1. White Belt DMAIC Project
Project Goal:
To reduce MTTR of line G by 45% before 30 April 2015.
Sheikhupura Factory
Project Leader
Irfan Rasheed
Shift Engineer
Dairy and Juice Dept

2. Key Concepts Definitions:
Failure & Minor Stops PPI’s
6 June 2015TPM - PM Pillar 2
TypeTechnical Operational, etc.
Time
10 min
FailuresMinorStops
MTBFT
MTTAT
MTTR
Owner: PM Pillar
Support: FI Pillar
MTBFO, etc,
MTTAO, etc.
Owner: AM Pillar
Support: FI Pillar
MTBF, MTTA
Breakdowns
MTBSm
Owner: AM Pillar
Support: PM Pillar Support: FI Pillar
MTBS
Notes:
1. MTBF is a shared target between AM
and PM Pillars and is key to work with
the same figure for both Pillars.
Priority for Phase zero is MTBSm for
Autonomous Maintenance -which is
tracked through the Index of Minor
Stops, and MTBF(t) for Planned
Maintenance in order to develop the
competences while improving the
Reliability of the Line.
2. MTBS, which considers all stops
independent of its origin, will be
tracked as a standard after Phase zero.
Focus of AM Step 4 and PM Steps 3-5
are to eliminate un-planned stops.
Tracking MTBS before Phase 1 is
optional.
Notes:
1. MTBF is a shared target between AM
and PM Pillars and is key to work with
the same figure for both Pillars.
Priority for Phase zero is MTBSm for
Autonomous Maintenance -which is
tracked through the Index of Minor
Stops, and MTBF(t) for Planned
Maintenance in order to develop the
competences while improving the
Reliability of the Line.
2. MTBS, which considers all stops
independent of its origin, will be
tracked as a standard after Phase zero.
Focus of AM Step 4 and PM Steps 3-5
are to eliminate un-planned stops.
Tracking MTBS before Phase 1 is
optional.
MTBF
Mean Time Between Failures
MTTA
Mean Time To Action requirements
MTTR
Mean Time To Repair
MTBS
Mean Time Between Stops
Note:
MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars.
MTBFT and MTBFo, etc, can be used as internal departmental KPI.
Note:
MTBF is a shared target between AM and PM Pillars and is key to work with the same figure for both Pillars.
MTBFT and MTBFo, etc, can be used as internal departmental KPI.
ProcessFailures

3. PM
Step 1
PM
Step 2
PM
Step 3
MTTR Drivers
Targetper
step.
NA
+ 25%
+ 60 %
Definition: Indicates the mean time for a production Line to start operating again under normal conditions, after the
occurrence of a Breakdown. (Excluding startup cleaning time etc).
Frequency: Monthly.
When: Start measuring from Step 2. This is an OPTIONAL indicator that can help to understand skill gaps or
preparation for intervention gaps
PPI’s Influenced: Productivity, Quality, Cost, Delivery. And Morale.
6/6/2015TPM - PM Pillar 3
.Calculation
Inputs:
MTTR =
Total Duration of Breakdowns (1)
Total Number of Breakdowns (2)
Calculation:
Description Unit Data Source:
1. Time allocated to corrective
maintenance activities > 10 min).
2. # of Corrective Maintenance Orders in
Breakdown > 10 min.
Hrs AMM
# AMM
Considerations:
Consolidate data from
AMM
Consolidate data from
AMM
PPI: MTTR  Optional Indicator.

4. DEFINE Phase
Define
Define precisely the scope
of the project
Problem
Includes…
1. Time Series Chart
2. Financial Impact
3. Team Charter
4. Skill Matrix
5. Project Charter
ProblemProblem

5. 5W1H – Is/Is NotProblemProblem
What
Which
When
Where
IS IS NOT
Who
Reduce MTTR MTTA
Filling Line Plant
All Shifts
Line G Other Lines
M-Team PRODUCTION STAFF
45 % Reduction of Total
MTTR
How

6. Time Series Plot: Justification to do DMAIC
6
ProblemProblem
Target: Current Average is 32.3 minutes, Bench mark is 11 minutes, Target is
45% gap reduce up to 22.7 minutes.
Weeks
MachineMTTRinMinutes
0
10
20
30
40
50
60
70
30 31 32 33 34 35 36 37 38 39 40 41 42 45 46 47 49 1 2 3 4 5 6
Current MTTR
Average MTTR
Target
Bench Mark

7. 7
Team Leader
Team LeaderTeam Leader
Irfan rasheed
(SE D&J)
Process OwnerProcess Owner
Asif Saddique
(PM-D&J)
Team MemberTeam Member
Tauseef
(Tech-MT)
Team MemberTeam Member
Imran
(Operator-D&J)
TEAM CHARTER
D M A I C
Awais
(Team Leader D&J)
Team MemberTeam Member
CoachCoach
Ahsan
(NCE Champion D&J)
Abdul Moeed
(Engineer-Tetrapak)
Team MemberTeam Member
Team MemberTeam Member
Inam
(Operator-D&J)
Previous
DMAICS
As
member
As Team
Leader
Meetings
Participation
50%
100%
100%
75% 75%
100%

8. 8
Competency MatrixProblemProblem
WB Project Team name
Team Leader
Team
Member
Team Member Team Member Team Member Team Member Average
competency
level
Function Function Function Function Function Function
Irfan rasheed Imran inam Abdul moeed Tauseef Awais
Competency
Initial
Current
Required
GAP
Before
Initial
Current
Required
Initial
Current
Required
GAP
Before
Initial
Current
Required
GAP
Before
Initial
Current
Required
GAP
Before
Initial
Current
Required
GAP
Before
Initial
Current
Required
GAP
Before
DMAIC Overview
2 3 4 2 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 2 2 3 1 1.7
1
2.1
4
3.1
3
1.4
1
WB roadmap
3 3 4 1 1 2 2 2 2 2 0 2 2 2 0 1 2 2 1 2 2 2 0 1.7
1
2.1
4
2.2
5
0.5
4
DEFINE phase
2 3 4 2 1 2 3 2 2 3 1 2 2 3 1 2 2 3 1 3 2 3 0 1.8
6
2.1
4
3.1
3
1.2
7
MEASURE phase
2 3 4 2 1 2 3 1 2 3 2 1 2 3 2 2 3 3 1 2 2 3 1 1.7
1
2.4
3
3.1
3
1.4
1
ANALYSE phase
2 3 4 2 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 1 2 3 2 1.4
3
2.2
9
3.1
3
1.7
IMPROVE phase
3 3 4 1 2 2 3 3 2 3 0 1 2 3 2 1 2 3 2 1 2 3 2 1.8
6
2.1
4
3.1
3
1.2
7
CONTROL phase
3 3 4 1 1 2 3 2 2 3 1 1 2 3 2 2 2 3 1 1 2 3 2 1.7
1
2.2
9
3.1
3
1.4
1
DMAIC storyboard
3 3 4 1 2 2 3 2 2 3 1 2 2 3 1 2 2 3 1 1 2 3 2 1.8
6
2.1
4
3.1
3
1.2
7
WB Tollgate content
2 3 4 2 1 2 2 1 2 2 1 1 2 2 1 1 2 2 1 2 2 2 0 1.2
9
2 2.2
5
0.9
6
Member Gap Before and After
2.4
4
3 4 1.5
6
1.2
2
2 2.7
8
1.8
9
2 2.7
8
0.8
9
1.3
3
2 2.7
8
1.4
4
1.6
7
2.1
1
2.7
8
1.1
1
1.6
7
2 2.7
8
1.1
1
1.6
8
2.1
9
2.9
3
1.2
5
Score Definition:
1 Knowledge not acquired / required
2 Basic knowledge, but no competency
3 Can practice with help
4 Can do alone
5 Can train others

9. Project Charter
ProblemProblem
Project Title: To reduce MTTR of line G by 45% before 30 April 2015
Project Leader: Irfan Rasheed Team Members:
Department Name
Production Team Leader Awais
Engineering(M Team) Abdul Moeed
PLE D&J Inam Abbas
TPP Maintenance Imran
TPP Maintenance Touseef
Business Case (Importance):
Reduction in MTTR will increase our productivity as well as line efficiency will improve.
Aligned with Key Priorities of Technical
“enhance reliability in operations to meet consumer demand”
“maximize operational productivity with lean mindset to reduce cost of production”
 Speed up delivery time
 Enhance technician availability.
 438 Ton increase in production capacity.
 Reduce MTTR 9.7 minutes per stoppage.
Problem Statement (Purpose):
Currently MTTR is 32.3 minute.caused by the stoppages due to Final Folder, Straw applicator , ASU and Conveyor
during production, on line G our target is to reduce up to 22.7 minutes.
Goal Statement (Measures):
Project can be measured on basis of following KPIs:
 To reduce MTTR on line G up to 22.7 minutes
Project Scope, Constraints:
In scope: Tetra Filler ,Conveyor, Straw Applicator, Shrink
Out scope: Plant
Deliverables:
At the End of Project following will be deliverables:
 Standard work
 Coaching of People
 Reduce MTTR to 22.7 minutes
 Financial Impact / Financial Sheet
Resources:
Coordination among following departments will be required:
 Plant Engineer: Saleem Ashraf
 Tetra pak Support: Umair Younis
 Factory Costing: Momiza Ahmed
 SHE Coordinator: Ahsan Abbas
Stakeholders:
Customer, project sponsor, process owner
Department Name Position
Project Sponsor Asif Siddique Plant Manager
Stake holder Babar Khan BEM Juice
Coach Ahsan Abbas D&J
Preliminary Plan:
Phase Milestones Target Start Date Target Completion Date
DEFINE Establish team and Project Charter 25-01-15 08-02-15
MEASURE Identify required data / Generate/Analyze data 9-02-15 15-02-15
ANALYZE Identify highest contributors / Determine root causes 16-02-15 20-03-15
IMPROVE Identify corrective actions / Implement corrective actions 21-02-15 15-03-15
CONTROL Track and trend impact of actions 16-03-15 30-04-15
Date: Project Leader Project Sponsor
25-01-2015 irfan Rasheed Asif Siddique

10. Financial Impact
10
ProblemProblem
Estimated
Annual Savings
4.4 Mio (approx)
NPH 5465
BD # 542
Before Hrs Lost 129.7 MTTR 32.3
After 90.8 MTTR 22.7
Saved 87.6
Lean Permannent 2 400 800
Labor 5 140 700
Electricity 64 16.4 1049.6
Steam 100 16 1600
4149.6
Financial Saved 363,504.96
Flush Flush Saved (Hrs) 87.6
Ton 438
Conversion Cost/Ton 10000
Saved 4,380,000.00

11. MEASURE Phase
Measure
Understand the problem
Problem
Includes…
1. Data Stratification Criteria
2. Data Collection Plan & Form
3. Pareto Chart
4. Time Series Plot
5. Flow Chart
6. Focused Problem Statement
ProblemProblem

12. Data Stratification Criteria
12
MTTR ON Line G
Average MTTR Shift
wise
MTTR Line wise
MTTR Technician
wise
Technician
3
Technician
2
Technician
1
Shift CShift BShift A
Technician
4
Machine Parts wise

13. Data Collection:
13
ProblemProblem
WHAT WHERE WHEN
(Due Date)
WHY WHO
(Responsible)
HOW
STATUS
MTTR of G
Line
Filler, Conveyor, Straw
applicator, shrink
From JUL 21,2014 to
March 22 ,2015
To reduce
MTTR of line G
TPP
( Moeed)
Imran
Inam
Register the different
problems related to Filling
Line and their MTTR time
from SAM and Log sheet
Data
Done

14. Data Reliability:
,
14
ProblemProblem
SAM
Data Reliability is ensured by Log sheets
Log Sheets
Log Sheets of machine is used to find stoppages

15. MTTR Total Time Lost stoppages wise
15
Noofstoppagesinminutes
Straw missing, final folder are the main contributor
No of stoppages
Data StratificationProblemProblem
0
200
400
600
800
1000
1200

16. No of stoppages frequency wise
16
NoofStoppages
Straw missing, final folder are the main contributor
No of breakdown stoppages
Data Stratification
ProblemProblem
0
10
20
30
40
50
60

17. Data Stratification
17
ProblemProblem
31
31.5
32
32.5
33
33.5
34
34.5
Shift A Shift B Shift C
MTTRINMINUTES
Shifts
Average Shift wise MTTR same MTTR in all three shifts

18. Data Stratification Average Technician wise MTTR
18
ProblemProblem
MTTRINMINUTES
Technicians
MTTR is high when Alvi and Ahmad attend the issues
0
5
10
15
20
25
30
35
40
Ahmad raza Alvi Kamran Rizwan

19. Pareto Chart (Technician wise)
19
ProblemProblem
AverageMTTRInMinutes
MTTR dependents on Technicians

20. Pareto Chart (Problem wise)
20
ProblemProblem
AverageMTTRInMinutes
Stoppages
Conveyor, ASU splice, final folder, and straw missing problems takes
high MTTR as compare to others.

21. Process Mapping
21
ProblemProblem
ASEPTIC
CHAMB
ER
Machine
Body
Jaws
System
SERVICE
UNIT
DRIVE
UNIT
FINAL
FOLDER
ASU Straw
Applicator
ConveyorTray Shrink

22. 5W 1H for Problem Statement
22
What What is happening?
High MTTR
How How does it happen?
Due to BD stoppages on ASU, Final Folder, Conveyor, Straw
Applicator
Which pattern do you see? (does it happen on the right, left,
above, bellow, in front of, behind, randomly…)
Same MTTR in all shifts
When When does it happen? When did the problem happen?
It happens randomly
Where Where does it happen?
Final Folder, Conveyor, straw Applicator, ASU
Who Is the problem correlated to operator abilities?
Partly depends on Technician ability
ProblemProblem
High MTTR caused the stoppages due to Final Folder ,Straw Applicator, ASU,
and Conveyor during production in all shifts on line G partly depending on
technician ability.

23. Focused Problem Statement
23
To Reduce MTTR, caused by the stoppages due to Final
Folder, Straw applicator , ASU and Conveyor during
production, on line G

24. ANALYZE Phase
Analyze
Identify the root causes
Problem
Includes…
1. Brainstorming
2. Sorting
3. Cause & Effect Diagram
4. Probable Causes Verification
5. WHY-WHY Analysis
ProblemProblem

25. 25
ProblemProblem
Brain Storming Final Folder
• Final Folder Synchronization not as per Standard
• Packet Delay from Jaws
• Packet De-shape from Jaws
• Tube flushing & TS cooling water Nozzle blocked
• Infeed Belt Damaged
• Infeed Belt position Offset Not as per standard
• Infeed Gear box coupling broken and Gearbox play
• Station chain guides misaligned
• Station chain Gear box coupling broken and Gearbox play
• Flap squeezer belts condition & Flap Nozzle position
• Flap Open problem & Flap temperature variation
• Packet twisting problem
• Outfeed brush condition, Bearings jammed drive belt lose
• Outfeed wheel offset & gearbox play
• Outfeed wheel motor faulty.
• Sprinkling water nozzle block at Outfeed
• Outfeed finger broken
• Conveyor links broken
• Conveyor speed
• Quality of weekly checks is not up to mark
• Low quality of cleaning material

26. 26
ProblemProblem
Brain Storming Straw Applicator
• Bottom flap of the packets opened due to which packets fall at belt brake of
straw applicator.
• Conveyor Jerk
• Conveyor lubrication not properly done as no frequency is defined
• Gaps in guide rods
• Guides not properly cleaned as lose control on weekly checks
• Friction at the guide surface
• Improper conveyor cleaning
• Juice spillage at the conveyor
• Packet design out problem due to which packets unstable at feed wheel.
• Sensors of belt brake are improperly aligned
• Gaps between packets
• Glue nozzle choke
• Straw quality banana shape
• Improper cleaning of feed wheel and
• Quality of weekly checks is not up to mark
• Low quality of cleaning material

27. 27
ProblemProblem
Brain Storming Straw Applicator
• Hot melt temperature
• Gun module choke
• Air pressure
• Air Solenoid valve malfunction
• Synchronization issue between machine conveyor speed and in feed belt break
• Conveyor speed
• Packets shape issue from filling machine side
• Knife dull
• Feed wheel position
• Bent foil heater temperature
• Pressure arm override
• Ladder Band guide
• Straw Position sensor
• Leaf Spring
• Untrained operator
• Glue quality
• improper cleaning material
• Feed wheel synchronization out
• Conveyor guides miss align
• conveyor speed
• irresponsible operator

28. 28
Brain Storming ASU Splice missing problem
Prol
• Paper miss aligned cutting table setting out
• Splice not prepared according OM
• ASU cutting problem
• ASU Constant heat bar Temperature
• ASU photocell barcode detection not working
• ASU thermocouple wire distortion
• Reel empty sensor miss aligned
• Bellow for splice not operate
• Reel not prepared
• Mandrill position out
• Manual Splice performed by operator
• Time delay between Problem and inform to Maintenance staff
• Long distance between Filling machine and Distribution equipment's
• Untrained Technicians & competency level
• Untrained or Irresponsible Operator
• Low man power
• Work load during meal timings
• Electrical Panel keys not available at machine
• Cleaning of Machine
ProblemProblem

29. 29
Brain Storming on conveyer
Prol
• conveyer links broken
• conveyer dry lubrication
• conveyor direction
• conveyer railings
• conveyers guides adjustment
• conveyer speed
• conveyer drive motor
• conveyer length
• conveyer quality
• Time delay between Problem and inform to Maintenance staff
• Long distance between Filling machine and Distribution equipment's
• Untrained Technicians & competency level
• Untrained or Irresponsible Operator
• Low man power
• Work load during meal timings
• Electrical Panel keys not available at machine
• Cleaning of Machine
ProblemProblem

30. Restoration of Basic Machine Conditions Final Folder
30

31. Restoration of Basic Machine Conditions Straw Applicator
31

32. CLI
32
C L I

33. ProblemProblem
Fish Bone (Cause & Effect Diagram Final Folder)
To reduce MTTR of
m/c G due to Final
folder
Method
machine
Material
Man
1. In feed belt
2. In correct Volume
3. Waste conveyor improper function
4. Crease out
5. Conveyor guides misalign
6. Tube flushing water
7. Gear box fault
8. FFU motor fault
9. Flap nozzle cleaning issue
10. Paper dust in station wheel
11. Conveyor jerks
12. Pusher synchronization out
13. Conveyor speed improper
14. Tube flushing water
15. High MTTR due to Packet twisting problem
16. Out feed gear box play
17. Improper Lubrication of conveyor
18. flap open
19. Design out
20. Sensor fault
21. Packet delay
1. Untrained operators
2. Irresponsible operators
3. Technician Response time
4. improper manual cleaning
1. Low quality of paper
2. Low quality of lubricant
3. low quality of cleaning material
1. Weekly checks not properly done
2. Improper flap nozzle cleaning
3. Final Folder Synchronization not as
per Standard

34. ProblemProblem
Fish Bone (Cause & Effect Diagram Straw Applicator)
Method
machine
Material
Man
Improper manual cleaning
Low quality of cleaning material
Improper glue nozzle cleaning
Pressure arm override
High MTTR due to Straw missing
Conveyor guide rods gap
Conveyor speed
Glue module choke
Air pressure
Synchronization out
flap open
Bent foil theater
Sensor fault
In feed belt brake
nozzle choke
Hot melt Temperature
Conveyor guides misalign
Glue missing
Packets top support belt
Feed wheel motor fault
glue nozzle cleaning issue
Feed wheel
Weekly checks not properly done
lubrication of conveyor
Banana type straws
Low quality of glue
Untrained operators
Irresponsible operators
To reduce
MTTR of
m/c G due
to Straw
Applicator
Technician Response Time

35. ProblemProblem
Fish Bone (Cause & Effect Diagram ASU)
Method
machine
Material
Man
Weekly checks not properly done
Low quality of paper
Untrained operators
To reduce
MTTR of
m/c G due
ASU
Technician Response Time
Paper miss aligned cutting table setting out
High MTTR due to Splice not
prepared according OM
ASU cutting problem
ASU tpc bar Temperature
High MTTR due to ASU photocell barcode detection not working
High MTTR due to ASU splice missing
Reel empty sensor miss aligned
Mandrill position out
Reel not prepared According OM
High MTTR due to Manual
Splice performed by operator

36. ProblemProblem
Fish Bone (Cause & Effect Diagram Conveyor)
Method
machine
Material
Man
Weekly checks not properly done
Low quality of conveyor
Untrained operators
To reduce
MTTR of
m/c G due
to
Conveyor
Technician Response Time
High MTTR due to conveyer links broken
High MTTR due to conveyer dry lubrication
conveyor direction
conveyer railings
conveyers guides adjustment
conveyer speed
conveyer drive motor
conveyer length

37. Potential cause verification
Possible Causes Logic Verification Criteria Status
Technician Response Time When Technician will not attend problem in time
MTTR will be high
Experience/ Gemba Verified
Final folder Packet
twisting
When packet twisting problem will comes it takes
too much time to resolve.
Experience/ Gemba Verified
Straw missing
(Banana shape
straws )
When straw will miss due to banana shape ,straws
will not make properly contact with packages. Due
to this reason technician disturb its basic setting.
Which takes time to restore.
Experience/ Gemba Verified
ASU splice missing When splice will miss operator takes 30 to 40
minutes for manual joint which cause high MTTR.
Experience/ Gemba Verified
37

38. Potential cause verification
Possible Causes Logic Verification Criteria Status
Conveyor When conveyor links break it takes more than 50
minutes to change because of conveyor layout .
Experience/ Gemba Verified
38

39. 1st Round Hypo-
thesis
2nd Round Hypo-
thesis
3rd Round Hypo-
thesis
4th Round Hypo-
thesis
5th Round Hypo-
thesis
Actio
n
Why MTTR
high due to
technicians
Response
time
Why work load on
technicians
MTTR high
due to
Technicians
Response
time
Because of
work load on
technicians
Because of man
power shortage on
L,N,G,J machines
One tech=12
machines
Because of too
many problems at
same time
Because of
behavior
Because of
long path
between DE
and Filler side
Only one door
available for
movement
between both
areas
Yes
No
No
Root
Cause
1
 Priority problem :
ProblemProblem
5 Whys
YesYes
Yes
Root
Cause
2
Yes

40. 1st Round Hypo-
thesis
2nd Round Hypo-
thesis
3rd Round Hypo-
thesis
4th Round Hypo-
thesis
5th Round Hypo
-
thesi
s
Actio
n
Why High
MTTR due to
packet twisting
Why technician’s
different competency
level
Why technicians
not trained
High MTTR
due to
packet
twisting
Because of
technician’s
different
competency
level
.
Lack of trainings Because of high
work load training
session not
planned
Difficult to
plan and
spare
technicians
for training
Trainer not
available
Because of
complexity
of the
problem
Too much settings
involved
High
competency
required for
troubleshooting
Training
required for
competency
building
No standard
procedure is
define for
trouble shooting
Yes
 Priority problem :
ProblemProblem
5 Whys
YesYes
Yes
Root
Cause
3
Yes
No
Yes Yes
Yes
Root
4
Root
Cause
4
Root
Cause
3

41. 1st Round Hypo
-
thesi
s
2nd Round Hypo
-
thesi
s
3rd Round Hypo-
thesis
4th Round Hypo-
thesis
5th Round Hyp
o-
thes
is
Acti
on
Why High
MTTR due to
splice miss
Why Splice
sequence
interrupt
Why air
leakage
Why brittle
pipes
High
MTTR due
to Splice
miss
Because of
splice
sequence
interrupt
.
Because of air
leakage from
system
Because of
brittle pipes
Because
no interval
is define
for pipes
change
Because of
sensors
Because of
PLC
Because of
Temperature
Because of
Constant heat
bar
Because of
sludge
accumulate
on heat bar
Because of
software
issue its
heat bar is
continuous
ly on
during CIP
Yes
 Priority problem :
ProblemProblem
5 Whys
YesYes Yes
No
Yes
Root
Cause
5
No
Yes Yes Yes
Root
Cause
6

42. 1st Round Hypo-
thesis
2nd Round Hypo-
thesis
3rd Round Hypo-
thesis
4th Round Hypo-
thesis
5th Round Hypo-
thesis
Actio
n
Why MTTR
high due to
conveyor
why MTTR high
due to conveyor
links change
MTTR high
due to
Conveyor
Because of
adjustment
and conveyor
broken links
change
.
Because of
conveyor lay out it
is very difficult to
work on congested
area
Because of
speed
adjustment
Because of
drive gear
box
Yes
No
No
Root
Cause
7
 Priority problem :
ProblemProblem
5 Whys
Yes

43. 1st Round Hypo-
thesis
2nd Round Hypo-
thesis
3rd Round Hypo-
thesis
4th Round Hy
po-
the
sis
5th Round Hypo-
thesis
Actio
n
Why Straw
missing
takes high
MTTR
Why MTTR high
due to banana
shape straw
Why MTTR is
high due to
applicator
setting
High
MTTR due
to
Straw
Missing
Because of
Banana
shape straw
.
Because of straw
applicator settings
Because
applicator setting
takes too much
time. No standard
procedure is
define for set
applicator unit
according to
banana shape
straw
Because
conveyor speed
Root
Cause
8
 Priority problem :
ProblemProblem
5 Whys
YES YES
No
YES

44. 1st Round Hypo-
thesis
2nd Round Hypo-
thesis
3rd Round Hypo-
thesis
4th Round Hypo-
thesis
5th Round Hypo-
thesis
Actio
n
Why MTTR
high due to
straw missing
Why MTTR high
due to dot missing
why MTTR high
due to solenoid
valve and its
module
Why
solenoid
valve
malfunction
MTTR high
due to straw
missing
Because of
glue dot
missing
.
Because of solenoid
valve and its
module
Because of
solenoid valve
and its module
malfunction
Because of
continuous
operation
and its
interval is
not define it
takes too
much time
for trouble
shoot
during
production
Because of
electrical supply
Because of
temperature
Yes
No
No
Root
Cause
9
 Priority problem :
ProblemProblem
5 Whys
YesYes Yes

45. Problem
ProblemProblem
IMPROVE Phase

46. 46
IMPROVE Phase
Problem
•Brain Storming
•Prioritisation Process
•Action Plan
•Before and After Time Series

47. ProblemProblem
IMPROVE Phase Brain Storming
1. P1. Man power shortage.
2. P2. Only one door is available for DE and Filler side( long path)
3. P3. Lack of Trainings.
4. P4. No standard procedure is define for trouble shooting packet twisting problems.
5. P5. Pneumatic pipes interval not define.
6. P6. Software issue (ASU Constant heat bar).
7. P7. Conveyor Layout.
8. P8. Module and solenoid valve interval is not define it takes too much time for cleaning and
change during production.
9. P9. Banana shape straws.

48. Action Plan (5W 2H)
WHAT WHY HOW WHERE WHO HOW
MUCH
WHEN STATUS
Long path
between DE
and Filling side
Because of one
door is
available.
Technician
takes average 5
to 8 minutes
between Filler
and DE side
By built new door or
depute one
technician on DE
side
At the front of
L,N,G line
or
At shrink and
straw
applicator
irfan Once Week # 14 Done
High MTTR
due to lack of
trainings
Because un
trained
technician takes
extra time to
resolve the
problems as
compared to
trained
technician
Provide training to
the Technician from
Tetrapak
Or
Provide training on
the machine for
specific modules or
problems
On the
machine
Umair
Irfan
one week Week # 15 Done
High MTTR
due to packet
twisting
Because of No
standard
procedure is
define for
trouble shooting
also high
competency is
required for
trouble shoot
preparing standard
instructions for the
Technician
On Machine
Imran
Touseef Once Week # 8 Done

49. Action Plan (5W 2H)
WHAT WHY HOW WHERE WHO HOW
MUCH
WHEN STATUS
ASU
Pneumatic
pipes leakages
Because of
brittle Define interval
In 6000 hrs
service Touseef Once Week # 8 Done
Sludge
accumulate
on ASU
constant heat
bar
Due to machine
Software issue
Modification In PLC Irfan Once Week # 13 Done
Conveyor
Due to
conveyor layout
it is very difficult
for work on it.
Change Conveyor
layout On Machine
Umair
mudasa
r
Once Week # 11 Done

50. 50
Action Plan (5W 2H)
Prol
WHAT WHY HOW WHERE WHO HOW
MUCH
WHEN STATUS
Solenoid
Valve and
Glue module
Because of
continues
operation it
takes high
MTTR during
production
By Define interval
In 3000 Hrs
TPMS
check list
Abdul
moeed
Once Week #8 Completed
Banana
shape straws
Due to quality
issue
Increase quality
checks ,block
banana shape
straws
Educate the
operators about
banana shape
straws
.
O n
Machine
Imran
Week # 9 Pending
Man power
shortage.
Due to number
of machines in
Dairy and juice
Increase the
number of
technician or
Shift TBA 8 group
technician
Juice Filling
lines
Umair
Irfan
Rasheed
Week # 7 Completed
ProblemProblem

51. 51
Prioritisation Of Root Causes
Effort
Impact
High
High Priority / Do
It!
More Strategic? /
Simplify or Split
Low
DropExecute if no other
priorities
Low
P1
P6
P7
P3
P4
P9
P5
P8
P2
ProblemProblem

52. 52
Time Series Plot: Before and After
Prol
ProblemProblem
SAM used for data collection
Before After
Improve
MachineMTTRinMinutes
Weeks Numbers
0
10
20
30
40
50
60
70
30 31 32 33 34 35 36 37 38 39 40 41 42 45 46 47 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Current Position
Target
Average MTTR
Bench Mark
Define
Define

53. 53
Control Phase
CONTROL
Standardize and make
Future Plans
Problem
•OPLs
•Checklist
•Training
•Update Financial Sheet.
•Update Skill Matrix.
•SWOT Analysis.
ProblemProblem

54. Shift Coverage (number of technicians increased for
line LNGJ)
54
Focus Groups - 2015
Crystal
(C M B P F)
Valencia
(L N G J)
Prisma
(V R W K)
Everyday
(H U O D)
Ahsan Ullah Javed Asghar Abdul Moeed Arsalan Ashraf
Imran Virk Rizwan Nasir Abbas M. Kamran
Muhammad Tauseef Salahuddin Ahmed Raza Arshad Mirza
Kaleem Zeeshan Asad Raza Umer Mahfooz
Asif Mohsin Hamood Abu Huraira
Abbas S. Kamran Babar Hussain
Saeed Khan Hafiz Khalid
Sohaib Minhas
Initials/YYYY-MM-DD Security Level / 1
ProblemProblem

55. ASU Pneumatic pipes (interval define)
55
A3 Speed 6000hrs TPMS Extra Task
Sr # Task Task Description Part # New P/N Part
Description QTY
Time
1 Change Station chain bearing 321330-0108 Bearing 1
2
2 Change Seal 90458-1387 Seal 1
3 Change In feed bearing seal 90091-0438 Seal 2
2.5
4 Change In feed bearing bearing 90214-0096 344226-0105 Bearing 2
5 Change Out feed brush seal 90091-0406 Seal 1
26 Change Out feed brush bearing 90214-0165 90603-2356 Bearing 1
7 Change Out feed brush bearing 90214-0225 90603-2403 Bearing 2
8 Change A-3speed bottom flap drive bearing 321308-0205 344224-0205 Bearing 2
2
9 Change A-3speed bottom flap drive Seal 90091-0148 Seal 2
10 Change pneumatic pipes of ASU
315400-
0004 Hose 100m
6
11 Change pneumatic pipes of ASU
315400-
0001 Hose 100m
12 Check Inspection of jaw chain sprocket bearing 0:30
13 Check In feed shaft 0:05
14 Check Waste box cylinder check 0:10
15 Check Out feed brush shaft 0:10
16 Check A-3speed bottom flap drive shaft 0:10
17 Check All forming ring roller 0:20
Time 16:00
ProblemProblem

56. 56
Standard work for Final folder settingsProblemProblem

57. Standard work for Out feed packages twisting problem
57

58. OPL FOR SOLINOID VALVE
58
Color Strip should be on the side of Small Bended Pipe
ProblemProblem

59. Standard Setting of Straw Applicator
59
Recommended Setting For Line G Straw Applicators
Ser. Checks Recommended
1 Machine air pressure 5.5-5.8 Bar
2 Pressure of Hotmelt nozzle 4.5 Bar
3 Hot melt tank pump pressure 3 Bar
4 Position of upper glue under the bend
5 position of lower glue Straw bottom edge
6 position and Angle of upper glue nozzle 10-15°
7 position and Angle of lower glue nozzle 10-15°
8 Applicator unit angle 23° right
9 Position of Straw on package -4 mm
10 Glue position lower -3mm
11 Glue position upper -7mm
12 Glue duration lower 14ms
13 Glue duration upper 16ms
14 Out feed queue deactivation delay 2700ms
15 Out feed queue alaram activation delay 10000ms
16 Discharge Speed factor 5%
17 infeed Speed factor 5%
18 Temperature of Tank 145 °C
19 Temperature of Upper Glue Nozzle 155 °C
20 Temperature of Lower Glue Nozzle 155 °C
21 Temperature of upper Glue Hose 150 °C
22 Temperature of lower Glue Hose 150 °C
23 Conveyor Fine tune -2HZ
ProblemProblem

60. 60
ProblemProblem
Modification in PLC for ASU Constant Heat Bar

61. Training of Technicians
61
Training for Technicians about
settings
ProblemProblem

62. Financial Impact
62
ProblemProblem
Estimated
Annual Savings
4.4 Mio (approx)
NPH 5465
BD # 542
Before Hrs Lost 129.7 MTTR 32.3
After 90.8 MTTR 22.7
Saved 87.6
Lean Permannent 2 400 800
Labor 5 140 700
Electricity 64 16.4 1049.6
Steam 100 16 1600
4149.6
Financial Saved 363,504.96
Flush Flush Saved (Hrs) 87.6
Ton 438
Conversion Cost/Ton 10000
Saved 4,380,000.00

63. Competency Matrix
63
WB Project Team name
Team Leader Team Member Team Member Team Member Team Member Team Member Average
competency
level
Function Function Function Function Function Function
Irfan rasheed Imran inam Abdul moeed Tauseef Awais
Competency
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
Initial
Current
Required
GAPBefore
GAPAfter
DMAIC Overview
2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 2 3 1 1 2 3 3 1 0 1.7
1
3 3.1
3
1.4
1
0.1
3
WB roadmap
3 4 4 1 0 1 2 2 1 0 2 2 2 0 0 2 2 2 0 0 1 2 2 1 0 2 2 2 0 0 1.7
1
2.2
9
2.2
5
0.5
4
-0
DEFINE phase
2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 2 3 3 1 0 2 2 3 1 1 3 3 3 0 0 1.8
6
3 3.1
3
1.2
7
0.1
3
MEASURE phase
2 4 4 2 0 1 3 3 2 0 1 3 3 2 0 1 3 3 2 0 2 3 3 1 0 2 3 3 1 0 1.7
1
3.1
4
3.1
3
1.4
1
-0
ANALYSE phase
2 4 4 2 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 2 3 1 1 1 3 3 2 0 1.4
3
3 3.1
3
1.7 0.1
3
IMPROVE phase
3 4 4 1 0 2 3 3 1 0 3 3 3 0 0 1 3 3 2 0 1 2 3 2 1 1 3 3 2 0 1.8
6
3 3.1
3
1.2
7
0.1
3
CONTROL phase
3 4 4 1 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 2 3 3 1 0 1 3 3 2 0 1.7
1
3.1
4
3.1
3
1.4
1
-0
DMAIC storyboard
3 4 4 1 0 2 3 3 1 0 2 3 3 1 0 2 3 3 1 0 2 2 3 1 1 1 3 3 2 0 1.8
6
3 3.1
3
1.2
7
0.1
3
WB Tollgate content
2 4 4 2 0 1 3 2 1 -1 1 2 2 1 0 1 2 2 1 0 1 2 2 1 0 2 2 2 0 0 1.2
9
2.4
3
2.2
5
0.9
6
-
0.2
Member Gap Before and After
2.4
4
4 4 1.5
6
0 1.2
2
2.8
9
2.7
8
1.5
6
-
0.1
1.8
9
2.7
8
2.7
8
0.8
9
0 1.3
3
2.7
8
2.7
8
1.4
4
0 1.6
7
2.2
2
2.7
8
1.1
1
0.5
6
1.6
7
2.7
8
2.7
8
1.1
1
0 1.6
8
2.8
9
2.9
3
1.2
5
0.0
4
Score Definition:
1 Knowledge not acquired / required
2 Basic knowledge, but no
competency
3 Can practice with help
4 Can do alone
5 Can train others
ProblemProblem

64. YOU
ProblemProblem