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…….