

Consolidate data from AMM

Consolidate data from AMM

PPI: MTTR Optional Indicator.

DEFINE Phase

Define

Define precisely the scope of the project

Problem

Includes…

1. Time Series Chart2. Financial Impact3. Team Charter4. Skill Matrix5. Project Charter

ProblemProblem

5W1H – Is/Is NotProblemProblem

What

Which

When

Where

IS IS NOT

Who

Reduce MTTR MTTA

Filling Line Plant

All Shifts

Line G Other Lines

M-Team PRODUCTION STAFF

45 % Reduction of Total MTTR

How

Time Series Plot: Justification to do DMAIC

6

ProblemProblem

Target: Current Average is 32.3 minutes, Bench mark is 11 minutes, Target is 45% gap reduce up to 22.7 minutes.

Weeks

Mach

ine M

TT

R in

Min

ute

s

0

10

20

30

40

50

60

70

30 31 32 33 34 35 36 37 38 39 40 41 42 45 46 47 49 1 2 3 4 5 6

Current MTTR

Average MTTR

Target

Bench Mark

7

Team Leader

Team LeaderTeam Leader

Irfan rasheed(SE D&J)

Process OwnerProcess Owner

Asif Saddique

(PM-D&J)

Team MemberTeam Member

Tauseef(Tech-MT)


Imran(Operator-D&J)

TEAM CHARTER

D M A I C

Awais(Team Leader D&J)


CoachCoach

Ahsan(NCE Champion D&J)

Abdul Moeed(Engineer-Tetrapak)



Inam(Operator-D&J)

PreviousDMAICS

As member

As Team Leader

Meetings Participation

50%

100%

100%

75% 75%

100%

8

Competency MatrixProblemProblem

WB Project Team nameTeam Leader

Team Member

Team Member Team Member Team Member Team Member Average competency

levelFunction Function Function Function Function Function

Irfan rasheed Imran inam Abdul moeed Tauseef Awais

Competency

Init

ial

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

reIn

itia

l

Cu

rre

nt

Re

qu

ire

d

Init

ial

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

reIn

itia

l

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

reIn

itia

l

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

reIn

itia

l

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

reIn

itia

l

Cu

rre

nt

Re

qu

ire

dG

AP

B

efo

re

DMAIC Overview2 3 4 2 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 2 2 3 1 1.7

12.1

43.1

31.4

1

WB roadmap3 3 4 1 1 2 2 2 2 2 0 2 2 2 0 1 2 2 1 2 2 2 0 1.7

12.1

42.2

50.5

4

DEFINE phase2 3 4 2 1 2 3 2 2 3 1 2 2 3 1 2 2 3 1 3 2 3 0 1.8

62.1

43.1

31.2

7

MEASURE phase2 3 4 2 1 2 3 1 2 3 2 1 2 3 2 2 3 3 1 2 2 3 1 1.7

12.4

33.1

31.4

1

ANALYSE phase2 3 4 2 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 1 2 3 2 1.4

32.2

93.1

31.7

IMPROVE phase3 3 4 1 2 2 3 3 2 3 0 1 2 3 2 1 2 3 2 1 2 3 2 1.8

62.1

43.1

31.2

7

CONTROL phase3 3 4 1 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 1 2 3 2 1.7

12.2

93.1

31.4

1

DMAIC storyboard3 3 4 1 2 2 3 2 2 3 1 2 2 3 1 2 2 3 1 1 2 3 2 1.8

62.1

43.1

31.2

7

WB Tollgate content2 3 4 2 1 2 2 1 2 2 1 1 2 2 1 1 2 2 1 2 2 2 0 1.2

92 2.2

50.9

6

Member Gap Before and After2.4

43 4 1.5

61.2

22 2.7

81.8

92 2.7

80.8

91.3

32 2.7

81.4

41.6

72.1

12.7

81.1

11.6

72 2.7

81.1

11.6

82.1

92.9

31.2

5

Score Definition:1 Knowledge not acquired / required2 Basic knowledge, but no competency3 Can practice with help4 Can do alone5 Can train others

Project CharterProblemProblem

Project Title: To reduce MTTR of line G by 45% before 30 April 2015

Project Leader: Irfan Rasheed Team Members: Department Name

Production Team Leader

Awais

Engineering(M Team)

Abdul Moeed

PLE D&J

Inam Abbas

TPP Maintenance

Imran

TPP Maintenance

Touseef

Business Case (Importance):

Reduction in MTTR will increase our productivity as well as line efficiency will improve.

Aligned with Key Priorities of Technical

“enhance reliability in operations to meet consumer demand”

“maximize operational productivity with lean mindset to reduce cost of production”

Speed up delivery time

Enhance technician availability.

438 Ton increase in production capacity.

Reduce MTTR 9.7 minutes per stoppage.

Problem Statement (Purpose): Currently MTTR is 32.3 minute.caused by the stoppages due to Final Folder, Straw applicator , ASU and Conveyor during production, on line G our target is to reduce up to 22.7 minutes.

Goal Statement (Measures):

Project can be measured on basis of following KPIs:

To reduce MTTR on line G up to 22.7 minutes

Project Scope, Constraints:

In scope: Tetra Filler ,Conveyor, Straw Applicator, Shrink

Out scope: Plant

Deliverables:

At the End of Project following will be deliverables:

Standard work

Coaching of People

Reduce MTTR to 22.7 minutes

Financial Impact / Financial Sheet

Resources: Coordination among following departments will be required:

Plant Engineer: Saleem Ashraf Tetra pak Support: Umair Younis Factory Costing: Momiza Ahmed SHE Coordinator: Ahsan Abbas

Stakeholders: Customer, project sponsor, process owner

Department Name Position

Project Sponsor Asif Siddique Plant Manager Stake holder Babar Khan BEM Juice Coach Ahsan Abbas D&J

Preliminary Plan:

Phase Milestones Target Start Date Target Completion Date

DEFINE Establish team and Project Charter 25-01-15 08-02-15 MEASURE Identify required data / Generate/Analyze data 9-02-15 15-02-15 ANALYZE Identify highest contributors / Determine root causes 16-02-15 20-03-15 IMPROVE Identify corrective actions / Implement corrective actions 21-02-15 15-03-15 CONTROL Track and trend impact of actions 16-03-15 30-04-15

Date: Project Leader Project Sponsor 25-01-2015 irfan Rasheed Asif Siddique

Financial Impact

10

ProblemProblem

Estimated Annual Savings 4.4 Mio (approx)

NPH 5465

BD # 542

Before Hrs Lost 129.7 MTTR 32.3

After 90.8 MTTR 22.7

Saved 87.6

Lean Permannent 2 400 800

Labor 5 140 700

Electricity 64 16.4 1049.6

Steam 100 16 1600

4149.6

Financial Saved 363,504.96

Flush Flush Saved (Hrs) 87.6

Ton 438

Conversion Cost/Ton 10000

Saved 4,380,000.00

MEASURE Phase

Measure

Understand the problem

Problem

Includes…

1. Data Stratification Criteria

2. Data Collection Plan & Form

3. Pareto Chart

4. Time Series Plot

5. Flow Chart

6. Focused Problem Statement

ProblemProblem

Data Stratification Criteria

12

MTTR ON Line G

Average MTTR Shift wise

MTTR Line wise

MTTR Technician wise

Technician

3Technician

2Technician

1

Shift CShift BShift A

Technician

4

Machine Parts wise

Data Collection:

13

ProblemProblem

WHAT WHERE WHEN(Due Date)

WHY WHO (Responsible)

HOWSTATUS

MTTR of G Line

Filler, Conveyor, Straw applicator, shrink

From JUL 21,2014 to March 22 ,2015

To reduce MTTR of line G

TPP( Moeed)

ImranInam

Register the different problems related to Filling Line and their MTTR time from SAM and Log sheet

Data

Done

Data Reliability:

,

14

ProblemProblem

SAMData Reliability is ensured by Log sheets

Log SheetsLog Sheets of machine is used to find stoppages

MTTR Total Time Lost stoppages wise

15

No o

f sto

pp

ages

in m

inu

tes

Straw missing, final folder are the main contributor

No of stoppages

Data StratificationProblemProblem

0

200

400

600

800

1000

1200

No of stoppages frequency wise

16

No o

f S

top

pages

Straw missing, final folder are the main contributor

No of breakdown stoppages

Data StratificationProblemProblem

0

10

20

30

40

50

60

Data Stratification

17

ProblemProblem

31

31.5

32

32.5

33

33.5

34

34.5

Shift A Shift B Shift C

MT

TR

IN

MIN

UT

ES

Shifts

Average Shift wise MTTR same MTTR in all three shifts

Data Stratification Average Technician wise MTTR

18

ProblemProblem

MT

TR

IN

MIN

UT

ES

Technicians

MTTR is high when Alvi and Ahmad attend the issues

0

5

10

15

20

25

30

35

40

Ahmad raza Alvi Kamran Rizwan

Pareto Chart (Technician wise)

19

ProblemProblem

Ave

rage M

TT

RIn

M

inute

s

MTTR dependents on Technicians

Pareto Chart (Problem wise)

20

ProblemProblem

Ave

rage M

TT

RIn

M

inute

s

Stoppages

Conveyor, ASU splice, final folder, and straw missing problems takes high MTTR as compare to others.

Process Mapping

21

ProblemProblem

ASEPTICCHAMB

ER

MachineBody

JawsSystem

SERVICE UNIT

DRIVEUNIT

FINALFOLDER

ASU Straw Applicator

ConveyorTray Shrink

5W 1H for Problem Statement

22

What What is happening?

High MTTR

How How does it happen?

Due to BD stoppages on ASU, Final Folder, Conveyor, Straw Applicator

Which pattern do you see? (does it happen on the right, left, above, bellow, in front of, behind, randomly…)

Same MTTR in all shifts

When When does it happen? When did the problem happen?

It happens randomly

Where Where does it happen?

Final Folder, Conveyor, straw Applicator, ASU

Who Is the problem correlated to operator abilities?

Partly depends on Technician ability

ProblemProblem

High MTTR caused the stoppages due to Final Folder ,Straw Applicator, ASU, and Conveyor during production in all shifts on line G partly depending on technician ability.

Focused Problem Statement

23

To Reduce MTTR, caused by the stoppages due to Final Folder, Straw applicator , ASU and Conveyor during production, on line G

ANALYZE Phase

Analyze

Identify the root causes

Problem

Includes…

1. Brainstorming

2. Sorting

3. Cause & Effect Diagram

4. Probable Causes Verification

5. WHY-WHY Analysis

ProblemProblem

25

ProblemProblem Brain Storming Final Folder

• Final Folder Synchronization not as per Standard• Packet Delay from Jaws• Packet De-shape from Jaws • Tube flushing & TS cooling water Nozzle blocked• Infeed Belt Damaged • Infeed Belt position Offset Not as per standard • Infeed Gear box coupling broken and Gearbox play• Station chain guides misaligned • Station chain Gear box coupling broken and Gearbox play• Flap squeezer belts condition & Flap Nozzle position • Flap Open problem & Flap temperature variation • Packet twisting problem• Outfeed brush condition, Bearings jammed drive belt lose • Outfeed wheel offset & gearbox play • Outfeed wheel motor faulty.• Sprinkling water nozzle block at Outfeed• Outfeed finger broken• Conveyor links broken• Conveyor speed • Quality of weekly checks is not up to mark • Low quality of cleaning material

26

ProblemProblem Brain Storming Straw Applicator

• Bottom flap of the packets opened due to which packets fall at belt brake of straw applicator.

• Conveyor Jerk• Conveyor lubrication not properly done as no frequency is defined• Gaps in guide rods• Guides not properly cleaned as lose control on weekly checks• Friction at the guide surface• Improper conveyor cleaning• Juice spillage at the conveyor• Packet design out problem due to which packets unstable at feed wheel.• Sensors of belt brake are improperly aligned• Gaps between packets• Glue nozzle choke• Straw quality banana shape• Improper cleaning of feed wheel and• Quality of weekly checks is not up to mark • Low quality of cleaning material

27

ProblemProblem Brain Storming Straw Applicator

• Hot melt temperature• Gun module choke• Air pressure • Air Solenoid valve malfunction• Synchronization issue between machine conveyor speed and in feed belt break• Conveyor speed• Packets shape issue from filling machine side• Knife dull• Feed wheel position• Bent foil heater temperature• Pressure arm override• Ladder Band guide• Straw Position sensor• Leaf Spring• Untrained operator• Glue quality• improper cleaning material • Feed wheel synchronization out • Conveyor guides miss align• conveyor speed• irresponsible operator

28

Brain Storming ASU Splice missing problem

Prol

• Paper miss aligned cutting table setting out• Splice not prepared according OM• ASU cutting problem• ASU Constant heat bar Temperature• ASU photocell barcode detection not working• ASU thermocouple wire distortion • Reel empty sensor miss aligned• Bellow for splice not operate• Reel not prepared • Mandrill position out• Manual Splice performed by operator• Time delay between Problem and inform to Maintenance staff• Long distance between Filling machine and Distribution equipment's• Untrained Technicians & competency level• Untrained or Irresponsible Operator• Low man power • Work load during meal timings• Electrical Panel keys not available at machine• Cleaning of Machine

ProblemProblem

29

Brain Storming on conveyer

Prol

• conveyer links broken • conveyer dry lubrication • conveyor direction • conveyer railings • conveyers guides adjustment• conveyer speed• conveyer drive motor• conveyer length• conveyer quality• Time delay between Problem and inform to Maintenance staff• Long distance between Filling machine and Distribution equipment's• Untrained Technicians & competency level• Untrained or Irresponsible Operator• Low man power • Work load during meal timings• Electrical Panel keys not available at machine• Cleaning of Machine

ProblemProblem

Restoration of Basic Machine Conditions Final Folder

30

Restoration of Basic Machine Conditions Straw Applicator

31

CLI

32

C L I

ProblemProblem Fish Bone (Cause & Effect Diagram Final Folder)

To reduce MTTR of m/c G due to Final

folder

Method

machine

Material

Man

1. In feed belt

2. In correct Volume

3. Waste conveyor improper function

4. Crease out

5. Conveyor guides misalign

6. Tube flushing water

7. Gear box fault

8. FFU motor fault

9. Flap nozzle cleaning issue

10. Paper dust in station wheel

11. Conveyor jerks

12. Pusher synchronization out

13. Conveyor speed improper

14. Tube flushing water

15. High MTTR due to Packet twisting problem

16. Out feed gear box play

17. Improper Lubrication of conveyor

18. flap open

19. Design out

20. Sensor fault

21. Packet delay

1. Untrained operators2. Irresponsible operators3. Technician Response time4. improper manual cleaning

1. Low quality of paper2. Low quality of lubricant3. low quality of cleaning material

1. Weekly checks not properly done2. Improper flap nozzle cleaning 3. Final Folder Synchronization not as

per Standard

ProblemProblem Fish Bone (Cause & Effect Diagram Straw Applicator)

Method

machine

Material

Man

Improper manual cleaning

Low quality of cleaning material

Improper glue nozzle cleaning

Pressure arm override

High MTTR due to Straw missing

Conveyor guide rods gap

Conveyor speed

Glue module choke

Air pressure

Synchronization out

flap open

Bent foil theater

Sensor fault

In feed belt brake

nozzle choke

Hot melt Temperature

Conveyor guides misalign

Glue missing

Packets top support belt

Feed wheel motor fault

glue nozzle cleaning issue

Feed wheel

Weekly checks not properly done

lubrication of conveyor

Banana type straws

Low quality of glue

Untrained operators

Irresponsible operators

To reduce MTTR of

m/c G due to Straw

Applicator

Technician Response Time

ProblemProblem Fish Bone (Cause & Effect Diagram ASU)

Method

machine

Material

Man


Low quality of paper

Untrained operators

To reduce MTTR of

m/c G due ASU


Paper miss aligned cutting table setting outHigh MTTR due to Splice not prepared according OM

ASU cutting problem

ASU tpc bar Temperature

High MTTR due to ASU photocell barcode detection not working

High MTTR due to ASU splice missing

Reel empty sensor miss aligned

Mandrill position out

Reel not prepared According OM

High MTTR due to Manual Splice performed by operator

ProblemProblem Fish Bone (Cause & Effect Diagram Conveyor)

Method

machine

Material

Man


Low quality of conveyor

Untrained operators

To reduce MTTR of

m/c G due to

Conveyor


High MTTR due to conveyer links broken

High MTTR due to conveyer dry lubrication

conveyor direction

conveyer railings

conveyers guides adjustment

conveyer speed

conveyer drive motor

conveyer length

Potential cause verification

Possible Causes Logic Verification Criteria Status

Technician Response Time When Technician will not attend problem in time

MTTR will be high

Experience/ Gemba Verified

Final folder Packet

twisting

When packet twisting problem will comes it takes

too much time to resolve.


Straw missing (Banana shape

straws )

When straw will miss due to banana shape ,straws

will not make properly contact with packages. Due

to this reason technician disturb its basic setting.

Which takes time to restore.


ASU splice missing When splice will miss operator takes 30 to 40

minutes for manual joint which cause high MTTR.


37

Potential cause verification

Possible Causes Logic Verification Criteria Status

Conveyor When conveyor links break it takes more than 50

minutes to change because of conveyor layout .


38

1st Round Hypo-thesis

2nd Round Hypo-thesis

3rd Round Hypo-thesis

4th Round Hypo-thesis


Action

Why MTTR high due to technicians Response

time

Why work load on technicians

MTTR high due to

Technicians Response

time

Because of work load on technicians

Because of man power shortage on L,N,G,J machines

One tech=12 machines

Because of too many problems at same time

Because of behavior

Because of long path

between DE and Filler side

Only one door available for movement between both areas

Yes

No

No

Root Cause

1

Priority problem :

ProblemProblem

5 Whys

YesYes

Yes

Root Cause

2

Yes






Action

Why High MTTR due to

packet twisting

Why technician’s different competency

level Why technicians not trained

High MTTR due to packet twisting

Because of technician’s

different competency

level .

Lack of trainings Because of high work load training session not planned

Difficult to plan and spare technicians for training

Trainer not available

Because of complexity of the problem

Too much settings involved

High competency required for troubleshooting

Training required for competency building

No standard procedure is define for trouble shooting

Yes

Priority problem :

ProblemProblem

5 Whys

YesYes

Yes

Root Cause

3

Yes

No

Yes Yes

Yes

Root

4

Root Cause

4

Root Cause

3






Action

Why High MTTR due to splice miss

Why Splice sequence interrupt

Why air leakage

Why brittle pipes

High MTTR due to Splice

miss

Because of splice

sequence interrupt

.

Because of air leakage from

system

Because of brittle pipes

Because no interval is define for pipes change

Because of sensors

Because ofPLC

Because of Temperature

Because of Constant heat bar

Because of sludge accumulate on heat bar

Because of software issue its heat bar is continuously on during CIP

Yes

Priority problem :

ProblemProblem

5 Whys

YesYes Yes

No

Yes

Root Cause

5

No

Yes Yes Yes

Root Cause

6






Action

Why MTTR high due to conveyor

why MTTR high due to conveyor

links change

MTTR high due to

Conveyor

Because of adjustment

and conveyor broken links

change.

Because of conveyor lay out it is very difficult to

work on congested area

Because of speed adjustment

Because of drive gear

box

Yes

No

No

Root Cause

7

Priority problem :

ProblemProblem

5 Whys

Yes






Action

Why Straw missing

takes high MTTR

Why MTTR high due to banana shape straw

Why MTTR is high due to applicator setting

High MTTR due

to Straw

Missing

Because of Banana

shape straw.

Because of straw applicator settings

Because applicator setting takes too much time. No standard procedure is define for set applicator unit according to banana shape straw

Because conveyor speed

Root Cause

8

Priority problem :

ProblemProblem

5 Whys

YES YES

No

YES






Action

Why MTTR high due to

straw missing

Why MTTR high due to dot missing

why MTTR high due to solenoid

valve and its module

Why solenoid valve malfunction

MTTR high due to straw

missingBecause of

glue dot missing

.

Because of solenoid valve and its

module

Because of solenoid valve and its module

malfunction

Because of continuous operation and its interval is not define it takes too much time for trouble shoot during production

Because of electrical supply

Because of temperature

Yes

No

No

Root Cause

9

Priority problem :

ProblemProblem

5 Whys

YesYes Yes

Problem

ProblemProblem

IMPROVE Phase

46

IMPROVE Phase

Problem

•Brain Storming•Prioritisation Process•Action Plan•Before and After Time Series

ProblemProblemIMPROVE Phase Brain Storming

1. P1. Man power shortage.

2. P2. Only one door is available for DE and Filler side( long path)

3. P3. Lack of Trainings.

4. P4. No standard procedure is define for trouble shooting packet twisting problems.

5. P5. Pneumatic pipes interval not define.

6. P6. Software issue (ASU Constant heat bar).

7. P7. Conveyor Layout.

8. P8. Module and solenoid valve interval is not define it takes too much time for cleaning and change during production.

9. P9. Banana shape straws.

Action Plan (5W 2H)

WHAT WHY HOW WHERE WHO HOW

MUCH

WHEN STATUS

Long path between DE

and Filling side

Because of one door is

available. Technician

takes average 5 to 8 minutes

between Filler and DE side

By built new door or depute one

technician on DE side

At the front of L,N,G line

or

At shrink and straw

applicator

irfan Once Week # 14 Done

High MTTR due to lack of

trainings

Because un trained

technician takes extra time to resolve the problems as compared to

trained technician

Provide training to the Technician from

Tetrapak

Or

Provide training on the machine for

specific modules or problems

On the machine

Umair

Irfan

one week Week # 15 Done

High MTTR due to packet

twisting

Because of No standard

procedure is define for

trouble shooting also high

competency is required for

trouble shoot

preparing standard instructions for the

Technician On Machine

Imran

Touseef Once Week # 8 Done

Action Plan (5W 2H)


MUCH

WHEN STATUS

ASU Pneumatic

pipes leakages

Because of brittle Define interval

In 6000 hrsservice Touseef Once Week # 8 Done

Sludge accumulate

on ASU constant heat

bar

Due to machine Software issue

Modification In PLC Irfan Once Week # 13 Done

Conveyor

Due to conveyor layout it is very difficult for work on it.

Change Conveyor layout On Machine

Umair

mudasar

Once Week # 11 Done

50

Action Plan (5W 2H)

Prol


MUCH

WHEN STATUS

Solenoid Valve and

Glue module

Because of continues

operation it takes high

MTTR during production

By Define interval

In 3000 Hrs TPMS

check listAbdul moeed

Once Week #8 Completed

Banana shape straws

Due to quality issue

Increase quality checks ,block banana shape

straws

Educate the operators about banana shape

straws

.

O n Machine

Imran

Week # 9 Pending

Man power shortage.

Due to number of machines in Dairy and juice

Increase the number of

technician or Shift TBA 8 group

technician

Juice Filling lines

Umair

Irfan

Rasheed

Week # 7 Completed

ProblemProblem

51

Prioritisation Of Root Causes

Effort

Impa

ct

High

High Priority / Do It!

More Strategic? / Simplify or Split

Low

DropExecute if no other priorities

Low

P1

P6

P7

P3

P4

P9

P5

P8

P2

ProblemProblem

52

Time Series Plot: Before and After

Prol

ProblemProblem

SAM used for data collection

Before After

Improve

Mach

ine M

TT

R in

Min

ute

s

Weeks Numbers

0

10

20

30

40

50

60

70

30 31 32 33 34 35 36 37 38 39 40 41 42 45 46 47 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Current Position

Target

Average MTTR

Bench Mark

DefineDefine

53

Control Phase

CONTROL

Standardize and make Future Plans

Problem

•OPLs•Checklist •Training•Update Financial Sheet.•Update Skill Matrix.•SWOT Analysis.

ProblemProblem

Shift Coverage (number of technicians increased for

line LNGJ)

54

Focus Groups - 2015Crystal(C M B P F)

Valencia(L N G J)

Prisma(V R W K)

Everyday(H U O D)

Ahsan Ullah Javed Asghar Abdul Moeed Arsalan Ashraf

Imran Virk Rizwan Nasir Abbas M. Kamran

Muhammad Tauseef Salahuddin Ahmed Raza Arshad Mirza

Kaleem Zeeshan Asad Raza Umer Mahfooz

Asif Mohsin Hamood Abu Huraira

Abbas S. Kamran Babar Hussain

Saeed Khan Hafiz Khalid

Sohaib Minhas

Initials/YYYY-MM-DD Security Level / 1

ProblemProblem

ASU Pneumatic pipes (interval define)

55

A3 Speed 6000hrs TPMS Extra Task Sr # Task Task Description Part # New P/N Part

Description QTY

Time

1 Change Station chain bearing 321330-0108 Bearing 12

2 Change Seal 90458-1387 Seal 1

3 Change In feed bearing seal 90091-0438 Seal 22.5

4 Change In feed bearing bearing 90214-0096 344226-0105 Bearing 2

5 Change Out feed brush seal 90091-0406 Seal 1

26 Change Out feed brush bearing 90214-0165 90603-2356 Bearing 1

7 Change Out feed brush bearing 90214-0225 90603-2403 Bearing 2

8 Change A-3speed bottom flap drive bearing 321308-0205 344224-0205 Bearing 22

9 Change A-3speed bottom flap drive Seal 90091-0148 Seal 2

10 Change pneumatic pipes of ASU 315400-0004 Hose 100m

6

11 Change pneumatic pipes of ASU 315400-0001 Hose 100m

12 Check Inspection of jaw chain sprocket bearing 0:30

13 Check In feed shaft 0:05

14 Check Waste box cylinder check 0:10

15 Check Out feed brush shaft 0:10

16 Check A-3speed bottom flap drive shaft 0:10

17 Check All forming ring roller 0:20

Time 16:00

ProblemProblem

56

Standard work for Final folder settingsProblemProblem

Standard work for Out feed packages twisting problem

57

OPL FOR SOLINOID VALVE

58

Color Strip should be on the side of Small Bended Pipe

ProblemProblem

Standard Setting of Straw Applicator

59

Recommended Setting For Line G Straw Applicators

Ser. Checks Recommended

1 Machine air pressure 5.5-5.8 Bar

2 Pressure of Hotmelt nozzle 4.5 Bar

3 Hot melt tank pump pressure 3 Bar

4 Position of upper glue under the bend

5 position of lower glue Straw bottom edge

6 position and Angle of upper glue nozzle 10-15°

7 position and Angle of lower glue nozzle 10-15°

8 Applicator unit angle 23° right

9 Position of Straw on package -4 mm

10 Glue position lower -3mm

11 Glue position upper -7mm

12 Glue duration lower 14ms

13 Glue duration upper 16ms

14 Out feed queue deactivation delay 2700ms

15 Out feed queue alaram activation delay 10000ms

16 Discharge Speed factor 5%

17 infeed Speed factor 5%

18 Temperature of Tank 145 °C

19 Temperature of Upper Glue Nozzle 155 °C

20 Temperature of Lower Glue Nozzle 155 °C

21 Temperature of upper Glue Hose 150 °C

22 Temperature of lower Glue Hose 150 °C

23 Conveyor Fine tune -2HZ

ProblemProblem

60

ProblemProblem

Modification in PLC for ASU Constant Heat Bar

Training of Technicians

61

Training for Technicians about settings

ProblemProblem

Financial Impact

62

ProblemProblem

Estimated Annual Savings 4.4 Mio (approx)

NPH 5465

BD # 542

Before Hrs Lost 129.7 MTTR 32.3

After 90.8 MTTR 22.7

Saved 87.6

Lean Permannent 2 400 800

Labor 5 140 700

Electricity 64 16.4 1049.6

Steam 100 16 1600

4149.6

Financial Saved 363,504.96

Flush Flush Saved (Hrs) 87.6

Ton 438

Conversion Cost/Ton 10000

Saved 4,380,000.00

Competency Matrix

63

WB Project Team nameTeam Leader Team Member Team Member Team Member Team Member Team Member Average

competency level

Function Function Function Function Function Function

Irfan rasheed Imran inam Abdul moeed Tauseef Awais

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Cu

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DMAIC Overview2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 2 3 1 1 2 3 3 1 0 1.7

13 3.1

31.4

10.1

3

WB roadmap3 4 4 1 0 1 2 2 1 0 2 2 2 0 0 2 2 2 0 0 1 2 2 1 0 2 2 2 0 0 1.7

12.2

92.2

50.5

4-0

DEFINE phase2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 2 3 3 1 0 2 2 3 1 1 3 3 3 0 0 1.8

63 3.1

31.2

70.1

3

MEASURE phase2 4 4 2 0 1 3 3 2 0 1 3 3 2 0 1 3 3 2 0 2 3 3 1 0 2 3 3 1 0 1.7

13.1

43.1

31.4

1-0

ANALYSE phase2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 2 3 1 1 1 3 3 2 0 1.4

33 3.1

31.7 0.1

3

IMPROVE phase3 4 4 1 0 2 3 3 1 0 3 3 3 0 0 1 3 3 2 0 1 2 3 2 1 1 3 3 2 0 1.8

63 3.1

31.2

70.1

3

CONTROL phase3 4 4 1 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 1.7

13.1

43.1

31.4

1-0

DMAIC storyboard3 4 4 1 0 2 3 3 1 0 2 3 3 1 0 2 3 3 1 0 2 2 3 1 1 1 3 3 2 0 1.8

63 3.1

31.2

70.1

3

WB Tollgate content2 4 4 2 0 1 3 2 1 -1 1 2 2 1 0 1 2 2 1 0 1 2 2 1 0 2 2 2 0 0 1.2

92.4

32.2

50.9

6-

0.2

Member Gap Before and After2.4

44 4 1.5

60 1.2

22.8

92.7

81.5

6-

0.11.8

92.7

82.7

80.8

90 1.3

32.7

82.7

81.4

40 1.6

72.2

22.7

81.1

10.5

61.6

72.7

82.7

81.1

10 1.6

82.8

92.9

31.2

50.0

4

Score Definition:1 Knowledge not acquired / required2 Basic knowledge, but no competency3 Can practice with help4 Can do alone5 Can train others

ProblemProblem

YOU

ProblemProblem

Documents

White Belt DMAIC Project Line G MTTR