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

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

CUSTOMER AND QUALITY FOCUS CUSTOMER AND QUALITY FOCUS 3

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

DIAGNOSTIC APPROACH 5

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

DEFECTS PICTURES 7

METHODOLOGY FOR DEPLOYMENT 8

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

IMPLEMENTATION OF 7QC TOOLS TO SOLVE THE QUALITY PROBLEMS 10

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

 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

Collection of the Data LINE CARTON PACKING SECTION Date1: Defects/ Rejection Date2: Defects/ Rejection Date3: Defects/ Rejection Date4: Defects/ Rejection Date5: Defects/ Rejection Date6: Defects/ Rejection Date7: Defects/ Rejection Sr. No. DefectsA1A2B1B2 A1A1 A2B1B2A1 A2A2 B1B2A1A2B1B2A1A2B1 B2B2 A1A2B1B2A1A2B1B2 1 Machine Punching problem Flap opening problem Leakage problem Vendor end PM problem Adhesive pasting problem Printing problem Weight variation TOTAL

LINE CARTON PACKING SECTION Date1: Defects/ Rejection Date2: Defects/ Rejection Date3: Defects/ Rejection Date4: Defects/ Rejection Date5: Defects/ Rejection Date6: Defects/ Rejection Date7: Defects/ Rejection Total Sr. No. DefectsA1 A2A2 B1B2A1 A2A2 B1B2 A1A1 A2 B1B1 B2 A1A1 A2B1 B2B2 A1A2B1B2A1 A2A2 B1B2A1A2B1B2 1 Machine Punching problem Flap opening problem Leakage problem PM specifications problem 0 5 Vendor end PM problem Adhesive pasting problem Printing problem Weight variation Inner laminate problem 0 10Others 0 11 TOTAL

Histograms/Pie Chart of Defects 15

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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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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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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

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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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

QC TEAM EFFORT 26

AFTER IMPLEMENTATION DATA 27

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Sr. No. DefectsBeforeAfter QC% Changes 1 Machine Punching problem Flap opening problem Leakage problem Vendor end PM problem Adhesive pasting problem Printing problem Weight variation Inner laminate problem Total Effect/ Improvement % DATA ANALYSIS AFTER QC 29

Defects Rate After QC Defects Rate Before QC Defects Rate Before QC: Mean = 410 Defects Rate After QC: Mean =

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FINANCIAL BENEFITS DERIVED 32

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

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

SUSTAINABILITY AND APPLICABILITY 35

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

PACKING M/C UTILISATION DETAILS 37

The journey to 100 miles begins with a single step

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