A PRESENTATION ON “PAPER WASTAGE REDUCTION IN WEB OFFSET PRINTING” OF

Conducted at

CHENNAI

Submitted by:

Santosh Kumar Gupta

Contact no: 09543008645

Email: santoshmax20@gmail.com

AU, ISBR, Chennai

VISION

“To contribute towards the upliftment of education in India and to provide highest quality education materials”Rajiv Beri M.D

INTRODUCTION

* *HISTORY

1. It founded in England in 1843.

2. Verlagsgruppe Georg von Holtzbrinck GmbH, a large media group created in 1971, whose headquarters are in Stuttgart, owns the Macmillan group.

3. It has been operating in India since 1892.

4. The former Prime Minister of UK, Harold Macmillan, inaugurated the company’s ITES operations in Bangalore in 1976.

* *PRODUCT

1. It publishes a wide range of books for schools, colleges, individual buyers, corporate and academic books for reference and research.

2. It associates with rich authors.

3. It was chosen by UNICEF as a critical partner in the publication of the ‘Meena’ books – a venture of high social impact aiming at empowering the underprivileged girl child.

4. It associates with premier institutes like IIM Calcutta, MDI Gurgaon, IIT Delhi and IIFT Delhi.

* *MARKET

1. It is characterized by high-quality academic, educational, fiction and non-fiction publishing in many forms.

2. A huge and an exciting opportunity.

3. The current export market estimated to be around Rs 8,000 million (US$ 181.82 million)

(Source: Industry estimates).

4. It focuses on publishing innovative, need-based, stimulating and enlightening books, which are true companions to teachers and students.

* *ACHIEVEMENTS

1. It is probable that almost every child in India who has studied in a public school in the last 100 years or so has studied from some Macmillan book.

2. Shiv Khera's ‘You Can Win’, ‘Living with Honour’ and ‘Freedom is not Free’ – having sold more than a million copies.

3. It has won 23 awards for excellence in publishing and production in the last five years & also won the Capexil Award for highest exports in its category continuously for the last 22 years.

4. It has been selected as a Business Super brand by Super brand Council of India.

What is SIX SIGMA?

1. It is a management mandated and directed improvement program which focused on BREAKTHROUGHS in financial performance and customer satisfaction.

2. Focused on the core business and customer needs.

3. Excellence : 3.4 defects per million opportunities.

DMAIC

Define : Identify the problemMeasure : Quantify how serious it is Analyze : Diagnose the causeImprove : Prescribe a remedyControl : Take steps to avoid relapse

Phases of Six Sigma

DEFINE PHASEOBJECTIVES Identifying & defining a prioritized area of improvement

that will benefit the company financially.

2. Finding through a business case what is important that anything else to work on.

Define Opportunity

1. Voice of Business (VOB)

We are facing high paper wastages at various types and stages of printing.

2. Critical to Process (CTP)

% of paper wastage per stage and printing type

% wastages in various types of printing and various stages of printing

In Reel Printing – 45% In Sheet fed Printing – 15% Transportation, Loading & Unloading – 15% Storage, Handling – 13% In Cutting of Sheet Fed – 8% In Other Methods – 4%

• The company is facing a high paper wastages in Reel Printing or web offset printing.

• We can take this as our opportunity and will work on it to reduce the paper wastages and to improve the business performance and profitability.

AREA TO IMPROVE

(PARETO DIAGRAM)

REEL PRINTING

Machine – Web king Two Colour Perfector

Supplier –

Perfect Rotary Offset (P) Ltd.

B-100, Sector – 2,

Noida-201301

PROCESS FLOW MAP OF WEBKING

START

Filling ink

Feeling Water

Loading reel

Start printing

1st colour printing

2nd colour

1st fold

2nd fold

cutting

Last fold

END

Fitting plate

CONSUMABLE ITEMS FOR WEBKING OFFSET PRINTING

Paper – Dy or Cr

Printing Ink – Black, Magenta, Yellow, Crayon

Chemicals

PS Plate

Knife

Rope

MEASURE PHASE - OBJECTIVE

Measuring the wastage amount and in what way such wastages reducing the business performance.

Types of Wastages in Reel printing (Opportunity)

Reel MAT not in good condition Printed Forms not meeting specification Reel End not suitable for printing

REEL MAT

Reel MAT is the upper part of a reel.

If the upper part of a reel is not suitable for printing than it is called as Reel MAT Wastages.

Why wastages?

The Reel MAT may get tore in transportation, while in storage.

The upper part may get spoiled due to weather influence.

There may be manufacturing error.

Sometimes loading and unloading may cause damage.

While shifting from one place to another inside the factory.

PRINTED FORMS These are the printed part of the paper to be used to make Book. One form contains two sides of printing. In total, one form contains 16 pages (8 pages both sides) If there is any printing error in a form, it is rejected and taken as paper

wastage. Forms used for inspection also taken as wastages.

Rejection Criteria for Printed Form Overlapping of text on other side of the paper. Less quality printing in terms of colour. If some scratches on form. Colour displacement. Improper folding of forms. Torn forms. Text and picture registration error. Last part of the reel before new reel is loaded

REEL END

Reel end is the last part of the reel.

If only few amount of paper is there on reel and one job is finished, than it cannot be used for printing. Because it will require stoppage of machine one more time when the reel completes and new reel is to be loaded.

Last part of the reel is left because at last the quality is not that much good for printing.

Due to waving also paper is not suitable for printing.

DATA COLLECTION PROCEEDURE

Data are taken for one colour (Black) printing.

We took 8 reels as sample for calculating wastage.

The samples are randomly chosen.

These are taken at four different days i.e. 2 per day.

The unit for paper weight is Kilogram (Kg).

Wastage is calculated on per reel basis as percentage of wastage per reel.

Wastage is calculated separately for each opportunity or type of wastage.

LOSS TO THE BUSINESS(70 GSM PAPER)

Cost of Blank Paper – Rs. 45 per Kg + Rs. 5 per kg for storage, handling, inspection etc. = Rs. 50 per kg

Cost of printed paper (from) –55 per kg

Total wastage as Reel MAT and Reel End = 107kg + 14Kg = 121 kg

So, loss to the business = 121 kg * Rs. 50 = Rs. 6050

Total wastage as printed form = 179 kg

So, loss to the business = Rs. (179*55) = Rs. 9845.

Total Loss = Rs. 6050+ 9845 =Rs. 15895 in 8 reels only.

*Contd……

Production is done in 2 shifts.

8 reels are used per day.

Now, we can see that per day approximately the company is loosing Rs. 15895.

So, for one month it is loosing around Rs. 15895*30 = Rs. 4,76,850.

And for one year the loss may be amounted to Rs. 57,22,200 (apprx.).

ANALYZE PHASE - OBJECTIVE Finding all the possible causes of the problem. Finding among causes which causes can be controlled and which cannot

be controlled.

PROBLEM High Paper wastage in Reel Printing

CAUSES The causes of the problem have been divided into four major heads.1. Manpower

2. Machine

3. Method

4. Material Various sub causes have been found out under each major head. A fish Bone diagram has been prepared which shows the various causes of

the problem

FISH BONE (CAUSE & EFFECT) DIAGRAM FOR PAPER WASTAGE IN REEL PRINTING

.

Incorrect setting of Ink rollers drive motor

Frequent stoppage of m/c

Paper Wastage in Reel Printing

MACHINE MANPOWER

MATERIALSMETHOD

Improper method of unloading

Low packing quality

Improper registration from one reel to another

More than one joint per reel

Less diameter reel for single long run job

Low reel surface quality

Low grade winding quality

Hard loading floor area

Short run job

More than one job per reel

Fluff on paperManual folding problem

Ink spills on paper

Registration Problem

Lack of Training on folding & inspection

Slow response to m/c problem

Less Co-ordination among employees

Improper storage

Less care in transportation

Less care while handling reel

Improper method of transferring

Incorrect handling while loading into the m/c

Lack of training on settings of m/c

Manual method of testing form

Improper loading of reel into the machine

Low initial setup

Frequent change in m/c setting

Waving in paper

Lack of regular checking

Over compliance due to negligence

Rigid working hour

Plate change in between the current reel

Carelessness while changing plate

No full use of a reel

Incorrect Speed

Leakage of Ink

MULTI VOTING By multi voting technique we found out the

following most important causes of the paper wastage in reel printing.

1. Frequent stoppage of machine2. Short run job3. More than one job per reel4. Less care in transportation5. Less care in handling6. Improper unloading of reel7. Less diameter reel for long run job8. Slow response to machine problem9. Registration problem10. Lack of training on folding & inspection

IMPROVE PHASE - OBJECTIVE

In this stage we will find out the ways to improve on the main causes of paper wastage in reel printing.

By way of discussion we found various possible solutions to above given causes.

Solutions for Frequent Stoppage of Machine

Should do long run job. Flexible refreshment break by workers. Less quantity reel for small job. Proper training to workers regarding setting of the Machine. Proper feeding of paper. A supervisor can be appointed to direct the workers on how to

reduce the frequent stoppage.

Solutions for the Main problemsSolutions for the Main problems

Solutions for Short run job

Only long run job should be carried out by reel printing. Short run job should be done by sheet fed printing. Minimum number of short run job order should be taken.

Solutions for More than one job per reel

Single job i.e. one type of form should be printed with one reel. Required amount of reel should be used for the required amount

of printing. Order for larger volume of book should be taken.

Solutions for Less care in Transportation

Instruction should be given to the transportation company for proper handling of the reel.

Reels should be covered properly. Proper care should given while loading from factory. These should be properly tied.

Solutions for Less diameter reel for long run job

For long run job reel of big diameter i.e. more weighted reel should be used.

Training should be given to workers on how much paper should be used for printing a particular number of forms.

Big diameter reel must be kept available for long run job.

Solutions for Less care in Handling

While moving reels proper care should be given. Edge protector can be used. Should have smooth flooring. Half used reels should be covered properly. Reels should be kept at dry place.

Solutions for Improper Unloading of Reel

Reels should be unloaded properly. Foam bed can be used to unload. Reels should be loaded horizontally not vertically.

Solutions for Slow response to machine problem

Always there must be someone to ensure the smooth flow of work. Proper Training should be given to workers to fix the problem immediately. Regular checking must be done to avoid any machine problem. For big problem the engineer can be called immediately. Workers should be given required authority to take immediate steps to

resolve the problem.

Solutions for Registration Problem Sample should be collected to ensure proper registration. Skilled personnel should be recruited for better performance. Training should be given to workers on checking whether properly

printed or not.

Solutions for Lack of training on folding & inspection

Care should be taken while feeding to folding equipment. Automatic folding can be done by having extra equipment. A supervisor can be appointed at work area to inspect the quality

of printing and to check other printing problem.

Multi Voting

Through multi voting we found out following solutions that can minimize the wastage level to a considerable level.

1. Should do long run job.2. Flexible refreshment break by workers.3. Short run job should be done by sheet fed printing.4. Single job i.e. one type of form should be printed with one reel.5. Proper care should given while loading from factory.6. Edge protector can be used.7. Foam bed can be used to unload.8. Reels should be loaded horizontally not vertically.9. For long run job reel of big diameter i.e. more weighted reel should

be used.10. Proper Training should be given to workers to fix the problem

immediately.11. Workers should be given required authority to take immediate

steps to resolve the problem.12. Sample should be collected to ensure proper registration.13. A supervisor can be appointed to inspect the quality of printing and

to check other printing problem.

Recommendations

If long run jobs are carried out, there will not be frequent stoppage of machine and no need of changing plate in between one job which will considerably reduce printed form wastages.

With long run job with big diameter wastage in the form of Reel MAT in new reel can be minimized.

It will increase the per labour productivity.

Quality ink must be used to so that it does not damage the paper.

Flexible refreshment time can reduce the stoppage of machine for lunch break, tea break etc, which will result to increased productivity.

If one job is carried out in one reel, the wastage due to changing of plate and reel end wastages can be reduced.

Contd…..

If proper care is taken in transportation, loading and unloading, it will reduce the wastages as there will be less reel mat wastage.

Edge protector will save the reel to be cut from side and thus will save reel mat wastage.

If trained workers are appointed and they are given required authority, they can take immediate steps to solve any problem as soon as possible.

Proper collection of sample in regular interval can help to reduce printed form wastages.

With a supervisor various problem can be solved like regular checking will be done which will reduce the wastages.

Control Phase - Objectives

Setting standards to stick on to the increased performance by continuously applying the given solutions.

No further deviation should arise.

Early action can be taken to ensure no further wastages.

Control Chart

After implementing the given solutions again data can be taken to find out whether everything is going right or not.

If something wrong immediate steps can be taken to resolve the problem.

Improvement which can be achieved

By applying above mentioned solutions and recommendation the overall wastages can be reduced.

Reel MAT wastages, printing wastages and reel end wastages can be reduced considerably.

We have targeted to bring down the overall wastage percent to 2 %.

This can increase the sigma level to 5.

KAIZEN IMPROVEMENT (WEBKING MACHINE)

1. Water chilling unit

2. Brush at level unwinding to remove dust

3. Pneumatic shaft for wastage reduction and quick change over

4. Extra plate at folding unit to avoid cross fold

5. Completed bearer overhaul on machine and reconditioned.

6. Ensure uniform break time period for machine overhaul

5S SEIRI (Sort)

NEEDED NOT NEEDED

ink Waste paper

Tools Used plate

Trolley Waste form

Range Waste cloth

Kerosene Extra air pipe

Sponge for cleaning Employees cloth

Water bucket Waste calendar

Ladder Unused motor

Reel should be covered Unused board

knife Reel end still on pneumatic shaft

Reel improperly kept Old forms on the table

Rope Shoes

Fan Brush

Mug Unused pneumatic shaft

Cup board Big plastic cane

Tables

Exhausted water tank

Sweep stick

Duster

Tools case

Brush for cleaning

Dust bin

Empty pneumatic shaft

Contd…..

SEITON (SET IN ORDER) The unwanted things are taken out and all the needed things are

kept at their respective place.

SEISO (SHINE) Cleaning is done of the area nearby to the machine. Dusts are

taken out.

SEIKETSU (STANDARDIZE) Standard is set that the things must be kept at their respective

place, regular cleaning should be done.

SHITSUKE (SUSTAIN) Instructions are given to maintain the standard.

Kanban initiatives

A sticker is used to mark the next reel to be used for printing.

Two dustbin were used so that when one is full other can be used to throw out the dusts till the other one is empty.

A container is used to store the wastages.

Conclusion

By applying above mentioned recommendation the paper wastages in reel printing can be minimized to an acceptable level.

This will cause financial benefit to the organization.

Job can be finished very early.

It will increase the confidence of the workers as with less wastages they will be satisfied.

This can increase the profit of the organization. And as such it will increase the stakeholders value.

Customer value will also increase as they will get good quality book at required time.

Organization's creditworthiness will also increase.

With the help of Kaizen, 5S and Kanban methodology smooth flow of work and continuous improvement can be achieved.

OUR LEARNINGS