QCC DATA Facilitator Leader Members Age DECREASING THE DAMAGE OF PLATE SLATE CONVEYOR OF BAGGING MACHINE -LE UP TO % WITHIN MONTHS INCLINE QCC KUJANG FERTILIZER COMPANY CIKAMPEK KARAWANG WEST JAVA INDONESIA THE MAIN PRODUCT : UREA : Chairul Mutaqin : Asep Suwita : Suhanan Saputra Rosadi Moch. Maliki Dhohri Ridwani Indra Joni : The youngest 7 years old The oldest years old Education Establishment Division Section Finished themes Number of meeting Duration of meeting The presence of Facilitator The presence of Members The period of activity : Senior High School : February, 99 : Production : Bagging and Loading : : (working hour) : 9 minute : % : 9 % : February to July, QCC ACTION PLANNING IN STEPS Meeting Feb Mar Apr May Jun Jul Plan Real. Deciding theme and title. Analyzing the causes P. Examining and deciding dominant causes 7 D. Planning and implementing the improvement C. Studying the result of improvement A. Standardizing the result of improvement 7. Deciding further planning Plan : Real : REASONS OF CHOOSING THE THEME:. It is the main priority. The bagging machine experienced to loose much production time due to the of its plate conveyor. Bulk handling conveyor Vibrator Feeder PROBLEM AREA Bagging machine THE FLOW OF UREA BAGGING AND LOADING PROCESS Bin conveyor Traveling conveyor Sewing machine Bag handling conveyor Accumulator conveyor Short loading conveyor Number of meeting Warehouse Truck Train The process of urea bagging and loading from the bulk handling conveyor to warehouse, trucks, and train was in trouble due to the of bagging machine mainly in part of plate conveyor.
STEP I DECIDING THE THEME AND TITLE Period: February to,. DECIDING THE THEME.. Below is the Pareto diagram of bagging machine -L base on frequency, duration, financial lost. Period of January, data resource: daily report of bagging section taken by Suhanan Saputra and Moch. Maliki. Frequency (times) Pareto diagram the of bagging machine base on frequency -LE -LE -LD -LD -LG -LF -LF -LH -LH Item Equipment num ber bagging number m achine 9.7.. 7. Duration (minutes) 9 Pareto diagram the of bagging machine base on duration -LE -LE -LD -LG -LF -LH -LH Item Number Equipment of Bagging number Machine Based on pareto diagram above, bagging machine -LE was maximum times, minutes with the financial lost of Rp.,,9,. Therefore, the incline QCC decided the theme as follows: DECREASING THE DAMAGE OF BAGGING MACHINE -LE IN BAGGING AND LOADING SECTION. DECIDING THE TITLE.. Below is the Pareto diagram of the spare part of bagging machine -LE base on frequency, duration, financial lost. Period of January, data resource: daily report of bagging section taken by Suhanan Saputra and Moch. Maliki. Frequency (times) Gearbox Choking choking Canvas canvas Slate stuck belt Damage break stuck belt break Kind of Problem Kind of.. Duration (minutes) Gearbox box Choking choki Canvas ng canvas Slate Stuck belt Damage stuck break bel t br eak Kind Kind of of Problem Based on pareto diagram above, the of bagging machine -LE mostly causes by the of plate times, minutes with financial lost up to Rp.,9,9,.-. DECIDING INITIAL GOAL The initial goal is decided based on the lowest of plate historical data which is times per month, therefore the initial goal is decided %. Considering the condition above the Incline QCC decided the title as follows: DECREASING THE DAMAGE OF PLATE SLATE CONVEYOR BAGGING MACHINE -LE UP TO % WITHIN MONTHS 9. 9.. 7. 9. 9.. % Financial lost (Rp) Financial lost (Rp) Pareto diagram the of bagging machine base on financial lost..99. 9 7 99 99 -LE -LD -LG -LF -LH -LE -LD -LG -LF -LH Item Number Equipment of Bagging number Machine 9 99 99 7 7 Gearbox Choking Canvas Gear box choki ng canvas Slate Stuck belt Damage stuck break bel t br eak Kind of Problem 9. 9.. 7. 9. 9.. Acknowledged By: Incline QCC Chairul Mutaqin Chief of Bagging and Loading Section Asep Suwita The Leader
II. Ishikawa Diagram STEP II ANALYZING THE CAUSES Period February to 9, The Operator has less quality awareness The operator wished to finish the work as soon as possible The chain is broken The chain suspense is too high The arrangement of the chain suspense is not accurate The chain is out of track (derailed) The distance between sprocket is minimum MAN The machine operator worked hastily The arrangement of sprocket is incorrect 7 METHOD The plate is corrosive easily MATERIAL The thickness of plate is decreasing The strength of plate declining The plate is bent easily The chain movement is zigzag The chain is not in line with the plate The distance between the bolt of plate is different No standard distance between the bolts of plate MACHINE There is a lot of urea dust ENVIRONMENT The atmosphere at the area of bagging machine is corrosive The plate is out of chain The bolt of plate is broken The plate is bent The plate conveyor of bagging machine - LE is frequently The falling distance of packed urea is too high The distance of bag holder and the plate is mm The guide plate cannot muffle sudden energy of falling thing The gap between guide plate and plate is wide II. Nominal Group Technique (NGT) N o Dominant suspected factors AS SS MM RS DR Total Rank The operator has less quality awareness The plate is corrosive easily There is a lot of urea dust 7 The distance between the bag holder and plate is mm The gap between guide plate and the plate is wide 7 No standard distance between the bolts of plate 7 7 7 The arrangement of sprocket is incorrect 7 7 The arrangement of chain suspense is not accurate Based on the NGT questionnaire of all the QCC members, it can be counted that the index of NGT is. The NGT table shows that there are five suspected factor which influence the of plate conveyor of bagging machine - LE ranked from to or respectively number,,, 7, and. NGT = ½ x + = + =. The arrangement of sprocket is incorrect.. No standard distance between the bolts of plate.. The gap between guide plate and the plate is wide.. The distance between the bag holder and plate is mm.. The arrangement of chain suspense is not accurate.
STEP III EXAMINING AND DECIDING DOMINANT CAUSES Period March to April, Scatter Diagram Of Dominant Suspected Factors III.. The arrangement of III.. The distance between bolt III.. The gap of guide plate to sprocket is incorrect. of plate.. The suspense of plate (mm) r = -.99 -,99 r =.99,99 9 9 9 99999 The distance of sprocket (mm) The distance of sprocket (mm) r r = = -.99 -,99 r r = =.9,9 The distance of of plate plate bolt (mm) bolt ( mm) r r = =.99,99 r r= =.997,997 7 9 The gap between guide plate and The gap between guide plate and plate plate (mm) (mm) Conclusion III.: The distance of sprocket greatly influences the of plate conveyor of bagging machine (negative correlation) Conclusion III. : The distance between plate bolt highly affects the of plate conveyor of bagging machine (negative correlation) Conclusion III. : The width of guide plate gap extremely influences the of plate conveyor of bagging machine (positive correlation) III.. The distance of bag holder III.. The arrangement of chains Is mm. suspense. r =.99 r,99 r =.99 r =,99 9 The The distance distance of bag of bag holder holder to plate to plate (mm) (mm) III.. Pie Chart of Suspected Dominant Causes 9 r =.99,99 r r =.9 =,9 7 The The distance distance of of chain chain bent bent from the from line the line position (mm) (mm) Conclusion III. : The distance of bag holder to mm affects the the of plate conveyor of bagging machine (positive correlation) Conclusion III. : The arrangement of chain suspense greatly influences the of plate conveyor of bagging machine (positive correlation) r =.99 (7.7 ). r =.99 (7. ). 9.9%.% /.7% r =.99 (7. ) 9.99% 9.97% r = -.99 (7.97 ). 7.97 r = -.99 (7.9 ) Based on the experiment result and pie chart, the dominant causes of the of plate conveyor of bagging machine -LE are as follows:. The arrangement of sprocket is incorrect. No standard distance between the bolts of plate. The gap between guide plate and the plate is wide. The distance between the bag holder and plate is mm. The arrangement of chain suspense is not accurate
N o Dominant factor The arrangement of sprocket is incorrect No standard distance of plate bolt The gap between the guide plate and the plate is wide The distance between bag holder and the plate is mm The arrangemen t of chain suspense is not accurate STEP IV THE PLANNING AND IMPLEMENTATION OF IMPROVEMENT Period May to, Why What Where When Who How Straighten the position of chain to sprocket To avoid the suspense of plate and out of track due to the chain pull or pressure To avoid the suspense of plate due to the strike of kg packed urea To avoid hard strike of packed urea to the plate To avoid the of plate and the chain due to the tight or loose chain To arrange the distance between sprocket to 9 9 mm Create the distance of plate bolt to 7 mm Create a gap between guide plate and the plate to mm Create the distance between bag holder and the plate to 9 mm Create the distance of chain straight to 9 mm The area of bagging machine -LE in bagging and loading section May to, Suhanan, and Rosadi Asep S, and Dhohri Asep S, and Suhanan Dhohri, and Suhanan Asep S, and Dhohri. Release all bolt of key sprocket.. Straighten one of the sprockets to the track and fasten the key bolt.. Arrange other sprockets to the distance of 9 9 mm.. Take a plate ; draw the diameter of plate.. Draw two points of the plate with the distance of 7 mm.. Drill a hole of mm on both points of the plate with a drill tool.. Refine the hole.. Lift the guide plate by using jack bolt.. Use feeler gauge to decide a gap between guide plate and the plate to mm.. Lock the position of guide plate by welding it to the supportive iron.. Hang the bagging machine by using sling and chain block.. Release the foundation bolt of bagging machine.. Cut the base plate to mm and make new base plate.. Haul down the bagging machine, measure the distance of bag holder and the plate, then make a distance to 9 mm.. Tighten the foundation bolt.. Press the chain and measure stretch by using moving calipers.. If it is wider than mm, tighten the chain by pulling out both sprockets.. Re-measure the distance of its stretch and create the distance to 9 mm. How much % % % % %
IV. DECIDING THE TARGET Frequency (times) THE BAR DIAGRAM OF DAMAGE FREQUENCY OF PLATE SLATE CONVEYOR OF BAGGING MACHINE -LE AT BAGGING AND LOADING SECTION % % Before improvement Initial Goal Intermediate target The members of QCC agreed to decline the of plate conveyor of bagging machine - LE from times to per month or intermediate target of % IV. IMPROVEMENT IMPLEMENTATION MONITORING GRAPHIC OF DAMAGE OF PLATE SLATE Maximum tolerant limit of plate suspense Maximum tolerant limit of plate suspense 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 The experiment result of arranging the distance between sprocket to 9 9 mm and the monitoring graphic shows there is no of plate over tolerant limit therefore the experiment is successful The experiment result of arranging the distance of plate bolt to 7 mm and the monitoring graphic shows there is no of plate over tolerant limit therefore the experiment is successful Maximum tolerant limit of plate suspense Maximum tolerant limit of plate suspense 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 7 9 The experiment result of arranging the gap between the guide plate and the plate to mm and the monitoring graphic shows there is no of plate over tolerant limit therefore the experiment is successful The experiment result of arranging the distance between bag holder and the plate to 9 mm and the monitoring graphic shows there is no of plate over tolerant limit therefore the experiment is successful Maximum tolerant limit of plate suspense 7 79 9 7 9 7 9 7 9 7 9 Acknowledged By: The experiment result of arranging the stretch of chain to 9 mm and the monitoring graphic shows there is no of plate over tolerant limit therefore the experiment is successful Incline QCC Chairul Mutaqin Chief of Bagging and Loading Section Asep Suwita The Leader
V. EVALUATION OF IMPROVEMENT RESULT STEP V STUDYING THE RESULT OF IMPROVEMENT Period June to, Frequency (times) Before improvement THE BAR DIAGRAM OF DAMAGE FREQUENCY OF PLATE SLATE CONVEYOR OF BAGGING MACHINE -LE AT BAGGING AND LOADING SECTION % % % Initial Goal Intermediate target After improvement CONCLUSION: The bar diagram shows that after improvement, the of plate conveyor decreased from times to per month. Therefore the initial goal and the intermediate target of % is successful V. THE COMPARISON OF PARETO DIAGRAM OF BAGGING MACHINE -LE DAMAGE IN BAGGING AND LOADING SECTION a. Viewed from the frequency of Before improvement Gearbox stuck choking Kind of canvas belt break.. %Cumulative After improvement % Gearbox stuck choking Kind of canvas belt break CONCLUSION: The comparison of Pareto diagram base on the frequency shows the frequency of the bagging machine -LE decrease from times to, it proved that the improvement is % successful b. Viewed from the duration of Before improvement Gear box stuck choki ng Kind of canvas bel t br eak 9. 9.. %Cumulative After improvement % Gear box choki ng canvas stuck belt br eak Kind of CONCLUSION: The comparison of Pareto diagram base on duration shows the decline of time of bagging machine -LE from minutes to, it is concluded that the improvement is % successful c. Viewed from the financial lost Before improvement 9 99 99 7 7 Gear box stuck choking Kind of canvas bel t br eak 9. 9.. %Cumulative After improvement % Gear box choking canvas stuck belt br eak Kind of CONCLUSION: The comparison of Pareto diagram shows the decline of budget for the of bagging machine -LE from Rp.,,9,, - to Rp.. Therefore, the improvement is concluded to be % successful 7
STEP VI STANDARDIZATION Period July to, VI. STANDARD PROCEDURE N THE IMPROVEMENT STANDARD OF PLATE SLATE CONVEYOR DAMAGE OF O BAGGING MACHINE -L Decide the distance of sprockets to 9 9 mm. Decide the distance between the bolt of plate to 7 mm. Decide the gap between guide plate and the plate to mm. Decide the distance of bag holder and plate to 9 mm. Decide the stretch of chain to 9 mm of the line position. VI. STANDARD RESULT. The decline of the frequency of plate from times to per month.. The duration of and the financial lost decreased to zero. Acknowledged By: Approved by: Incline QCC H. Rusdi Djamdjito Chairul Mutaqin Asep Suwita Chief of Production Division Chief of Bagging and Loading Section The Leader STEP VII DECIDING FURTHER PLANNING Period July to, VII. The Pareto diagram of of sewing machine -L in bagging and loading section, data resource: daily report of bagging section in the period of July,, taken by Suhanan Saputra and Moch. Maliki. The Pareto diagram of frequency of sewing machine -LF -LG -LH -LE Equipment number.7 The Pareto diagram of duration of sewing machine 9 -LF -LG -LH -LE Equipment number Based on pareto diagram above, it shows that sewing machine -LF is the highest rank with frequency times, duration: 9 minutes, financial lost Rp. 97,9,.. Therefore, the incline QCC decided the next theme as follows: DECREASING THE DAMAGE OF SEWING MACHINE -LF IN BAGGING AND LOADING SECTION The Pareto diagram of financial lost of sewing machine,,. 97,9,. 7,7,. -LF -LG -LH -LE Equipment number P QCC ACTION PLANNING IN STEPS Aug Oct Sep Nov Dec Jan Feb. Deciding theme and title. Analyzing the causes. Examining and deciding dominant causes. Planning and implementing the D improvement C. Studying the result of improvement. Standardizing the result of improvement A TURN AROUND 7. Deciding further planning Planning : Number of meeting Meet Plan Approved by: Chairul Mutaqin Chief of Bagging and Loading Section Incline QCC: Asep Suwita The Leader