Due Tobacco Company has four main departments; · GLT

 

Due to variation in customer demands, industries
often need to improve their processes and approach them in different angles
(ways). Muda elimination is very important for every industry in their quest to
reduce costs, compete with competitors and to use their resources efficiently
for best Quality and Quantity Production rate. Variation reduction helps keep
processes steady and more accurate. Two powerful tools for process improvement
are Lean and Six Sigma, when combined can bring many benefits to organizations
that decide to implement them. Lean and Six Sigma methodologies have gain a lot
of popularity in recent years. The improvements they bring to companies not
only in an economical but as a way to develop professionals are impressive.

This project is involved with the use of “Lean
tools” to reduce the different Mudas and increase the efficiency for different
Machine, in the Khyber Tobacco Company.
Different approaches are used for problem identification and their solution
(DMAIC (Define, Measure, Analyze, Improve, and
Control), Kaizen, Kanban, 5s etc.). Some problem are identified
technically according to the data provided, so for them the technical
suggestion are given, while for others the suggestions are given based on
Literature Review and studying the other Tobacco industries. After implementing
the suggestions given for particular department/Machine without too much
investment, we must say based on our results the Muda will be reduced and
efficiency will be increased.

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Introduction

All manufacturing organizations are striving to
eliminate different types of Mudas (Wastes). Muda minimization is mandatory to
stay competitive in any market. For Khyber Tobacco Company, this is very
important when competing against different brands of cigarettes industries and
against regional affiliates that try to move operations to their countries.

Khyber Tobacco Company has four main departments;

·        
GLT
(Green Leaf Threshing) Department

·        
PPD
(Primary Processing Department)

·        
CMD
(Cigarette Making Department)

·        
CPD
(Cigarette Packing Department)

 

GLT is the initial processing deportment where the tobacco
came directly from the ware-houses or from the formers, here is the tobacco is
passed through different machines for different processes (conditioning,
moisturizing, sand Reeling, etc.) and then divided into two sections (Lamina
and Stem).

 

In the PPD the Lamina and Stem are further processed and
finally mixed with ratio (4:1) in this department and final product (processed
tobacco) and stored in the CTS (cut Tobacco store).

 

CMD is making/manufacturing department where is filter/plug
and cigarette rods are manufactured and through Max-s/ Max-5 the cigarette rods
are combined with the plug/filter.

 

CPD is the packing department where the cigarettes are packed
into their respective packets and then packed into the cartons. 

 

All the 4-Departments in Khyber Tobacco Company are studied
thoroughly, and based on our qualification different problems (in different
Machine) are picked in the above departments based on their share in the Waste
production. The problems extracted from the different departments are given
below.

For more explanations of the Problems with details see the
Methodology section.

                    

 

Distributer Problem

A small problem in the Doffers
speed (same speed for all doffers) in the Distributer due to which 2-conveyors
wasted the energy. The problem will be solved very easily simply based on the
data, by changing the doffers speed only.

 

 

Conditioning
Cylinder (CC) Problem

Staking
of Tobacco leaf in the outlet of CC, which will be solved by changing the
direction of narrow plates inside the CC.

 

Stem
Collection from the vibrator and uprising conveyor

This
is not the problem in any part of the apparatus, but the engineers did not pick
the best solution to collect the stem and an extra motor and uprising conveyor
is used the detail solution is given the methodology section.

 

Reduction
of waste (Dust in Tobacco)

This
is the main problem in the PPD, due to which 47.25 Kg waste (Dust) is produced
form the 1050 Kg. Our suggestion for this, to reduce waste by using of Bail
slices (Most efficient) or vilkrostrips. These are used by the other Tobacco
Industries like PTC, PMI etc.

 

Low
Production Rate and Poor Quality of Cigarette

This
is the Problem of PM5/TO6E (Filter Making Machine) a very expensive and only
one Machine in the Whole Industry and they locally import the parts for that
Machine due which the production as well as quality is degraded and also other
problems are arises, suggestion for the Khyber Tobacco industry is that the
PTC, and PMI never import local parts (Less accuracy, and precision) for such
an expensive Machine, that why they compete Globally due to the maximum
production and good  Quality and also
greater life time for Machine.

 

Break
down Analysis of MK9-Machine

Machine
breakdown is inversely proportional to productivity. Breakdowns on critical
machines disrupt the desired productivity significantly.

Different
Types of Problem were identified from the Data for five days, when the data was
plotted on the Pi-chart. Pi-chart also shows the percentage of run/stop time
for production and Failure (no Production). The Major Issues (due to which the
machine has zero production/ stopped) identified from the Pi-chart is given
below:

·        
Tray Shortage and

·        
RBO (Cigarette Rod Breakout)

 

 

 

 

 

 

The
suggestion to resolve this problem is given based on the mathematics and
technicality according to the data provided from (KTC Engineer), explained with
detail in the methodology section.

After
implementing the suggestions given for particular department/Machine without
too much investment means either they will invest very less amount or without
investment they will achieve their desired target but it’s totally depends on
the technical staff that they have work for money or they favor with whom they
are working, we must say based on our results the Muda will be reduced and
efficiency will be increased and also these are the ways to compete with best
industries like PTC (Pakistan Tobacco Company), PMI (Philip Morris
International) etc. One of Our Gikian friend Engineer in PTC also told us that
PTC always focused more on the small level changes within the limits of their
budget, but the cycle is continuous for the small level improvement and that is
the reason that they provide good quality product and services which leads to
the customer’s satisfaction.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Literature Review

In
global market intelligent production systems, maintenance techniques and
trainings are essential to have a competitive system. Systematic elimination or
reduction of unneeded resources or waste is the key principle of lean
philosophy .

In
this research the Lean Manufacturing philosophy is applied for reduction in the
Muda (Waste) and to improve the efficiency of their manufacturing plants
through different statistical analysis. Lean Manufacturing is sometimes called
the “Toyota Production System (TPS)” because Toyota Motor “Company’s Eiji”
Toyoda and “Taiichui Ohno” are given credit for its approach and innovations.

A
way to eliminate waste and improve efficiency in a manufacturing environment. Lean
focuses on the value stream and eliminating MUDA, the Japanese word for waste.
In the supply chain management the objective of the Lean are the following:

·        
Achieving low cost along with

·        
High levels of quality and

·        
Higher responsiveness throughout the
supply chain

 

Two important
operating philosophies that are central to the success of supply chain
management are:

·        
Lean
thinking and

·        
Six
Sigma

 

According to the “Taiichi Ohno” the Muda
(waste) have the following seven- types:

 

Elements of Lean

The
elements used in helping to the identification of the problems and there
solution in the manufacturing department are the following:

·        
Waste Reduction

·        
Lean Supply Chain Relationships

·        
Lean Layouts

·        
Inventory & Setup Time Reduction

·        
Small Batch Scheduling

·        
Continuous Improvement

·        
Workforce Empowerment

 

Kaizen,
Kanban and 5-S approachs are is applied in this research to minimize the Muda
(waste) and enhance the overall efficiency of Khyber Tobacco Company.

Kanban (Sign or
Billboard) is a permission slip or authority to pull the material from upstream
supply chain partner.

When manufacturing
cells need parts or materials, they use a kanban to signal their need for items
from the upstream manufacturing cell, processing unit, or external supplier.

Continuous
approach to reduce process, delivery, & quality problems, such as machine
breakdown problems, setup problems, & internal quality problems is called
Kaizen.

 

The
problems which are explained with complete details in the methodology portion
below are mainly extracted during the 2-months traineeship period and during
the visits when this project was selected for the supply chain management
course.

These
problems were then discussed with the engineer from the PMI and KTC and asked
for the solution as will. They guided us best according to the knowledge that
they have, and concurrently from the internet a lot of tobacco industry data
papers are studied, after that the suggestion are given to the problems.

The
way we arises the problems and then find/calculate the technical solution/suggestions
to the problem at the limited time and less resources available will helps a
lot for the Khyber Tobacco industry and they will realize that what small level
problems we have and how can we utilized that with the limited resources
available.

After
implementing the suggestions given for particular department/Machine without
too much investment means either they will invest very less amount or without
investment they will achieve their desired target but it’s totally depends on
the technical staff that they have work for money or they favor with whom they
are working, we must say based on our results the Muda will be reduced and
efficiency will be increased and also these are the ways to compete with best
industries like PTC (Pakistan Tobacco Company), PMI (Philip Morris
International) etc. One of Our Gikian friend Engineer in PTC also told us that
PTC always focused more on the small level changes within the limits of their
budget, but the cycle is continuous for the small level improvement and that is
the reason that they provide good quality product and services which leads to
the customer’s satisfaction.

The
suggestion/solutions to the problems we have given are already adopted by the
big firms like (PTC (Pakistan Tobacco Company), PMI (Philip Morris
International), Imperial Brands Tobacco Company, Japan Tobacco International, and China Tobacco), and
because of these small changes but continuously they become big industries.
These industries knows if we wanna to compete globally we must have to change
continuously in the areas where it is required and that is the key for success
also