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LEONY Y. SINGSON

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LEONY Y. SINGSON JUNE ,2010 ISO 14001:2004 CI/3414I/03/12/361 CIP/3414I/03/12/361 ISO 9001:2000 Universal Robina Corporation Packaging Division - BOPP Films COMPANY ... – PowerPoint PPT presentation

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Title: LEONY Y. SINGSON


1
LEONY Y. SINGSON JUNE ,2010
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4
COMPANY PROFILE
UNIVERSAL ROBINA CORPORATION PACKAGING
DIVISION IS AN ISO 90012008 140012004
CERTIFIED PLANT CAPABLE OF PRODUCING MORE THAN
30,000 MT OF BI-AXIALLY ORIENTED POLYPROPYLENE
(BOPP) FILMS PER YEAR.
  • APPLICATIONS
  • - PLAIN FILM for Printing, Lamination flower
    packaging
  • - TAPE FILM for Pressure sensitive adhesive
    tape application
  • - HEATSEALABLE FILM for printing, lamination
    and over wrap
  • - CIGARETTE FILM for Tobacco Industries
  • - WHITE FILM for soap, chocolate wrapping
    labels
  • - MATT FILM FOR Printing lamination for
    brochures poster.
  • - METALLIZABLE FILM for Vacuum Metallizing

5
OVERVIEW OF THE PROCESS
6
INSTRUCTIONS
PROBLEM STATEMENT

On time and in full (OTIF)
delivery commitment below the target
7
DELIVERY COMMITMENT MONITORING OCT2009 MAY2010
Date Schedule of Item Actual Delivery Actual Delivery Actual Delivery Actual Delivery
Date Schedule of Item On Time OTIF
Oct-09 227 221 97.36 191 84.10
Nov-09 395 394 99.75 217 54.90
Dec-09 374 374 100.00 273 73.00
Jan-10 289 287 99.31 181 62.63
Feb-10 460 458 99.57 328 71.30
Mar-10 331 301 90.94 231 69.79
Apr-10 305 305 100.00 245 80.33
May-10 327 323 98.78 262 80.12
Average 338.50 332.88 98.21 241 72.02
8
CHALLENGE
  • BACKGROUND OF THE PROBLEM
    (What is the
    current scenario and assumptions regarding the
    problem? What was the situation or concern that
    had developed prior to the application of KT
    process? How were you dealing with this issue
    prior to the application of KT process?)
  • Perceived unreliable supplier
  • Projected opportunity loss per month Php5.18M

9
RESPONSE TO THE CHALLENGE
  • APPLICATION OF KT PROCESS
    (How was
    the challenge addressed? What KT processes and
    supporting methodologies were used? How were they
    implemented by KT and by you? How has KT made a
    difference or changed the way issues are
    resolved?)
  • After the problem analysis, we established a
    method that keep analysis visible to everybody.
    Then we identify Possible Causes using DA.

10
MAJOR / CHRONIC DOWNTIME FOR LINE 2 FROM JANUARY TO APRIL 2010
Line Component Reason for downtime No. of Occurrences No. of Occurrences No. of Occurrences No. of Occurrences No. of Hours lost No. of Hours lost No. of Hours lost No. of Hours lost Remarks
Jan Feb Mar Apr Jan Feb Mar Apr
Edge trim grinder Grinder overload Edge trim grinder motor drive fuses blows 0 9 10 21 0 30.5 46.7 63.8 Fixed on April 18 no recurrence since
Pre-dosing system System fault System shows negative weight then stops fill/refill cycle and eventually shuts down the line 0 0 2 11 0 0 7 16 Still a recurring problem we have asked for Bruckner's help to improve cooling in the area and improving cooling of electronics
Main dosing system Valve Malfunction Main dosing slide valve goes out of position due to mechanical blockage in the slide guides mainly due to PP powder accumulation 10 0 1 2 45.2 0 7.4 9.2 Fixed in January by reshaping slide valve
Chiller 3 Chiller 3 was not working This cause high temperature of Chill roll and water bath 3 0 0 0 10 0 0 0 Fixed in February after rehabilitation work of chiller 3
Chill rolling walker displacing motor Motor based detached This caused wrong position of water bath vs Chill roll 4 0 0 0 18.8 0 0 0 Fixed
11
Line Component Reason for downtime No. of Occurrences No. of Occurrences No. of Occurrences No. of Occurrences No. of Hours lost No. of Hours lost No. of Hours lost No. of Hours lost Remarks
Jan Feb Mar Apr Jan Feb Mar Apr
Pull rolling walker system Loose drive belt of pull rolling walker system Belt was already worn out 0 3 0 0 0 11 0 0 Fixed, replaced belt and adjusted tension
Hot Oil burner Burner fault Found defective relay for the burner firing sequence 0 0 5 0 0 0 14.4 0 Fixed
WATER REMOVAL BLOWER Stuck up blower Upon inspection it was found that the blower was running above the rated speed leading to frequent failures 0 0 1 0 0 0 8 0 Fixed We ran slow speed in March while the blower was out
COMPUTER SERVER Hard disk for server defective 1 0 0 0 352 0 0 0 Fixed Server and disk drive imported from Germany
12
Risk Probability Weight
Plant Unscheduled Shutdown 10 10 100
In House Rejects above target of 5 5 5 25
Realistic and Workable Mainline Scheduling 5 4 20
No Sales Order due to Credit Concerns 10 5 50
13
Risk Probability Weight
Hold Delivery 10 4 40
Truck Availability 10 2 20
Conclusion Plant unscheduled shutdown is the main root cause of OTIF delivery commitment lower than target
14
List of possible causes
POSSIBLE CAUSES RISK PROBABILITY WEIGHT
1. Ageing Machineries 7 6 42
2 Lack of dedicated personnel to handle Maintenance Planning 5 5 25
3. No established Preventive Program 8 8 64
15
ACTION PLANS
Corrective Actions RESPONSIBLE PERSON TIME FRAME
1. Complete audit of Machines performance RPM July 2010
2. Rehabilitation of machines RPM 6 months to 1 year
3. Assign a dedicated maintenance planner HPC June 2010
4. Implementation of comprehensive preventive maintenance program Planning Engineer ongoing

16
Potential Problem Analysis
Potential Problem Contingent Action Triggers
1. Incomplete Audit of Machines Performance Hire competent Consultant No accomplishment
2. No available Spare Parts Consult for Parts modification Failure to comply
17
RESULTS
  • FINAL RESULTS
    (What
    solution was chosen? What results were achieved?
    What were some key learnings from the
    experience?)
  • Audit and evaluate machine condition,
    continuously implement comprehensive maintenance
    program that will eventually lead to minimum
    unscheduled downtime and optimize plant
    operations.
  • Action plans that make good score and produced
    results were generated and implemented within
    define time frame.

18
THANK YOU
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