Presentation cadbury's -_copy

Process and Waste Mapping of Gum Plant&

Process Mapping and Texture Analysis of Soft Chew

Submitted by:

Sahil Garg(1050138)

Akchitta Srivastava

(1050102)

Project Manager:

Mrs. Horsuwan Papasaratorn (TDS & CSMS Manager)

To understand the complete process of gum

manufacturing.

To understand the Key Process Indicators, Zero base,

Bill of Materials.

To provide the fact base.

To find out the opportunities to reduce salvage and

waste.

To link the financial base with the actual plant data.

Objective:

Gum process and Manufacturing

The gum plant is divided in two areas:

1. SEA Plant

2. Japan Plant

Each plant has four divisions:

1. Manufacturing Process

2. Aging room

3. Coating and Polishing

4. Packaging

PROCESS DESCRIPTION

Continued..

VSM is a visualization tool oriented to the Toyota version of lean manufacturing.

It helps to understand and streamline work processes.The goal of VSM is to identify, demonstrate and

decrease waste in the process. VSM is primarily a communication tool but also used

as a strategic planning tool and a change management tool.

VALUE STREAM MAPPING(VSM)

Objectives:

To understand Cycle Time, Change Overtime, WIP, %Waste and % Salvage in each step of CFP process .

To identify Non value added activities in the process.

To make the process as close to lean as possible.

To reduce the lead time of the product.

To identify opportunities for future improvement.

What Is Value?A capability provided to a customer,

of the highest quality, at the right time, at an appropriate price,

as defined by the customer.•"Value" is what the customer is buying•Always think first about the end-customer

Who is the customer?What are they buying?

•Describe value using the customers' words

Planning tool to optimize results of eliminating waste

What Is Value Stream Analysis?

+ + =LeanBasics

current state VSM future state VSM

Apply Five Simple Principles:

Specify value from the standpoint of end customer

Identify the value stream for each product family

Make the product flow

So the customer can pull

As you manage toward perfection

Perfection

PULL FLOW

VALUE STREAM

VALUE

What is the Value that Flows?Specify value from the standpoint of the end customer

Ask how your current products and processes disappoint your customer’s value expectation:

price?

quality?

reliable delivery?

rapid response to changing needs?

7 Forms of WastePEOPLE

TYPESOF

WASTE

Processing

Motion

Waiting

FixingDefects

Making TooMuch

MovingThings

Inventory

CURRENT STATE I

CURRENT STATE II

Analysis:Current CFP process has only 23% Value added out of

the total lead time of 11.6 days.

5.5 Days Inventory in process (WIP ) is a major of Non Value Added .

Total Changing over time in CFP process is 21 hr which speedy project plan to reduce CO time down .

Bottling OEE is very low around 58% .

High waste at coating and sorting area = 4.3% .

Cycle time 11 hr for 2 Ton at packing part (5 Mc) .

Opportunities

Reduce WIP 5.5 Days which are before coating and after sorting.

Reduce CO time as per Speedy Target.

Improve Bottling OEE from 58% to 75%.

High waste at coating and sorting area = 4.3%.

Removal of sorting step from the process.

FUTURE STATE I

FUTURE STATE II

SalvageSyrup &

Gum Base Materials Center

Aug08 Total In-Out -Mixer,Forming 2.5% Total In-Out -Coating 4.6% Total In-Out -Sorting2.1%Recorded waste 0.4% Recorded Dust +waste 2.3% Recorded waste 1.8%Recorded Salvage 0.9% Recorded Salvage - Inventory/Miss 0.2%

Inventory 1.2% Missing/Unrecorded 2.3%Overall Loss(Input-good Output) 8.1%

Actual Waste % All Matrials (Center Bulk) - Center Bulk 0.5% Coated Bulk 2.1%

Standard Waste % All Matrials (to Center Bulk) 3.0% Center bulk 2.5% Coated Bulk 4.0%All Materials

Actual Financial %(Zero base) All Matrials Center Bulk 2.5% Coated Bulk 0.5%

Sep08 Total In-Out -Mixer,Forming 2.7% Total In-Out -Coating 4.5% Total In-Out -Sorting1.4%Recorded waste 0.5% Recorded Dust +waste 2.6% Recorded waste 1.0%Recorded Salvage 0.4% Recorded Salvage - Inventory/Miss 0.4%

Inventory 1.8% Missing/Unrecorded 1.9%Overall Loss(Input-good Output) 7.7%



Actual Financial %(Zero base) All Matrials Center Bulk 2.2% Coated Bulk 2.8%

Liquid Center fill

Mixer Extruding Forming Coating Sorting packagingMelter

II

Aging

Mapping of CFP

Aug'08

0

0.5

1

1.5

2

2.5

MIXER FORMING AGING COATING SORTING

Process

%ag

e

salvage Miss w aste

Sep'08

0

0.5

1

1.5

2

2.5

3

MIXER FORMING AGING COATING SORTING

Process

%ag

e

salvage Miss w aste

Missing data at the sections is most probably the inventories or unrecorded waste.

Coating defect to be corrected by improving coating process.

Overall loss is around 8% per month, in comparison to the monthly record of around 4%.

Dust waste is not included in Waste in OEE.Financial and plant data do not match.

Salvage Syrup &Gum Base Materials Center

Aug08 Total In-Out -Mixer,R&S 0.0% Total In-Out -Coating 2.6% Total In-Out -Sorting2.9%Recorded waste 0.5% Recorded Dust +waste 2.1% Recorded waste 0.1%Recorded Salvage 1.5% Recorded Salvage 0.5% Recorded Salvage 2.8%

Missing - Missing - Inventory -Overall Loss(Input-good Output) 7.5%



Actual Financial% All Matrials 0.5% Center Bulk -2.6% Coated Bulk 7.0%(Zero base)

Sep08 Total In-Out -Mixer,R&S 9.9% Total In-Out -Coating 2.1% Total In-Out -Sorting5.6%Recorded waste 2.3% Recorded Dust +waste 1.9% Recorded waste 0.10%

Recorded Salvage 4.1% Recorded Salvage 0.0% Recorded Salvage 1.8%

Missing 3.5% Missing 0.2% Inventory 3.8%Overall Loss(Input-good Output) 12.5%



Actual Financial% All Matrials 1.5% Center Bulk 6.8% Coated Bulk 5.1%(Zero base)

Mixer Extruding R & S Coating Sorting packagingMelterII

Aging

Mapping of XP

Data Split(Sep'08)

4.1%

0.0%

1.8%

2.3%

1.9%

0.1%

3.5%

0.2%0.4%

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

4.0%

4.5%

extruder coating sorting

Salvage Waste Miss Data

Data Split(Aug'08)

1.5%

0.0%

2.8%

0.5%

2.0%

0.1%

-2.4%

0.5%0.0%

-3.0%

-2.0%

-1.0%

0.0%

1.0%

2.0%

3.0%

4.0%

extruder coating sorting

Salvage Waste Miss Data

Comparison of Recorded Data

L iliy -Mapping Was te

-0.40

2.60 2.90

4.10

9.9

2.1

7.4

3.3

-2

0

2

4

6

8

10

12

extruder c oating s orting pac kaging

A ug-08

S ep-08

Summary –Lily

Missing Data (inventory) at Mixer and sorting.Coating defect reduction.Give away reduction is very important.*Weight tolerance 1.53 vs. BOM 1.5 gm.Overall loss increased to 12% from 7.5% in Sep.

month. This was due to metal detection and hair contamination.

Dust waste(1.9%) is not included in Waste in OEE .

Sep-08

148.0

150.0

152.0

154.0

156.0

158.0

160.0

162.0

164.0

166.0

168.0

170.0

Net

Wt.

/Bo

ttle

Series1

Series2

Series3

Series4

Series5

Series6

Series7

Series8

Series9

Series10

155.7149.9168.4

Giveaway% 3.8%

0 - 12.3%Range

Overall AvgMinMax

Bottling Oct-08

150.0

151.0

152.0

153.0

154.0

155.0

156.0

157.0

158.0

159.0

160.0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sample No

Wt(

g)/

Bo

ttle

Series1

Series2

Series3

Series4

Series5

Series6

Series7

Series8

Series9

Series10

Series11

154.6150.1159.6

Giveaway% 3.1%

0 - 6.4%Range

Overall AvgMinMax

Continued..

Background % Give away from bottling JP line(Jun-Oct 2008)

3.0%

3.6%3.9% 3.9%

3.7% 3.7%

3.2%3.1% 3.3%3.4%

3.1%

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

4.0%

4.5%

June July August September October YTD

Month

% L

os

s (

Ze

ro b

as

e)

XPCFT

Start Earth ProjectStart Papa Project

Action Plan for Improvement

1.Study relation of speed M/C with %give away and find potential point for reduce

August September OctoberJuly

W 1 2 3 4

W 1 2 3 4

W 1 2 3 4

W 1 2 3 4

2.Action:i Set one page standard for cleaning and calibration in shift production

3.Action:ii Set operation procedure forchange cylinder.

4.Action:iii Reduce the vibration of fillerand change design of bush

5.Action:iv Reduce the variation of checker weight

6.Action:v Study other option for to reduce with Eng. team

7.Action:vi Pre-proposal for managementteam for approve trial

Implemented

Plan

Result of study relation speed & %give away

B) Filler size No.47.5 Target 130 g Speed 60 bottle/min. SL 130 g

SU 136 gFrequency

129 0130 12131 22132 24133 22134 4135 12136 3

More 1

X bar 131.85gCpk 0.41

Histogram

0102030

129

130

131

132

133

134

135

136

Mor

e

Fre

qu

ency

Frequency

Result of study relation speed & %give away

Filler size No.47.5 Target 130 g Speed 70 bottle/min. SL 130 g

SU 136 gFrequency

129 2130 7131 20132 26133 14134 12135 8136 7

More 4

X bar 132.19 gCpk 0.39

Histogram

0

10

20

30

129

130

131

132

133

134

135

136

Mor

e

Fre

qu

enc

y

Frequency

The result show the speed is not significant related with Cpk in speed 60-70 bottle/min

Set operation procedure for change cylinder

:Standard for calibration filler before start up line, during production and change lot pallets gums

:We found the size of cylinder was relate with volume and weight of pallet in 1st step filling

:We must control the1st filling about 148g by change cylinder size after change pallets gum new lot or during production

:Found XP mostly use size 52-52.5 gCFT use 47.5-49 g

Reduce the vibration of filler and change design of bush in 1st filling

:Change a new bush for effective slice gum pallets in to the cylinder for control weight about 148 g after 1st filling step

Some pallets to slip off from here during production

Move in/out

Pallets drop into cylinder

Change a new bushInside for prevent pallets gumSlip

Reduce the vibration of filler by adjust the air cylinder

Action v: Reduce the variation of checker weight

:Mock up new design protective air condition fore to checker weigh cause of if more reject at M/C it effect operator increase setting point weigh at filler head

Before improve variation +/- 0.22-3 g

After improve variation +/- 0.01-0.05g

Air contact in checker weigh

Action vi: Study other option to reduce with Eng. team

Option:1 Need to change shape of rubber for control the pallet in pallet rail

Not good cause of many pallets inside rail Make the new rubber for control 1 roll

If more 1 roll of palletsit potential to 2nd filling over setting target

Action vi: Study other option to reduce with Eng. team Option:2 Need to change shape of rail for control pallet inside one roll

If we change the rail a new shape and more length team think to reduce the pallets inside to one roll

Or

current new new

Action vi: Study other option to reduce with Eng. team Option:3 Need add the air cylinder for automatic cleaning

The cylinder inject the air about 5-6 bar to automatic cleaning for reduce the variation of load cell

Action vi: Study other option to reduce with Eng. team Option:4 Additional counter sensor and PLC unit to control 2nd filling

1st filling control at 148-149 g by change the cylinder size

Vibration unit running filling and stop when weight was over setting 150 g

Signal of load cell sent the massage to open the vibration unit On

Some head was over fill cause of no timing, so the vibrator didn't know how long time to stop

2 or 3 sec for suitable

1st filling control at 148-149 g by change the cylinder size

Signal of load cell sent to PLC control

PLC calculate andsent massage to vibrator

The vibrator on 2-3 sec depend on weight still left for control

add 1-2 pallets by feed back from counter sensor

to control

Add the counter sensor

Current Method New Method

Action vi:New high speed counter machine

Production criteria for M/C1. Can count pallets about 90,000-120,000 pallets per

minute2. Can count accuracy + 0-0.5 pallets 3. Easy production with 1 operator control only 4. Can easy cleaning for change over finish in 1 hr.5. Don’t make the defect of cracking pallets when filling 6. In standard food safety and hygienic engineering 7. Size of M/C can replace in current filler or minor

modification 8. M/C efficiency should be 95%

Process Mapping and Texture Analysis of Soft Chew

Soft chew is the new technology to be installed at this plant.Project Sweet is the reconfiguration of the ANZ Candy

business. The project was approved in May 2007 & formally announced to the business in October

Project Sweet involves three main themes:ANZ portfolio harmonisationSKU rationalisationReduction in manufacturing complexity – closure of

Avondale and Notting Hill sites

Objective

•To understand project management•To understand the complete process of Soft Chew•To deal with the process parameters•To understand Texture and do instrumental texture analysis

Soft CandySoft Candies are Low Boiled Candies with residual moisture of 6-

10%. Main raw materials for soft candies are Sugar, Corn Syrup (Glucose),

Vegetable Fat and Emulsifier. There are three types of soft chew to be manufactured in the

Ladkrabang Plant:TNCC (Black Currant, Raspberry, Orange, Lemon, Strawberry)Fruit Burst (Wildberry, Orange, Banana, Lemon & Lime,

Strawberry)Minties.

There are two types of wrapping, square and twist which will be finally packed in bags and sticks.

Initial Process Flow of Soft Chew Candy

• The temperature and the moisture at the cooking section was more than desired.

• The adjustment of the dosing unit was done manually.• The sheet thickness at cooling drum was more than required.• The cooling drum temperature was too less which resulted in the hard candy

mass which was not easily pulled as its temperature was around 25-30◦C.• The pulling was not proper because of low temperature and hardness of the

mass.• As the pulling table was made of Teflon, so during the run Teflon was

sticking in the candy mass.• The pulling table had a chiller water system which was not needed for

pulling.

Problems occurred in the trial run:

Continue..• The temperature and RH of the room was fluctuating.• The mass after pulling required at least 45-50 mins for graining

so the conveyor belt system was not used.• The cutter was not in use.• Once the cutter was used it took almost half day for cleaning

since the mass was too sticky.• The ropes from the extruder were not of the proper shape and

size as it got swelled up after coming out from the cooling tunnel.

• The cut and wrap machine was not working proper.• The ropes were twisting in the cooling tunnel.• It was difficult to make the process flow continuous.

Continue..

• Talcum is used before cut and wrap machine so that the rope does not sticks to the packing machine but talcum sticks to the final product and the surface of the product has white particles on it.

Reasons for the problems:• The main problems were due to the temperature and moisture

content. More the moisture more was the stickiness in the candy.

• If chiller water is used in the pulling table, there is tendency of moisture to settle on the table and if it is not used the table becomes hot.

• Graining was the most important parameter.

Continue..• Improper and fluctuating room temperature and relative

humidity causes improper graining. If this drops beyond a certain level, the tendency of moisture loss will increase.

• The rope after the extruder will be of proper size, shape and texture only if it is properly grained.

• Stickiness is one of the most important problems which need to be reduced.

Solutions Recommended:The temperature of the cooling drum is decreased.Change the pulling table from Teflon to stainless steel as the

material will not stick on it.The Dosing & Mixing system has been calibrated and works

well for the various flavors / fruit juices and colour solutions. But we lose 2 hours each time to clean the system. We have to develop an online change over mechanism to remove the cleaning requirements in between TNCC flavors and in between Fruit burst flavours.

The pre-extruder is required for the proper quality of the candy and the performance of cut and wrap machine as one time extrusion through the co-extruder does not give proper results.

Continue..The chiller water is not used at the pulling table. Instead of this

there are several other possibilities:Use tower water continuous at ambient temperature of

around 35 to 40◦CDon’t use the continuous supply of chill water i.e.

continuous on and of the supply by the operator.Have a thin sheet of Teflon if the table is changed from

Teflon to steel. The temperature of the room is maintained to about 25◦C and

RH to about 48 to 50%.There should be some arrangement of hot water at the cutter so

that the cleaning is proper and takes place fast.

Contd..

The conveyor belt can be changed or some other options should be considered to complete the graining.

The product after the pulling should be kept at different conditions to check which the best graining process is.

The mass cannot be pulled longer than 6 minutes becauseThe mass collapses on the table and is no more held by the

hooks essentially no more pulling happens. Addition of milled sugar on the pulling machine changes the

texture of the product and it becomes grainy.The talcum used should be replaced by some other material.

Different Options For Graining:

The mass after pulling was kept for graining in three condition:Air condition roomAtmospheric conditionHot cabinet

Option 1

Result:The best graining was that after the hot cabinetIt took almost 1 hr 20 min for the materials after pulling to

go to the extruder.The graining in the air condition room was also good but

took a lot of time.The product took almost 2 hrs to grain in the atmospheric

condition

Option 2:

In this option the material was extruded two times in the co-extruder after the aging.

First the material was kept in AC room for around 30 minutes at 25-28◦C and RH of around 50-55%.

It is then extruded once at a temperature of around 30◦C, and then after passing through cooling tunnel.

Result:The rope after extruding 2nd time was of a fine texture and

smooth and the cut and wrap machine also showed better results.

In this method the cut and wrap machine was giving 65% performance and texture and weight of wrapped candy was good.

This design did not matched at all to the original process design.

One more problem was the hot cabinet

Option 3:

This option was similar to the option 2.The only difference was that after extruding once it was kept in the open

tubs for some time rather than cooling tunnel before sending it to the hot cabinet.

When the system is extruded two times, complete graining takes place since graining is initiated by proper extrusion.

Result:The product obtained from this option also satisfied the

desired conditions and was of good quality but the aging time was more than an hour.

The product from the above two options were similar but the problems were hot cabinet and different with the original plan.

As the process is not continuous, the number of heads has increased.

Option 4:

This option is also similar to the previous one but the aging time was increased to one hour.

Instead of keeping the material in the hot cabinet it was kept in AC room at 25-26◦C for some time and then extruded and passed through cooling tunnel.

Result:

This option also provided with satisfactory result and the problems related to hot cabinet was also solved.

The texture and weight of product was also good but cut and wrap machine was not giving proper performance.

the only problem was to make the system continuous and use only one extruder.

The aging time was also coming to about 2 hours which needs to be reduced for the proper flow of the process.

As the whole plant is designed keeping in mind the continuity of the process so changing the design will cause increased investment as well as delay in the commercial run.

Option 5:

Since two times extruder was not satisfying all the needs, so pre extruder was taken into consideration

As aging time was not coming to be less than 1 hour in any of the above case and 30 to 45 minutes was also required between the 1st and the 2nd extrusion so a total of at least 2 hours was reserved for aging.

In this we have increased the initial aging time to 1:15 to 1:20 hrs.After this the grained mass is passed through the pre extruder where it is

extruded into thin sheets.

Contd…It is then passed through the conveyor to the rove cutter and then to the co-

extruder and cooling tunnel. The conveyor takes approximately 6 minutes to transfer the material from

pre extruder to the cutter and 1 min from cutter to extruder. Result :

For some of the flavors the product was of fine texture but same process was not applicable for few flavors.

Since the candy mass is sticky after the pre extruder, it got stuck in the cutter and it was difficult to operate.

the change over and cleaning time is long of approximately 3 to 4 hrs. This option was good and the final product was also good in texture and

weight but there was some problem in the performance of cut and wrap machine.

Option 6:

The rove cutter is removed because of the problems discussed earlier.There were some more options similar to this one:

Instead of the conveyor the candy mass is kept in AC room for 30 minutes.

Instead of the conveyor the candy mass is kept in AC room for 30 minutes and then kept in the oven after first time extrusion at around 35◦C for 30 min. and then again passed through the extruder.

But these two options were not better than the one showed in the figure.

Result:This was by far the best option. The cut and wrap machine was also giving better

performance and the rope was smooth and not much hard. The pre extruder was installed near to the pulling table. The number of heads was also reduced as the material was

carried to the extruder by the conveyor belt. Overall a better product with not much change in the overall

process, except the installation of the pre extruder which was initially bought from the gum plant.

Results of the trial runs: The problem of continuity of the process still remains because

aging is necessary and it requires minimum of 1 hour 20 minutes.

The initial process design fails at this step and the conveyor and cutter system are not used significantly.

the chiller water arrangement is removed from the pulling table and the pulling table is changed to the stainless steel from black Teflon.

The best option after considering all was option 5 as only pre extruder installation was the change in the process and the product satisfied all the tests including texture, moisture, and acidity.

Two times passing through extruder was also a good option but for that the conveyor belt should be removed and a new co-extruder was to be installed which was not fitting the plant layout and also the number of heads in this process was more.

TEXTURE ANALYSISOBJECTIVES

Comparison of the trial products, S&T product, and original Avondale product.

To compare the texture of candy mass at different steps in the process.

To match the objectives of the trial run with the required product texture.

What do we mean by texture ?Texture can be regarded as a manifestation of the

rheological properties of a food. It is an important attribute in that it affects

processing and handling, influences food habits, and affects shelf-life and consumer acceptance of foods.

Characterization of food texture commonly falls into two main groups based on sensory, and instrumental methods of analysis.

Textural Properties

Hardness: resistance to deformationToughness: AdhesivenessStickiness

Texture analysis in lab:Texture of the candy was analysed for all the runs and it was

compared with the standard product from Avondale and that prepared in the S&T lab.

The graphs of all the flavours were compared after different steps in the processes and then the final candy was compared with the standards.

The different steps were:After pullAfter one time extrusion under different conditionsAfter two time extrusion under different conditionsAfter pre extruderAfter the wrapping of the candyAfter the final graining i.e. minimum 3 days after wrapping

Texture Analysis of all the 5 flavours of TNCC

The products from Avondale, Plant Trial Run and S&T were kept at same temperature.

5 samples were taken of each flavour All the samples taken from Plant trial were

kept for at least 6 days before texture analysis.The black line in the graph represents

Avondale productThe red line represents S&T product

The texture was analyzed for different flavors and the results for almost all the flavors was same.

FLAVOUR: LEMON

0 1 2 3 4 5 6

3.0

2.5

2.0

1.5

1.0

0.5

0.0

-0.5

-1.0

-1.5

-2.0

-2.5

-3.0

Force (kg)

Time (sec)

TNLM_AVN_AVGTNLM_TRIAL_DEC9_AVGTNLM_ST_AVG

Results..The products in the trial run are soft and less sticky than that of

S&T and Avondale product. Other properties toughness and adhesiveness is also less.

The product is formed using two times co-extruderThe product formed in the S&T lab varies greatly with the

others i.e. Avondale and plant trial run.The adhesiveness and stickiness of the trial run product is same

as that of Avondale.The product formed is of good quality

Business

Presentation cadbury's -_copy