2. DL SHAH AWARD QUALITY COUNCIL OF INDIA QUALITY IMPROVEMENT & STANDARDIZATION IN THE LINE CARTON PACKAGING CATEGORY – SPICES DHARAMPAL SATYAPAL GROUP DS SPICECO PVT LTD B-19, SECTOR – 3, NOIDA, U.P. INDIA 1

3. Contents Customer and Quality Focus Diagnostic Approach Methodology for Deployment Implementation of 7QC Tools QC Team Effort Financial Benefits Derived Sustainability and Acceptability 2

4. CUSTOMER AND QUALITY FOCUS CUSTOMER AND QUALITY FOCUS 3

5. CUSTOMER/ STAKEHOLDER SATISFACTION  Improved Quality  Improved Productivity  On-time Delivery  Optimum Utilization of Resources Social benefits Energy Conservation Optimum Utilisation of Resources/ Inputs – RM, PM etc. Indirect Benefit – Reduction in the Cost of Production 4

6. DIAGNOSTIC APPROACH 5

7. METHODS OF IDENTIFICATIONS OF THE INTERNAL PROBLEM Collection of random product/ Defects samples Interaction with Machine Operators /Supervisors about the Defects Review of previous data with Trend Analysis/ Review of all the above Problems Identification and Categorization of problems Authentication of the Defects 6

8. DEFECTS PICTURES 7

9. METHODOLOGY FOR DEPLOYMENT 8

10. METHODOLOGY Formation of QC Team Training Data Collection Data Analysis Root Cause analysis Collective Decision for Improvements Allocation of Responsibilities Implementation Review of Result Data collection Improvement Analysis Run chart preparation Process Modifications STANDARDIZATION 9

11. IMPLEMENTATION OF 7QC TOOLS TO SOLVE THE QUALITY PROBLEMS 10

12. QC TEAM Name of the Team – ISHIKAWA No. of Team Members – 4 Team Leader Team Member 1Team Member 2Team Member 3 11

13.  Formation of Quality Circle  Identification of problems  Allocation of Responsibilities  Monitoring and study of collected samples  Review and analysis of data  Categorization of defects  Root Cause Analysis  Corrective Action  Implementation and follow up with the result  Final Review of the Output DEGREE OF EFFORTS EMPLOYED 12

14. Collection of the Data LINE CARTON PACKING SECTION Date1: 7-7-14 Defects/ Rejection Date2: 8-7- 14 Defects/ Rejection Date3: 9-7-14 Defects/ Rejection Date4: 10-7-14 Defects/ Rejection Date5: 11-7-14 Defects/ Rejection Date6: 12-7-14 Defects/ Rejection Date7: 13-7-14 Defects/ Rejection Sr. No. DefectsA1A2B1B2 A1A1 A2B1B2A1 A2A2 B1B2A1A2B1B2A1A2B1 B2B2 A1A2B1B2A1A2B1B2 1 Machine Punching problem 2293062 313 1 231 3 2 Flap opening problem 6 1 2014 6 36562426184152 3245 3Leakage problem1284553742251324330 5526122560242617 1515 3513462562332210 5 Vendor end PM problem 11 42 212 1 6 Adhesive pasting problem 723960 43594222735219 12 5 743615080391463 1515 6178308435 1875 7Printing problem297 19 0 42016 144 90 171676 40 163 6 8Weight variation515883491330 41080 2940 103255412630256152107 11 TOTAL 551282136120149121 9474 151125 47 266114171280202 97 121272 42 152101127139103 8644 243 13

15. LINE CARTON PACKING SECTION Date1: 14-07-14 Defects/ Rejection Date2: 15-07-14 Defects/ Rejection Date3: 16-07-14 Defects/ Rejection Date4: 17-04-14 Defects/ Rejection Date5: 18-07-14 Defects/ Rejection Date6: 19-07-14 Defects/ Rejection Date7: 20-07-14 Defects/ Rejection Total Sr. No. DefectsA1 A2A2 B1B2A1 A2A2 B1B2 A1A1 A2 B1B1 B2 A1A1 A2B1 B2B2 A1A2B1B2A1 A2A2 B1B2A1A2B1B2 1 Machine Punching problem 4901 14 2 Flap opening problem 311012901198 3040261286 110110 423482258425 4819138 693 3 Leakage problem 1371535301718 22 5 22062 16 2 14 8 16 5 46 0 10 6 60 350350 13 2 120979379 2828 773743646045 3085 4 PM specifications problem 0 5 Vendor end PM problem 2110053 43 28 6 Adhesive pasting problem 286 68 135322 50 119400387363311 6080 645125165210116100130202254 43 396112275 86 250120 5810 7 Printing problem 743610 6 113 62 290280 312085 0 143 28 0 125121140 2242 633 642543396190 107 2690 8 Weight variation 94 2 5210 6 18 150127 4 50 0060 55 0 19 0 80 4 112 40 117 3 51 4 40 0 1044 9 Inner laminate problem 0 10Others 0 11 TOTAL 600142242381200220 10761023 468554323285 1284 274366795430363377363 1136 179640220456234453280 13364 14

16. Histograms/Pie Chart of Defects 15

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19. Name of Defects Causes of DefectsCompleted Corrective Action Machine Punching problem Non Compliance to scheduled maintenance Maintenance Schedule adhered Lack of Suction in Vacuum Pump Vacuum pressure gauge installed Improper Magazine setting Operators has been trained 18

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21. Name of Defects Causes of DefectsCompleted Corrective Action Flap opening problem Flap opening diagonal finger unit not installed Line carton diagonal fingers installed Ear guide alignment found out of order Ear guide alignment done 20

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23. Name of Defects Causes of DefectsCorrective Action Taken Leakage problem Improper inner laminate pasting Discussed the issue with the supplier. Corrective action has been taken Improper Sealer alignment Sealer alignment done. Alignment to be checked frequently. Improper setting of Diagonal Fingers Diagonal Finger setting has been done. Alignment to be checked frequently. Improper setting of temperature Standard operating temperature displayed on machines. Operators have been trained. Sealer pressure not Standardized Pressure standardized and displayed at the machines. Material filling at the sealing point Vibrator plate setting has been done. Setting to be checked regularly Material handling system is not defined Material handling system has been established. Training has been provided to all concerned. 22

24. Name of Defects Causes of DefectsCompleted Corrective Action Adhesive pasting problem Packing material gsm not specified (Thickness) not specified. Packing material and GSM specified for every SKU. Adhesive solution not specifiedStandard solution ratio has been defined Insufficient Flap Perforation Vendor has been communicated and the problem has been sorted out. Contamination of adhesive by spice powder Adhesive box top cover installed to make sure that raw material does not mix with the adhesive. Flap pusher plate alignment missing Alignment done and to be checked regularly Conveyer cleaning not properly Spare conveyor belt has been made available. Cleaning method has been defined. Misalignment of applicator Glue applicator guide alignment checked & corrected. 23

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26. Name of Defects Causes of DefectsCompleted Corrective Action Weight variation Material spillage due to Improper Funnel design Moving Funnel design (spillage control) is under process with OEM. Hopper filling level is not maintained as required Filling level has been identified. Minimum level is to be maintained. 25

27. QC TEAM EFFORT 26

28. AFTER IMPLEMENTATION DATA 27

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30. Sr. No. DefectsBeforeAfter QC% Changes 1 Machine Punching problem 140 100 2Flap opening problem693603 12.98 3Leakage problem30851136 63.18 4Vendor end PM problem2879 -182.14 5 Adhesive pasting problem 58101279 77.98 6Printing problem2690662 75.39 7Weight variation1044578 44.63 8Inner laminate problem00 0 9 Total Effect/ Improvement 13364433767.54% DATA ANALYSIS AFTER QC 29

31. Defects Rate After QC Defects Rate Before QC Defects Rate Before QC: Mean = 410 Defects Rate After QC: Mean = 361.4 30

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33. FINANCIAL BENEFITS DERIVED 32

34. FINANCIAL AND TANGIBLE BENEFITS After the Implementation of the 7QC tools for Quality Improvement with Internal Why Why analysis, the following Financial benefits are accrued by the Plant 33 FINANCIAL AND TANGIBLE BENEFITS Following Financial benefits are accrued by the Plant. 1)Saving of in Reproduction / Reprocessing Cost of 2.1% Rejected Materials of the Total Production 2. Reduction in the Cost of other Complementary Cost of the Production and Improve in Productivity – Manpower, Energy and Other Variable costs of the Production – Direct and Indirect

35. 1.REDUCTION IN PRODUCT CHANGEOVER/ MACHINE STOPPAGE TIME Analysis results the following outcomes:  Machine utilization against products  Machine utilization against packing materials used  Product selection against machine performance  The above improves the utilization and stability of the machines. 2. RE-DESIGN OF THE PACKING MATERIAL QC on Packing Materials is in vogue in the System with the following areas;  Re-assess the Packing Materials with the Target of reducing Opening Problems  Reduction in the Quantity of the PM as per the M/c specification.  Reduction of Leakage problems in the finished products  Reduction in cost of the Packing Materials 3. REDUCTION IN THE PRE-PRINTED MATERIAL INVENTORY  Converted the Manual Printing Inventory by Online Printing  It reduces the Huge inventory in the Line  Spaces are saved with Discipline in Handling  Saved in Manpower with Optimum Utlisation in the Packing Lines KNOWLEDGE CREATION 34

36. SUSTAINABILITY AND APPLICABILITY 35

37. SUSTAINABILITY OVERALL EQUIPMENT EFFICIENCY CALCULATION DESIGN AND MAINTAIN OF MIS (Management Information System)  OEE Calculation of the Machines (Availability X Performance X Quality)  Control Chart with Corrective Action  Defects Calculation Chart 36

38. PACKING M/C UTILISATION DETAILS 37

39. The journey to 100 miles begins with a single step

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