INTERNSHIP REPORTDone byGuided byanil Vishnu bk n sreenivasannit calicutmanager (bb),hll akkulam
AFT TRIVANDRUMAkkulam factory (AFT) is the 2 largest manufacturing plant of HLL in Trivandrum district. Which is set up in October 1992.In which the main production in this unit are Blood bags, Needles, Tubes, Suture implants, Copper T.
PROBLEM STATEMENTReduce the rejection in 4UP HF Welding by finding out the root causes of the rejection in blood bag manufacturing unit of Akkulam factory of HLL Life care Ltd
Importance of the projectCompany now facing around 4.5% rejection per annumTotal loss 66 lakhs per annumReducing 1% will save around 13 lakhs per annum
OBJECTIVESFind out the total rejection in 4UP HF weldingList out the various reason for the rejectionFind the root causes for the rejectionImplement the remedies to reduce the rejectionReduce the rejection percentage within the range of 1-2%
RESEARCH APPROACHCollection of Historical data on 4UP HF welding rejection.Detailed study about working of the machine.Comparison of historical data with online study on the machine.Finding out the problems in working of the machine.Searching for the root causes of the problem.Listing out the root causes of the problem.Taking Details about the input material for the machine.Detailed study about the requirement of input sheet for the machine.
Take samples from Sheet extruding machine.Take all readings as well as parameters of the sample sheet taken.Run the sample sheets in 4UP HF welding machine.Calculate the rejection percentage for the population from the sample.Compare it with Historical data collected.Implement the remedies for the reason for rejectionCompare the pre implementation and post implementation data.
DATA SOURCESPrimary:Primary data were collected through direct observation by sampling method. And also by discussion which have been held with various official employees and workers of the company. Secondary:Secondary data were collected through the historical data saved in the sorting register of the 4UP HF welding machine and also from various books, websites, company database etc.
Uniform thick sheet after extrusion
Production of blood bagsMaterial flow diagram
Raw material PVC granulesBlood bags after 4UP machine operationManually sorted bags
Process flow diagram
Sheet ExtrusionHF WeldingSortingLabellingAnti-coagulant fillingCoilingSealingSterilizationDryingVisual CheckPackingTube ExtrusionNeedle Production
HypothesisHo1: Rejection occurs in the m/c are because of the design imperfections in 4UP HF Welding
Ha1: Rejections occurs in the m/c are not because of the design imperfections in 4UP HF WeldingHo4:Excessive punching rejection in 4UP is due to thickness variation and there by bumps on input sheet
Ha4:Excessive punching rejection in 4up is not due to thickness variation and there by bumps on input sheetHo5:Rejection because of the feeding problem in the 4UP m/c
Ha5:Rejection is not because of the feeding problem in the 4UP m/cHo6:Rejection in sheet mainly because of the dust particle present in the bag
Ha6:Rejection in sheet mainly not because of the dust particle present in the bagHo7:Punching problem is because of the sticking of input sheet
Ha7:Punching problem is not because of the sticking of input sheetHo8:Punching rejection occurs mainly because of the mis-alignment of the m/c parts
Ha8:Punching rejection occurs not because of the mis-alignment of the m/c parts
Ho9:Punching rejection is mainly because of the bumps in the two ends of the sheet
Ha9:Punching rejection is not because of the bumps in the two ends of the sheetHo10:Punching rejection is due to variation of temperature using in the operation of sheet extrusion
Ha10:Punching rejection is not because of the variation of temperature using in the operation of sheet extrusionHo13:Sheet thickness variation is because of quality of pellet using.
Ha13:Sheet thickness variation is not because of quality of pellet using.
Method of study
1Collect the data from sorting department under various rejection
Classify the rejection under various category and find out which rejection is excessive.
2(A)Mark specific sheet from sheet extruderDraw chart for movement of the input sheet to the 4UP m/cNote down which roll is on the left & right side of the m/c rollerMark the movement of sheet in the 4UP m/c centres2(B) Observe the 2 pickup station processObserve kind of sheet that both pick up station accept & Reject from the samplesNote down the specific values of thicknessPoint out the sheet which is with more acceptable specific values
2(C) Find out the amount of rejection by both plates Take sample from the both accepted & rejected sheet.2(D) Collect 4 samples of imported sheetDivide sheet with length of 0.5 cmFind the thickness of each stripDraw the graph for thickness with length on x axis and thickness on y axisCollect the sealed sheet from the 4UP machineFind the thickness variation of the sheet along the length by cutting into strip of length 0.5cm and to plot it on the graphFrom a sample of 100 find out the total number of rejection in 4UP machineSo as to find the total percentage of rejection
3(A) Detailed study on how die is setting and the study on the parameters for the perfect sheetStudy on how to adjust the lip screws.
3(B).Take a set of sheet rolls which is in the accepted groupsTake samples from the taken sheet rollsDetermine the thickness from each sampleMake a trial run on the 4UP machine check whether the accepted sheets are running Properly on the machineNote down the sheet details with minimum acceptance level.
3(C).Take two sealed sheet samples from the 4UP machine which is not properly placed and the other is properly placedCompare the sheet parameters with the parameters of the imported sheet and the Sheets that are successfully running on the 4UP machineFormulate set of sheet parameters that are in region of acceptance for the 4UPmachine
Historical data collectionDATE-12/5/2016
SORTING DATED FROM 13/05/2016 TO 20/05/2016
CARD O/PM/C REJ/DUSTBAG WITHOUTTPSTOPPERCONNECTOR14385414783043153
WELDING COMPLAINT2WELDPUNCHINGOTHERSSORTED TPSTOPPERCONNECTOR% OF REJ6765567427065011410914.5
Month of MAY 2016
4 UP WELDING MONTH WISE REJECTION REPORT
MONTHTARGETACTUAL %M/C REJ %SORTING %TOTAL %OCT8,75,0008,60,61898.31.052.723.74NOV8,75,0007,90,04990.21.072.173.21DEC8,75,0007,99,60891.31.574.335.83JAN8,75,0008,36,31995.51.323.214.49
SORTING DETAILS KOREAN (1)
PRODUCTION DATE26/06/2016BAG TYPE350 ml TRANSFER BAG KORMASTER BATCH NOA126066KORSHIFTA
CARD O/PM/C REJ/DUSTBAG WITHOUTTPSTOPPERCONNECTOR99761023
WELDING COMPLAINT2WELDPUNCHINGOTHERSSORTED TPSTOPPERCONNECTOR% OF REJ165399760.3
4UP Roll Loading diagram
Sample sheet thickness calculation from sheet extruder
BATCH:W7624056B1-BSHIFT:BDATE:24/05/16PELLET NO:154730PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLLCOOLING ROLL EMBOROLLM/MIN 3.15 3.12 3.06DistanceThickness
Sealed sheet sample
BATCH:W7625056C1-BSHIFT:CDATE:25/05/2016OPERATORS:CKJ/GSMPELLET NO:154976-K76PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLLCOOLING ROLL EMBOROLLM/MIN 3.15 3.123.06Distance in cm Thickness in mm
Sample data collection
WELD COMPLAINT2 WELDPUNCHINGOTHERSTPSTOPPERCONNECTOR0012985600
Sheet specification with more acceptable levelBATCH:W7623056C1-BSHIFT:BDATE:23/05/2016PELLET NO:154730-K76PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLLCOOLING ROLL EMBOROLLM/MIN 3.15 3.123.06
DATE:25-02-2016TIME:04:31PVC SHEETDIMENSION:.35*260QTY:20KGLOT NO:92131186-13
BATCH:W7624056A1-FSHIFT:ADATE:24/05/16PELLET NO:154730PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLLCOOLING ROLL EMBOROLLM/MIN 3.15 3.123.06
Sheets that need to be avoided
BATCH:W7625056A1-ASHIFT:ADATE:25/05/16PELLET NO:154730K76PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLL COOLING ROLL EMBOROLLM/MIN 3.15 3.123.06
BATCH:W7628056A1-GSHIFT:ADATE:28/05/2016PELLET NO:154976-K76PARAMETERSTEMPERATURE - C1C2C3HD1D2D3IN OC 175179182185185185185TAKE OFF UNITNIP ROLLCOOLING ROLL EMBOROLLM/MIN 3.15 3.123.06
ConclusionLion share of the rejection is constituted by punching rejection which can be reduced by maintaining the thickness of input sheet in between 0.38 to 0.42 mmM/c or dust rejection can be reduced by reducing the rate of degradation in the extrusion die and also by controlling the floor waste.Proper maintenance in TP, CONNECTOR and BOV feeding section. Resorting of the rejected bags.
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