Project Title –

Reduction of Packing
Machine Changeover Time
Updating after May’15
 What is changeover

Last Good Changing of

packet of Cleaning required
previous of machine parts
variety machine for the desired
produced in SKU
machine

First Good Trial run

packet for final Machine
On line
produced in adjustme tuning /
run
machine nts Timing
after
changeover
Objective :

1. First time right , every time right

2. Less Wastages
3. High Productivity

Process Follows :

1. Make it easy
2. Error proofing
3. Deskilling Part by part
Noting Change over Steps in PP machine
1 Cleaning of machines
2 Remove existing Forming Box.
3 Remove existing biscuit Infeed Chain.
4 Remove existing biscuit Infeed Chain drive sprocket with chain.
5 Fittings of new variety Infeed chain
6 Fittings of new variety biscuit Infeed Chain drive sprocket with chain.
Dismantling &
7 Do the proper Lug gauge in Infeed chain.
fitting of new parts
8 Fittings of new Forming box.
9 Remove existing Side Clamper Chain.
10 Remove existing Side Clamper Chain drive Gear.
11 Fittings of new side clamper Chain .
12 Fittings of new Side Clamper Chain drive Gear .
13 Adjust the biscuit guide after biscuit feeding chut.
14 Make the Biscuit stack length at Inline pusher section
15 Correct the Cross pusher stroke length according to variety.
16 Timing the Cross pusher wrt. Inline Pusher
Timing the Cross pusher wrt. Infeed chain and position of Front Lug to hold the biscuit
17 stack
18 Position of Leap spring wrt both Cross & Inline pusher according to biscuit thickness
19 Timing of Side clamper chain wrt Biscuit Infeed chain.
Setting / Timng /
20 Timing of End sealer wrt Side clamper chain.
Tuning
21 Adjust the End sealer dwell.
22 Adjust the End sealer Height.
23 Do the wrapper Cut off length.
24 Positioning of Photo cell and scanner unit.
25 Adjust the guide plate below the side clamper wrt Biscuit
26 Adjust the Centre sealer pressure and temperature..
27 Adjust the price and date in printer
Trial for
28 stabilization Trial the m/c with biscuit
Noting  Change over Steps in FP machine
1 Machine cleaning
2 Remove existing Forming Box with "V" plate.
3 Remove existing biscuit Infeed Chain drive sprocket with chain.
4 Fittings of new variety biscuit Infeed Chain drive sprocket with chain.
5 Make the proper gauge in Infeed chain according to 2,3 & 4 rows.
6 Fittings of new Forming box with " V" plate..
7 Remove existing Top Transfer Chain.
8 Remove existing Top Transfer Chain drive Gear.
Dismantling &
9 Fittings of new Top Transfer Chain .
fitting of new parts
10 Fittings of new Top Transfer Chain drive Gear .
11 Adjust Top Transfer chain height according to biscuit height.
12 Remove existing colator Lug.
13 Fittings of new collator Lug.
14 Adjust the collator side guide according to stack length.
15 Adjust collator lug chain height according to biscuit height.
16 Fittings of Biscuit feeding chut according to variety.
17 Adjust the biscuit guide after biscuit feeding chut.
18 Make the Biscuit stack length at Inline pusher section
19 Correct the Cross pusher stroke length according to variety.
20 Timing the Cross pusher wrt Inline Pusher
21 Timing the Cross pusher wrt 1 st Infeed chain
22 Position of Leap spring wrt Cross pusher according to biscuit thickness
23 Timing of colator lug chain wrt 1st Biscuit Infeed chain.
24 Timing of 2 nd Infeed chain wrt Collator Lug chain.
25 Adjust the 2 nd infeed chain side guide.
Setting / Timng /
26 Timing the Top Transfer chain wrt 2 nd Infeed chain.
Tuning
27 Timing of End sealer wrt Top transfer chain.
28 Adjust the End sealer dwell.
29 Adjust the End sealer Height.
30 Do the wrapper Cut off length.
31 Positioning of Photo cell and scanner unit.
32 Adjust the side guide plate over the centre sealer wrt Biscuit stack.
33 Adjust the Centre sealer pressure and temperature..
34 Adjust the price and date in printer
Improvement comes in stages
Improvement comes in stages
STEPS FOLLOWED :

Believe in mind that change over time can be reduced.

1. Analysis :

1. Noting down steps of Change over.

2. Recording the time taken in each steps.
3. Analysis of waste time through video.

2. Action :

1. Using Tool free fastener

2. Using zigs for making infeed chain ready offline.
3. Single chain in case of double chain concept in FP
4. Using color mark on each Chain joint for easy to locate.
5. Done Parallel activities to use idle time.
6. Spring loaded lug pin in FP m/c to reduce time in changing of rows.

3. M/c Tuning :

1. Deskilling the operation.

2. Marking of every adjustments like pusher according to the variety.
3. Marking on adjusting height & gap like --- Mark on Collator chain & Top Transfer chain
adjusting height & gap accoding to variety.
4. Mark on Side clamper adjusting gap accoding to variety.
5. Mark on Knife dwell & Wrapper Reel distance according to variety.

4. Capturing the improvement status to improve more.

Results :
 Bringing confidence in doing changeovers

 Faster stabilization of lines after changeover.

 Reduction in quality rejection during

stabilization 35 kg to 15 kg per C/O.

 Reducing lam roll wastage from 0.59 Kg/ ton

to 0.38 Kg/Ton ( reduction by 36%) – Lam roll
rejection reduces from 3.88% to 2.41%

 Improvement in productivity.
◦ Increase in shift throughput from 11.40 T to 12.30 T
 Some steps :

Leaf spring fitting changes from CSK screw to wing bolt reduces
0.5 min

Hex Wing
Bolt Bolt

Forming box fitting arrangement with wing bolt instead of Hex Bolt reduces
time by 1 min
 Some More steps
 LUG with spring.mp4

Double
chain
Single
chain

2 nd stage modification -----

1st stage modification -----
Biscuit Infeed arrangement
Existing Biscuit Infeed single chain with double
arrangement with Double Block setting according to
chain No. of rows. It is suitable for
2 row to 3 row.
Biscuit Infeed arrangement
single chain with double
Block setting according to
No. of rows from to 2 row to 3
or 4 row & here one rod is
detachable. We can use it as
per requirement. Here
change over time will reduce
by 2 min.
Elimination of collator lug done in one machine & will be replicated after
seeing the result by Nov’15

No collator Lug.
Collator Collation of rows
Lug for will be near bag
collation of former
rows
Collation of rows will be after bag former near
Top transfer chain.
The benefit will be ---
Collation of rows at the collator lug causing 1. Reduction in changeover & tuning time
---- of Collator lug
1. Breakage of biscuits 2. Single row will help smooth transfer till
2. Disarrangement during collation. bag former.
3. Problem in sorting because of low 3. Because more length operator will get
space more time for checking.
4. Higher machine defective 4. Reduction in one transfer point will
generation. reduce breakage.
5. Ensure accurate number / no broken
biscuit inside the packet.
6. Reduction in machine defective
Thanks