INTERNSHIP REPORT

DONE BY GUIDED BYANIL VISHNU B K N SREENIVASANNIT CALICUT MANAGER (BB),HLL AKKULAM

AFT TRIVANDRUM

Akkulam 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 STATEMENT

Reduce 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 project

Company now facing around 4.5% rejection per annum Total loss 66 lakhs per annum Reducing 1% will save around 13 lakhs per annum

OBJECTIVES

Find out the total rejection in 4UP HF welding List out the various reason for the rejection Find the root causes for the rejection Implement the remedies to reduce the rejection Reduce the rejection percentage within the range of 1-2%

RESEARCH APPROACH

Collection 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 rejection Compare the pre implementation and post implementation data.

DATA SOURCES

Primary: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 bags

Material flow diagram

Raw material PVC granules

Blood bags after 4UP machine operation

Manually sorted bags

Packed bags

Process flow diagram

Sheet Extrusio

n

HF Welding Sorting Labelling

Anti-coagulant

fillingCoiling

SealingSterilizationDrying

Visual Check Packing

Tube Extrusio

n

Needle 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 Welding

Ho4 : 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 sheet

Ho5 : Rejection because of the feeding problem in the 4UP m/c

Ha5 : Rejection is not because of the feeding problem in the 4UP m/c

Ho6 : 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 bag

Ho7 : Punching problem is because of the sticking of input sheet

Ha7 : Punching problem is not because of the sticking of input sheet

Ho8 : 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 sheet

Ho10 : 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 extrusion

Ho13 : Sheet thickness variation is because of quality of pellet using.

Ha13 : Sheet thickness variation is not because of quality of pellet using .

Protocol

Method of study

1 Collect 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 extruder Draw chart for movement of the input sheet to the 4UP m/c Note down which roll is on the left & right side of the m/c roller Mark the movement of sheet in the 4UP m/c centres2 (B) Observe the 2 pickup station process Observe kind of sheet that both pick up station accept & Reject from

the samples Note down the specific values of thickness Point 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 sheet Divide sheet with length of 0.5 cm Find the thickness of each strip Draw the graph for thickness with length on x axis and thickness on y

axis Collect the sealed sheet from the 4UP machine Find the thickness variation of the sheet along the length by cutting into

strip of length 0.5cm and to plot it on the graph From a sample of 100 find out the total number of rejection in 4UP

machine So 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 sheet Study on how to adjust the lip screws.

3 (B). Take a set of sheet rolls which is in the accepted groups Take samples from the taken sheet rolls Determine the thickness from each sample Make a trial run on the 4UP machine check whether the accepted

sheets are running Properly on the machine Note 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 placed Compare the sheet parameters with the parameters of the

imported sheet and the Sheets that are successfully running on the 4UP machine

Formulate set of sheet parameters that are in region of acceptance for the 4UPmachine

Historical data collection1. DATE- 12/5/2016

SHIFT TARGET ACTUAL REJECT DEVIATIONA 12,500 11,000 124 150B 12,500 10,000 100 2500C 12,500 11,000 180 1500

37,500 32,000 404 5500

TARGET ACTUAL REJECT DEVIATION0

2,0004,0006,0008,000

10,00012,00014,000

REJECTION REPORT- 12/5/2016

A B C

1. DATE 17/5/2016

SHIFT TARGET ACTUAL REJECT DEVIATIONA 12,500 2200 60 10,300B 12,500 8700 100 3800C 12,500 8200 68 4300

37,500 19100 228 18400

TARGET ACTUAL REJECT DEVIATION0

4,000

8,000

12,000

REJECTION REPORT-17/5/2016

A B C

1. DATE 19/5/2016

SHIFT TARGET ACTUAL REJECT DEVIATIONA 12,500 6500 96 6000B 12,500 3400 100 9100C 12,500 5000 100 7500

37,500 14,900 296 22600

SHIFT TARGET ACTUAL REJECT DEVIATION0

2000400060008000

100001200014000

0

12,500

6,500

96

6,000

0

12,500

3,400

100

9,100

0

12,500

5,000

100

7,500

REJECTION REPORT -19/5/2016

Series1 Series2 Series3

SORTING DATED FROM 13/05/2016 TO 20/05/2016

CARD O/P

M/C REJ/DUST

BAG WITHOUT

TP STOPPER CONNECTOR

143854 1478 304 3 153

WELDING COMPLAINT

2WELDPUNCHIN

G OTHERS SORTED TP STOPPER CONNECTOR % OF REJ

676 556 74 2706 501 141091 4.5

M/C REJ/

DUST

BAG WITHOUT

WELDING COMPLAINT

2WELD PUNCHING OTHERS0

500

1000

1500

2000

2500

3000

Sorting

Punching prob-lem

Connector comp ins pro

TP comp inser-tion pro

Others Bag w/out TP Bag w/out connector

2nd weld prob-lem

Total N0

20

40

60

80

100

120

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

61 13 12 6 5 2 1 100

61%

74%

86%

92%97% 99% 100%

Defects in 4UP HF-350 ml transfer bag

Item

Num

ber

Perc

enta

ge

This bar represents the total (N) of your pareto.

Caption box.

Month of MAY 2016

4 UP WELDING MONTH WISE REJECTION REPORT

MONTH TARGET ACTUAL % M/C REJ % SORTING % TOTAL %

OCT 8,75,000 8,60,618 98.3 1.05 2.72 3.74

NOV 8,75,000 7,90,049 90.2 1.07 2.17 3.21

DEC 8,75,000 7,99,608 91.3 1.57 4.33 5.83

JAN 8,75,000 8,36,319 95.5 1.32 3.21 4.49

SORTING DETAILS KOREAN (1)PRODUCTION DATE 26/06/2016

BAG TYPE 350 ml TRANSFER BAG KORMASTER BATCH NO A126066KOR

SHIFT A

CARD

O/PM/C

REJ/DUST

BAG WITHOUT

TPSTOPPE

RCONNECT

OR997

6 10 2 3WELDING COMPLAINT

2WELD

PUNCHING

OTHERS

SORTED

TP

STOPPER

CONNECTOR

% OF REJ

1 6 5 3 9976 0.3

4UP Roll Loading diagram

Sample sheet thickness calculation from sheet extruder

BATCH :W7624056B1-B

SHIFT : B

DATE : 24/05/16

PELLET NO : 154730

0.5 3 5.5 8 10.5 13 15.5 18 20.5 23 25.5 28 30.5 33 35.5 38 40.5 43 45.5 48 50.50.33

0.34

0.35

0.36

0.37

0.38

0.39

0.4

0.41

SHEET THICKNESS

PARAMETERS

TEMPERATURE - C1 C2 C3 H

D1 D2 D3

IN OC 175 179

182 185 185 185 185

TAKE OFF UNIT NIP ROLL COOLING ROLL

EMBOROLL

M/MIN 3.15 3.12

3.06

Distance

Thick

ness

Sealed sheet sample

BATCH : W7625056C1-B

SHIFT : C

DATE : 25/05/2016

OPERATORS : CKJ/GSM

PELLET NO : 154976-K76

0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 10.5

11.5

12.5

13.5

14.5

15.5

16.5

17.5

18.5

19.5

20.5

21.5

22.5

23.5

24.5

25.5

26.5

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

SEALED SHEET THICKNESS VARIATION

TOP BOTTOM

PARAMETERS

TEMPERATURE - C1 C2 C3 H D1D2 D3

IN OC 175 179 182 185185 185 185

TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL

M/MIN 3.15 3.12 3.06

Distance in cm

Thi

ckne

ss in

mm

Sample data collection

CARDO/P

M/C/

DUST

BAG WITHOUT

TPSTOPPER

CONNECTOR

6108 116 0 0 0

WELD COMPLAINT2

WELDPUNCHI

NGOTHE

RSTP STOPPER CONNECTOR

0 0 129 8 560 0

14%

16%

1%69%

CONCLUSIONM/C/DUST BAG WITHOUT TP BAG WITHOUT STOPPERBAG WITHOUT CONNECTOR WELD COMPLAINT TP WELD COMPLAINT STOPPERWELD COMPLAINT CONNECTOR 2 WELD PUNCHINGOTHERS

Sheet specification with more acceptable level

BATCH : W7623056C1-B

SHIFT : B

DATE : 23/05/2016

PELLET NO : 154730-K76

0.5 4 7.5 11 14.5 18 21.5 25 28.5 32 35.5 39 42.5 46 49.5 530.37

0.375

0.38

0.385

0.39

0.395

0.4

0.405SHEET THICKNESS

PARAMETERS

TEMPERATURE - C1 C2 C3 HD1 D2 D3

IN OC 175 179 182185 185 185 185

TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL

M/MIN 3.15

3.12 3.06

DATE :25-02-2016

TIME :04:31

PVC SHEET

DIMENSION :.35*260

QTY :20KG

LOT NO :92131186-130.5 2 3.5 5 6.5 8 9.5 11 12

.5 14 15.5 17 18

.5 20 21.5 23 24

.5 26 27.5

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

KOREAN SAMPLE 2 THICKNESS

BATCH :W7624056A1-F

SHIFT : A

DATE :24/05/16

PELLET NO :154730

0.5 4 7.5 11 14.5 18 21.5 25 28.5 32 35.5 39 42.5 46 49.5 530.35

0.36

0.37

0.38

0.39

0.4

0.41

0.42

SHEET THICKNESS

distance

Thick

ness

i

RIGHT LEFT

PARAMETERS

TEMPERATURE - C1 C2 C3 H D1D2 D3

IN OC 175 179 182 185185 185 185

TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL

M/MIN 3.15 3.123.06

 

Sheets that need to be avoided

BATCH : W7625056A1-A

SHIFT : A

DATE : 25/05/16

PELLET NO : 154730K76

0.5 3 5.5 8 10.5 13 15.5 18 20.5 23 25.5 28 30.5 33 35.5 38 40.5 43 45.5 48 50.5 53 55.50.32

0.34

0.36

0.38

0.4

0.42

0.44

SHEET THICKNESS

PARAMETERS

TEMPERATURE - C1 C2 C3 H D1 D2 D3

IN OC 175 179 182 185 185 185185

TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL

M/MIN 3.15 3.12 3.06

BATCH :W7628056A1-G

SHIFT : A

DATE :28/05/2016

PELLET NO : 154976-K76

0.5 4 7.5 11 14.5 18 21.5 25 28.5 32 35.5 39 42.5 46 49.5 530.32

0.34

0.36

0.38

0.4

0.42

0.44

SHEET THICKNESS

PARAMETERS

TEMPERATURE - C1 C2 C3 HD1 D2 D3

IN OC 175 179 182 185185 185 185

TAKE OFF UNIT NIP ROLL COOLING ROLL EMBOROLL

M/MIN 3.15 3.12 3.06

Conclusion Lion 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 mm

M/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.

Thank you…….