Quality Circle From

Cheese Plant

Presented By
TEAM UDAAN
 COMPANY PROFILE
 Established : 31st Jan. 1969
 Founder Chairman: Late GalbaBhai N Patel
 Current Chairman: Sh. Shankarbhai Chaudhary
 Managing Director: Sh. Sangram R Chaudhary
 No. of Dairy Units: 5
 No.of Employee:5000
 Revenue: INR 15255 Crore (2021-22)
 ISO Certification:9001,15001,22001
 Started journey of Excellence as BEST

 It is Asia's largest dairy & the milk collection is

shortly expected to reach 1 crore lit per day.
 Dairy Products: Market Milk, Fermented products,
UHT Milk products, Milk Powder, Ghee, Butter, Ice-
cream & Cheese etc
 Non Dairy Products: Honey, oils, Atta,THR, Potato
based frozen products
 Services: Hospitals, medical college, Chain of Retail
Superstore(Umang Mall), Bio-CNG Plants &
Stations, Organic Fertilizers etc. J[ZFG E}lDGL lJZ0L v
 BANAS DAIRY IN A GLANCE

SANADAR-SANKUL

Medical College

CATTLE FEED:KATARWA
KANPUR

PALANPUR CAMPUS
FARIDABAD LUCKNOW
 Milk Procurement Area

1. બનાસકાંઠા
2. રાજસ્થાન
3. ઉત્તર પ્રદે શ
4. ઓરિસ્સા
5. આંધ્રપ્રદે શ
6. ઝારખંડ
7. ઉત્તરાખંડ

Started procurement with only 8village now

expanded its milk procurement to 7 States
Banas Products

Dairy Products Non-Dairy Products

 Organization Details
Banaskantha District co-operative milk producers’ union limited
Name of Highest Authority of the Organisation: Sangram R Chaudhary
Tick as appropriate:
Micro Small Enterprises:
Small Scale Enterprises:
Medium Enterprises:
Large Enterprises:
Turnover: More than Rs.15000 Crore
Name of Unit: Cheese Plant
Address of Unit: Cheese Plant, Banas Dairy, Palanpur.
Name of Highest Authority of the Unit: Kamraj R Chaudhary
Contact Person at Unit level: Ramesh D Patel
Mobile No of Contact Person: 9408701935
Email id of Contact person: rameshdpatel@banasdairy.coop
Products Manufactured

Cheddar Cheese
40 MTPD
Dice Cheese
24 MTPD

Process Cheese
24 MTPD

Mozzarella Cheese
30 MTPD
 Quality Circle Profile
 QC Title & Problem Definition: To Increase Moisture content In Slice Cheese from 49.0% to more than 51.0
%.
 Improvement Target: Increase Moisture by some modification in SOP of manufacturing Slice cheese,
Cheddar Cheese & quick lab testing
 Project Start Date: 16th Sep -2021
 Project Completion Date: 14th Jul -2022
 QC Name: UDAAN
 Working Area: Cheese Plant-Slice Line
 Meeting Place: Process Cheese Control Room (Fortnightly)
 Meeting Day/Time: Thursday-14:00 o'clock to 15:00 o'clock
 Meeting Attendance: 92%
 Name Of Organization: BANAS DAIRY-PALANPUR
 Name Of Event: VCCQC-2022
 Quality Circle No: 03
 MEET THE TEAM

RAMESH PATEL SHIVAM SINGH SUNNY JOSHI NITIN DHRUV KRUNAL

CHAUDHARY CHAUDHARY RAWAL
Plant I/C Coordinator
Identification Of Problem
&
Selection Of Problem
 Brainstorming To Identify Problem
Sr. No Our Pain Area Category Sr. No Our Pain Area Category
1 Water logging Issue in Vats so CIP delay C 27 Machine Parameter setting A
2 Long Recipe of Vats A 28 Sealing Leakage problem B
3 High moisture in Cheddar Cheese A 29 Weight Rejection A
4 High pH at stretcher Cooker in Mozzarella A 30 GBM/PFM HEATER CLEANING A
5 AOM or BF in CIP B 31 GBM/PFM PRINTER PROBLEM A
6 High rework generation A 32 GBM M/C PRIMARY ROLL AUTO SPLICING A
7 High fines generation/lumps formation B 33 CHEESE BROWN ISSUE A
8 Eye mark issue B 34 LOW SPEED DUE TO STICKY CHEESE A
9 Wrinkle formation C 35 PFM AXIS ERROR B
10 Weight Variation C 36 Low Moisture In Slice Cheese A
11 Roll defect C 37 SLOW SPEED DUE TO CHILLED WATER High Temp B
12 high leakage in dice laminate B 38 CUTTING PROBLEM. A
13 Electric/motor fault A 39 CHEESE LEVEL ISSUE AT BUBBLE A
14 Mechanical Damaged A 40 SLICE LEAKAGE B
15 Wrong handling A 41 PRE CRIMP ISSUE A
16 Software / Communication error B 42 HMI issue/SPX pump issue A
17 Delay maintenance A 43 Young Cheddar Cheese used in blend A
18 Double Stack problem B 44 Batch processed without rework A
19 High Temp Of slice B 45 Water addition during cooking A
20 Crimper problem C 46 Stacking issue A
21 Printing problem A 47 Moisture variation in cheddar cheese A
22 Packing problem B 48 Cut off misplace A
23 Conveyor Speed problem C 49 Secondary packing rejection B
24 Segrigation & Repack Of slice A 50 High moisture cheddar used A
25 Change over A 51 Cooker pump water leakage A
26 Gas injection A      
 Solved & Unsolved Problem with Category
Sr. No Our Pain Area Category Sr. No Our Pain Area Category
1 Water logging Issue in Vats so CIP delay C 27 Machine Parameter setting A
2 Long Recipe of Vats A 28 Sealing Leakage problem B
3 High moisture in Cheddar Cheese A 29 Weight Rejection A
4 High pH at stretcher Cooker in Mozzarella A 30 GBM/PFM HEATER CLEANING A
5 AOM or BF in CIP B 31 GBM/PFM PRINTER PROBLEM A
6 High rework generation A 32 GBM M/C PRIMARY ROLL AUTO SPLICING A
7 High fines generation/lumps formation B 33 CHEESE BROWN ISSUE A
8 Eye mark issue B 34 LOW SPEED DUE TO STICKY CHEESE A
9 Wrinkle formation C 35 PFM AXIS ERROR B
10 Weight Variation C 36 Low Moisture in Slice Cheese A
11 Roll defect C 37 SLOW SPEED DUE TO CHILLED WATER High Temp B
12 high leakage in dice laminate B 38 CUTTING PROBLEM. A
13 Electric/motor fault A 39 CHEESE LEVEL ISSUE AT BUBBLE A
14 Mechanical Damaged A 40 SLICE LEAKAGE B
15 Wrong handling A 41 PRE CRIMP ISSUE A
16 Software / Communication error B 42 HMI issue/SPX pump issue A
17 Delay maintenance A 43 Young Cheddar Cheese used in blend A
18 Double Stack problem B 44 Batch processed without rework A
19 High Temp Of slice B 45 Water addition during cooking A
20 Crimper problem C 46 Stacking issue A
21 Printing problem A 47 Moisture variation in cheddar cheese A
22 Packing problem B 48 Cut off misplace A
23 Conveyor Speed problem C 49 Secondary packing rejection B
24 Segrigation & Repack Of slice A 50 High moisture cheddar used A
25 Change over A 51 Cooker pump water leakage A
26 Gas injection A      
 Problem Summary
Problem Unsolved:
Category Wise Problem A:14, B:08 & C:04

C
12%
QC Scope: (A-Type)
Cost:04
B A Quality:08
25% B Productivity:2
A
63% C

Complexity
A-Type: 32 B: 13 & C:06
 Requirements to do this Quality Circle

High market demand of slice cheese cause attention on OEE of Machine. Further it require to
increase yield, improve quality & minimize cost. This all we can achieve by increase in Slice
Cheese Moisture.
15
 Process Flow Diagram of Slice Cheese

Cheddar Cheese Out From Grading & Testing of Grinding of Cheddar Grinding of Cheddar
ASRS After Ripening Cheddar Cheese Cheese Cheese

Transfer to Cold Storage Pelleting Of CBX Weighing & Metal Primary & Secondary
Detection Packing Of Slice Cheese
Analysis Of Problem
&
Root Cause Analysis
Attribute Analysis for September-21 month

Sr. No Cause Details Sep-21

1 Young Cheddar Cheese used in blend 16
2 Batch processed without rework 15
3 Water addition during cooking 13
4 Delay testing report 11
5 Moisture variation in cheddar cheese 21
6 Machine running ability issue 3
7 Cut off misplace 2
8 Addition of emulsifier 8
9 Secondary packing rejection 11
10 High moisture cheddar used 8
11 Cooker pump water leakage 0
12 High Chilled Water temperature 23
VITAL FEW

Remarks:
 Red star marks causes are cause belongs to same things.
 On Cheddar Cheese we works started immediately to make uniformity
on cheddar cheese.
 Utility has given responsibility for C.W. temperature.
 For delay testing lab take responsibility
Detail Fish Bone Analysis For Low Moisture In Slice Cheese
Fish Bone Analysis For Sticking Issue In Slice Cheese

Made by all 14 Slice line

Members after brainstorming
 Data Analysis
&
Development of Solution
Grading of Cheddar Cheese
 07. Increase Moisture content In Slice Cheese:50.5±1%
52.00
51.50
51.00
50.50
50.00
49.50
49.00
48.50
48.00
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
g /2 g/2 g/2 g/2 g/2 g/2 g/2 g/2 g/2 p/2 p/2 p/2 p/2 p/2 p/2 p/2 p/2 p/2 p/2 t/2 t/2 t/2 t/2 t/2 t/2 t/2 t/2 t/2 v/2 v/2 v/2 v/2 v/2 v/2 v/2 v/2 v/2 v/2
c c c c c c c c c
/ Au /Au /Au /Au /Au /Au /Au /Au /Au /Se /Se /Se /Se /Se /Se /Se /Se /Se /Se /O /O /O /O /O /O /O /O /O /No /No /No /No /No /No /No /No /No /No
2 6 9 12 15 18 21 25 28 1 4 7 1 0 13 16 19 22 25 28 3 6 9 12 1 5 18 21 2 4 27 2 6 9 12 15 18 21 24 27 30

UCL Target LCL Month

Particulars Aug-21 Sep-21 Oct-21 Nov-21 Action plan for KPI-07

01.Daily grading & analysis of cheddar cheese will be started
in which SFG team will involved along with Processed
7. Slice Moisture-
Moisture 49.86 49.99 49.8 49.77 cheese & QA team.
02. Work on Cheddar Cheese uniformity.
 RST-776 RST-776
Out of 108 sample Out of 73 sample
only 39 is in our range only 33 is in our
range

MOS064B
Out of 95 sample only
41 is in our range
Foreseeing Probable
Resistance
Likelihood of shifting to old pattern of maintaining productivity level to
conservative level by old hands.

Action:-
Training & Awareness provided to employees regarding the legal standards &
changing parameters in SOP.
1. Cheddar Cheese: To maintain uniformity, Salt to Moisture ratio
started reviewing after each run.
We are checking & grading of each pallet before use.
2. Processed Cheese Cooker: Water flow meter, calibration has
increased from 6 month to 3 month.
• Steam filter change frequency has revised from 2 Year to 1 Year
3. Additives: Emulsifying salt has increased to 0.8 to 1.1 Kg per batch
4. GBM Machine: Chilled water temperature recording & montoring
started during production.
Trial Implementation
&
Check Performance
 KPI Performance Of Slice line Daily Per Month Since Aug-21 to Aug-
22
35

30

25

20

15

10

0
KPI-06 KPI-07 KPI-08
Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22 Aug-22

 KPI-07: Working very well.  KPI-08: Working very well.

 KPI-06: Almost working well
 Average Performance: 76.99%.  Average Performance: 74.49%.
continuously.
 This is our highest achievement  This is our highest achievement
 Average Performance: 59.31 %
KPI till now. KPI till now.
 Slice Cheese Moisture & Stand. deviation Since Aug-21 to Aug-22

Slice Cheese Moisture & Deviation

52.5 Batch testing-
Chilled Water Cheddar Shift wise
52 Cheddar grading Temperature Uniformity
0.94
51.5 0.9 0.8

51 0.86
0.71
0.83 0.8
50.5 0.77
0.98 1 1.07
1.03 1
50

51.1 51.25
49.5 51.08
50.64
50.31 50.3 50.46
50.17
49
49.86 49.71 49.8 49.77 49.7

48.5

48
Aug-21 Sep-21 Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22 Apr-22 May-22 Jun-22 Jul-22 Aug-22

It gives lots of satisfaction

Histogram For Slice Moisture

Out of 172 days we Out of 89 days we

achieve 31 days more achieve 70 days more
than-50 % moisture than-50 % moisture

Out of 90 data only

Remarks:
3 data is less than Initially Slice avg. moisture lower limit was 48.4 %
50 % moisture. now it is 49.61.
Following -Up Review
 TANGIBLE BENEFIT

 Cost Reduction:
 Quality
 Production
 Delivery
 INTANGIBLE BENEFIT

 Boosting up self confidence

 Better exchange of ideas & improvement in
communication
 Improvement in interdepartmental relations
 Interpersonal relations improved
 Morale & spirit of team enhancement
 Personal growth of team members
 Enhance In Knowledge of QC-Tools & Technique

It gives lots of satisfaction to team

Thank you