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Production, maintenance, risk assessment_FMCG company
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“On the Job Training”at
Hetauda, Makwanpur
(29 May to 29 August, 2012)
Pratap Jung Rai
Institute of Engineering, Thapathali Campus
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
• Ganga Soap & Chemical Ind. Is 3P Company of UNL
• Established in 2005 A.D.
• Total Area = 1500 squa. ft
• Plant Area = 1200 squa. Ft
• Administrative Employees = 8
• Workers = 51
Thick and Long
Jasmine
Black
Sunsilk
(3.5 ml)Sunsilk
Sunsilk Black
100 ml
350 ml
Sunsilk Pink
180 ml
350 ml
Sunsilk Hair fall solution
350 ml
Clinic Plus
100 ml 180 ml 425 ml
Hair Care Product produced by Ganga 3P
Unilever Nepal LimitedAbout Ganga Soap & Chemical Industries Pvt. Ltd
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff
Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
RO Plant
Water tank
DM water heater
Hot water Tank
Carbopol charger
SLES Charger
Side pot agitator Emulsion
pump
Mixer
Silverson pump
Transfer Pump
Holding Tank
Hopper
FFS M/C
CLD Packing
Filling M/C
Printing M/C
CLD Packing
Transfer Pump
1. Shampoo Production Process
Shampoo Production Process
Cont….
Shampoo Attributes/ComponentsShampoos generally comprise of an aqueous mixture of ingredientsa) CleansingPrincipal function of the shampoo is cleaning; the removal of sebum and environmental dirt from the hair and scalp. b) ConditioningTypical conditioning agents are cationic polymers and silicone emulsions. c) Functional AdditivesFunctional additive includes ingredients that are added to adjust the pH and viscosity of the shampoo. Acidic or alkali solution for pH and Salt for viscosity.d) PreservativesShampoo is high water content and high risk products for the growth of mould, yeast and bacteria. This could result in decomposition of the product and/or a potential health risk to the consumere) FragranceThe addition of a fragrance in shampoo production appears to be a trivial task f) Anti-OxidantsAnti-oxidants are used in shampoo formulations to prevent the formation of nitrosamines and to prevent problems caused by the oxidation of certain raw materials such as perfume.
Water Treatment
System
Ingredient Charging System
Manufacturing and Packing
System
Mixer
Product Holding Tank
Bottle filling
machine Form fill seal
Machine
CLD
packaging
Printing
Machine
CLD
packaging
Ware House
Opaque
Storage
RO Plant
Water Storage
DM Water Heater
Hot Water Storage Tank
SLES
Charger
Carbopol
Charger
Packing lines 3.5ml Sachet line – Two 8- Track M/Cs 7ml Sachet line – Two 5- Track M/Cs Bottle line – Filling and Packaging M/C
Shampoo Batch
Finished Products
Sachet shampooBottle shampoo
Ingredients Water + Preservative
Heating in jacketed tank(80-90 deg. C)
Mixing
Cooling(<40 deg. C)
Mixing (approx. 3 hr)
PreservativesPerfume
Shampoo Production Process Flow DiagramScametic diagram of Shampoo Production Process1. Shampoo Production Process
Name of Machine
Amount/Sachet
(ml)N0. of
Stroke/minuteNo. of Nozzle No. of shift
Total Sachetproduction/Track
(Ton)
Total Packing Capacity (Sachet + Bottle) (Ton/day)
5 track, 01 Machine 7 61 5 2 3.07445 Track, 02 Machine 7 60 5 2 3.0248 Track, 02 Machine 3.5 63 8 2 2.540168 Track, 03 Machine 3.5 65 8 2 2.6208
Total Production 11.25936
Filling and Packaging M/C 100 6 5 2 4.32 15.57936
Filling and Packaging M/C 180 6 4 2 6.2208 17.48016
Filling and Packaging M/C 350 3 4 2 6.048 17.30736
Filling and Packaging M/C 425 3 4 2 7.344 18.60336
Packing Capacity
Manufacturing Capacity….Mixer Capacity: 13.2 tons/dayHolding Capacity: 20 tons/day
Packing Capacity: 17.48 Tons /day (middle bottle + Sachet)
Shortfall = 4.28 tons/day
Bottleneck between Batch Making Capacity and Packing Capacity
Capacity is given in 100%
1. Shampoo Production Process
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff
Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
2. Assist to prepare Preventive Maintenance Check listBackground study for maintenance practices for Ganga 3P
• Study part replacement history of all Form Fill Seal machine of 9 months
Cont….
Subsequently, developed CLIT checklist and Preventive Maintenance checklist (which is also provided in Local Language)
Clutch brake, 1 Cup
washer , 1
horizontal heater, 5
perforation blade, 4
Rod end bearing, 1
vertical heater, 2
5 Track 01 M/C(14/09/2011-26/06/2012)
Cup washer , 1 Horizontal heater, 2
perforation blade, 1
SSR , 1Thermocouple, 1
Vertical heater, 6
5 Track 02 M/C(13/05/2012-28/06/21012)
Bearing , 2Cup washer
12D, 1
hinge with
harden pin, 1
Horizontal sealer, 2
One way clutch, 2
pencil heater, 4
perforation blade, 7
pull roller , 2Rotary
cutter, 5
8 Track 01 M/C(28/09/2011-26/06/2012)
Bearing, 3 Horizontal heater, 2
one way clutch, 3
perforation blade, 8
piston seal, 2
PLC, 1
Pneumatic cylinder , 2
pull roller, 1
Rotary cutter , 3
spool , 3
switch, 1 Thermocouple, 1
8 TRACK 02 M/C(28/09/2011-26/06/2012)
Know how about MTBF and MTBR
CLIT Maintenance ChecklistDaily CLIT Maintenance @ 11:00 am for 15 minute
C= CleanL=LubricationI= InspectionT =Tightening
Weekly Preventive Maintenance, Friday @ 11:00 am for 30 minute
Daily CLIT Checklist
Month: Time: 15 minuteBottle Filling Machine
Date: 11:00 AM
S.N. Where to check what to check solution Status
1
Piston - Cylinder, M/C Body, Conveyer Belt, Nozzle, Switch Panel, Printing M/C body
dirt/drops of shampoo
clean by clean cloth
2
Piston-Cylinder Hanger block with Bush dryness keep oil
Speed Breaker sleepinessclean by clean cloth
Weight Adjustment Block dryness keep oil
Drive Chain and sprocket of main drive and printing conveyer
drynesskeep new grease
3 Jugli Clamp, Union loose tighten
shift supervisorMachine operator
Daily CLIT checklist
Month Time: 15 minute FFS M/C No.
DateS.N Where to check what to check Solution Status
1
Hopper, Drive Area, Spool, Cylinder piston, Transparent Guards, Main motor Dirt/drops of shampoo clean with clean cloth
2
Sealer Assembly- Horizontal Sealerclean sealer weather laminate stick or not clean by wire brush
Filling and Drive Assembly dryness1. Rod End Bearing of Spool Drive keep oil2. Rod End Bearing of Main Drive keep oil3. Rod End Bearing of Filling Cam keep oil
3 Rotary Cutter Set dryness keep oil
4
Main Drive Chain/ Rotary Cutter Drive chain loose tighten if loose
5Weight Adjustment Block Dryness keep oil
6Collating Conveyer and bearing dryness, drops of shampoo
keep grease/ clean by white cloth
shift supervisor Machine operator
Cont….2. Assist to prepare Preventive Maintenance Check list
Previous Weekly Preventive Maintenance Checklist
Weekly Preventive Maintenance-ChecklistFFS Machine
Month:Time:
11:00 am
Date: Friday
S.N. where to check what to check what to do Remark Status
1Turnbar Assembly-All rollers Dirt, Shampoo Drops, Remove laminate, Clean with wet cloth
2Filling/Sealing Assembly Dirt, shampoo metallic dust clean the previous grease with brush white cloth and apply new grease
Filling guide shaft
Vibration, loose check nuts tighten it
All bevel gearsRack and Pinion Assembly
Main Drive ChainMain Drive Cham
Rotary Cutter Drive Chain
Horizontal Sealer Shaft
H Block Shaft
U Hinge and Harden pin
3Rod Heaters(to be done by electrician) Current Consumption Replace if damage
4Pneumatic line Air Pressure (6-8) psi clean pipes if blocked6Main Motor V belt Slag and tight adjust, tighten or replace
7Clamp of billet (laminate cutter) orientation, loose tighten, change billet
Modified Weekly Preventive Maintenance-ChecklistMonth: Foam Fill Seal Machine Time: 11:00 amDate: Friday
S.N. Sub s.n. Where (Location) What to check What to do Remarks Status
1
FillingI Guide bar shaft dirt in LM bearing, alignment or play clean LM bearing, replace if damageII Piston leakage carbon "O" ring and "U" seal leakage adjust or change if damageIII Rod end bearing Play, dryness keep oil, adjust or change bearing if damageIV Hinge with coupling drive play, loose bolt, key broken tighten bolt or change key if brokenV Bevel gear play, teeth, loose bolt, dryness tighten bolt, keep greaseVI Dog clutch with clutch sprocket chain play, bearing, teeth of sprocket tighten, keep oil or change clutch if damageVII Driven hinge with coupling loose bolt, oscillate rotation, key way tighten bolt, coupling or change if damage
2
SealingI Rod end bearing Play, dryness tighten, keep oilII Main drive chain play, dryness tighten, keep grease
III Horizontal sealer loose bolt, LM bearing, compression spring, dirtclean sealer and keep maintenance as per requirement
IV Heater (vertical and horizontal)loose connection, open circuit, shut circuit, current consumption
replace if damage
3
CuttingI One way clutch bearing check one way rotation, loose tighten or replace if oscillateII Rotary cutter bearing, cutting profile, dryness keep oil, change cutter if damageIII Idler chain with sprocket Play, teeth profile, dryness keep grease, replace if damageIV Perforation blade tie, loose bolt, broken tighten bolt or replace blade if damage
4
PullingI Pull roller cutter profile, dirt clean with dry white clothII Magnetic brake Gap clearance, coil test, current consumption tighten bolt, replace if damageIII Magnetic clutch Gap clearance, coil test tighten bolt, clean and replace if damageIV Spur gear teeth profile, play, dryness clean with dry white cloth and keep greaseV Rack and pinion teeth profile, dryness keep greaseVI Bevel gears teeth profile, play, dryness greasing, replace if damage
5
UnwindingI All roller Dirt/drops of shampoos clean by clean cloth
II Spring Check tension replace if damage
III Adjustment valve with thread Thread profile keep oil6 Pneumatic line Air pressure (6-8 psi) clean pipe if block
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
Laminate(83.106 kg/ton)
Wrapper Adjustment
(0.303Kg)
GSM(57.35)(0.539Kg)
Changeover(0.055Kg)
Leakage(1.889Kg)
Others
Wrapper Change Wrapper Breakage
Equipment Problem
SSR fault
Set up & Adjustment
Weight Problem Electrical Problem
Level sensor V/H heater
Perforation blade
Pull roller Rotary cutter
QC storage
Weight adj. cylinder
Weight adj. blockPneumatic cylinder
Loss tree of Laminate based on (3.5ml)
Wastage given in per ton
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLESCont….
Wrapper Adjustment
(0.303Kg)
GSM(57.35)
(0.539Kg)
Changeover
(0.055Kg)Leakage
(1.889Kg)
Wastage given in per ton
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLESCont….
Laminate(90.353kg/ton)
Wrapper Adjustment(0.506Kg)
GSM(73.51)(0.631Kg)
Changeover(0.083Kg)
Leakage(0.548Kg)
Others
Wrapper Change Wrapper Breakage
Equipment Problem
SSR fault
Set up & Adjustment
Weight Problem Electrical Problem
V/H heater
Perforation blade
Pull roller Rotary cutter
QC storage
Weight adj. cylinder
Weight adj. blockPneumatic cylinder
Loss tree of Laminate(7ml)
Wastage given per ton
Cont….3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLES
Total Losses
(1.768Kg)
Changeover
(0.083Kg)
Wrapper adjustment
(0.506Kg)
Leakage/Over or Under wt.
(0.548Kg)
GSM
(0.631Kg)
Wastage given in per ton
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLESCont….
SLES(200Kg)
Leakage(1 Kg)
Packing give away
(1.78 Kg)
SLES Loading(1.5Kg)
Sanitization(4.2Kg)
Others
Gland Pipe line
Circulation pipePump
QC storage
PCRO RuleWeight adj. block
Piston
Loss tree of Sodium lauryl ether sulfate (SLES)
wastage given in per ton
Cont….
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLES
SLES Loading(1.5Kg)
Sanitization(4.2Kg)
Leakage(1 Kg)
Packing give away
(1.78Kg)
Total Losses(7.98 Kg)
Wastage given in per ton
Cont….
3. Acquire knowledge of Techeff Calculation and dig out reasons and quantity for
Techeff Losses in case of sachet laminates and SLES
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff
Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
Initial proposed Capping unit installation
Cont….
Problems encountered in initial design Bridging between two conveyors
Maintain gap between flowing bottles
Difficult to change orientation of Bottle
So After discussion, Modified design
Back View
Top View
Side View Front
View
Filling m/c
Printing Bench
Domino printer
Stamper
Pneumatic cylinder
Belt conveyer
Metal Belt conveyer
4. Assist in Designing , Capping Unit Installation
Criteria for Capping unit installation Maintain gap between two bottle is 30-40 mm
Change the orientation of flowing bottle
Initial Design, Advantages of Initial Design1. No disturbance to Domino printing unit
2. Buffer better easy for packer
Objective of Capping Unit Installation Eliminate Ergonomic hazard in palm Man power Elimination
Filling m/c
Metal Belt conveyer
Domino Printer
Stamper
Belt conveyer
Opaque flowing Direction
Pneumatic cylinder
Advantages of Modified
Capping Unit Installation Address all above Criteria
No extra electricity consumption
Reduce space consumption
Required less maintenance
Modified view of Capping Unit
4. Assist in Designing , Capping Unit Installation
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff
Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
5. Assist to prepare FWS documents for upcoming FWS auditCont….
Following of the documents were missing at Ganga 3P
• Listing of Inventory of Tasks
• Prepared Critical Task Inventory (CTI)
• Prepared Task Hazard Analysis (THA)
SOP has been updated.
Prepared Standard Operating Procedure (SOP) of Ganga 3P. (in Local
Language)
3224
32
16
3224 24 24 24
16 1624
32
20
05
101520253035
Severity Ranking of THA Candidate Operation
S. No. Location Tasks
1 Production Hall FFS operator
2 Production Hall Bottle Filling operator
3 Production Hall Changeover Process in FFS machine
4 Production Hall Changeover process in Bottle Machine
5 Batch Mixer Area Batch Maker
6 Batch Mixer Area Batch Changeover
7 Batch Charging Area SLES and Carbopol Charging
8 Batch Charging Area Squeezing
10 Minor Wightman Room Minor Weightiest
11 Engineering Store Engineering Store
12 Cooling Tower operation
13 Compressor operator
14 Entire factory GHK
15 RO plant RO operation
16 DM plant DM water Heater operation
17 DG Room DG operator
18 RM/PM Area RM/PM handler
19 PCC Room PCC operator
20 Canteen Caterer
21 Grinding
5. Assist to prepare FWS documents for upcoming FWS audit
Inventories of Tasks
Risk = Consequence×Probability
Task : Bottle Filling Operator Ref : 2
Assessed By : Date :
S.No.SEQUENCE OF
BASIC STEPSHAZARDS & PERSONS AT RISK
POTENTIAL
HARM
EXISTING CONTROLS & SAFE
PROCEDURES
Evaluation of riskACTION & ADDITIONAL
CONTROLSS L R
1 Bottle placing MSD (Musculoskeletal Disorder) Minor Injury Shoes, Ergonomic Chair 2 2 4
2Operating filling
Nozzle
shampoo splashes may enter into eye, Hand in Machine
Major Injury 6 4 24Goggles, nozzle should be covered by Transparent plastic cover
3Conveyer motor
operationElectric shock Single Death
ELCB, VFD, Double earthing have been provided
8 2 16timely check the condition of ELCB and Earthing
4 Weight adjustmentHand may damage if spanner broken, shampoo splashes may enter into eye
LTA 4 2 8Goggles, adjust weight of shampoo by stopping machine
5 Domino operation Electric shock Single Death Double Earthing, ELCB, Safety shoes 8 2 16timely check the condition of ELCB and Earthing
6 CLD packaging hand may cut, CLD may fall from the stack Minor InjurySafety shoes, Safe stacking procedure exist
4 2 8
Occupationor Job Title : Bottle Filling operator
Completed by :
Reviewed by:
Reviewed on:
Approved by:
Tasks Loss Exposures Risk Evaluation Programme Needs
S.N.
List all tasks or activities normally done or that
might be done by a person in this occupation Safe
ty
Health
Fire /
Ele
Ris
k
Equip
me
nt
Environ
ment
Severity
Pro
babili
t
y
Ris
k
Pro
cedur
es
Skill
Tra
inin
g
Specia
l
Rule
s /
Perm
its
PP
E
1 Bottle placing Yes No No No No 2 2 4 No No No Yes
2 Operating filling Nozzle Yes No No Yes No 6 4 24 No No No Yes
3 conveyer motor operation Yes No Yes Yes No 8 2 16 No No No Yes
4 Weight adjustment Yes No No No No 4 2 8 Yes No No Yes
5 Domino operation Yes No Yes Yes Yes 8 2 16 Yes Yes Yes Yes
6 CLD packaging Yes No No No No 4 2 8 No No No Yes
Sample of CTI and THA
5. Assist to prepare FWS documents for upcoming FWS audit Cont….
Assigned Projects by Unilever Nepal Limited
1. Shampoo Production Process
2. Develop Preventive Maintenance Check list
3. Acquire knowledge of Techeff Calculation and dig out reasons for Techeff
Losses in case of sachet laminates and SLES
4. Assist in Designing - Capping Unit Installation
5. Assist to prepare FWS document for upcoming FWS audit
Extra Activities
Extra activities done
• Design a pictorial information of From Fill Seal Machine parts (so that operators could easily identify the parts and it’s name and accordingly carry out maintenance job)
• Leakage Trouble shooting of FFS machine
• Prepared Electrical diagram of Ganga 3P
(Leakage was found the major problem in FFS line so made “Trouble Shooting Guide to Leakage”.)
Posters of 5 and 8 track Machine Parts Name
Any Quarries?????
THANK YOU !!!