No Slide TitleSix Sigma Project Template.PPT/*
Reduction in Di Butyl Ether (DBE) Consumption on Steag 5 Cups Lines
Present Status:- 111mg / CDR
Target :- 95 mg / CDR
Six Sigma Project Template.PPT/*
DBE (DI BUTYL ETHER) IS USE IN CDR PROCESS AS A SOLVENT
TO COAT THE DYE LAYER ON CDR AND TO REMOVE THE DYE
LAYER FROM OUTER EDGE OF CDR
Chart1
62
62
41
103
6
109
0.5
109.5
1.5
111
pareto
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
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Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
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I0621 SKR
Team Charter
Business Case
Opportunity Statement
We are Second Largest CDR Producer in The World . Management has taken initiative to increase the Profit in CDR.One of the way to increased the Profit is Reduction in Raw Material Cost. We have a scope for Reduction in DBE Consumption( use in Edge Wash & Dye Coating process of CDR on steag 5 cups lines ).
According to Six Month (Jan- June2007)DBE Consumption trend is Running 111 mg/ CDR by Reducing the DBE consumption(With out Affecting Yield ) to 95 mg/CDR we can save Rs. 11 Lac / year. Impact of pain in Rs. (or soft) 11 Lac/Year Sigma Level
Goal statement
Project scope
Current level
Goal / Target
Target date
Process under improvement: Dye Coating & Edge wash Starts with Dye Coating on CDR Ends with Finish CDR in Receiver Unit
DBE consumption
Chart1
jan'07
feb'07
march'07
april'07
may'07
june'07
AVERAGE
MONTH
mmo
month
I0621 SKR
REDUCTION IN RAW MATERIAL COST OF CDR
DBE CONSUMPTION REDUCTION
I0621 SKR
Process Name:- DYE COATING & EDGE WASH
Starting point: DYE COATING ON CDR
End point: FINISH CDR IN RECEIVER UNIT
DYE COATING ON CDR
LOT MARKING & FIRST INSPECTION
End point: FINISH CDR READY TO TRANSFER
DYE COATING
EDGE CLEANING
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
DISC TRANSFER TO CONVEYOR
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
DYE COATING ON CDR
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
CDR RECEIVED FROM CONVEYOR
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
DYE COATING ON CDR
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
CDR TRANSFER TO SCANNER
CDR TRANSFER TO SPUTTER
CDR TRANSFER TO RECIEVER AS PER GRADING
CDR CLASSIFICATION
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
CDR RECEIVED FROM CONVEYOR
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
DYE COATING ON CDR
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
CDR TRANSFER TO SCANNER
CDR TRANSFER TO SPUTTER
CDR TRANSFER TO RECIEVER AS PER GRADING
CDR CLASSIFICATION
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
CDR RECEIVED FROM CONVEYOR
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
DYE COATING ON CDR
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
CDR TRANSFER TO SCANNER
CDR TRANSFER TO SPUTTER
CDR TRANSFER TO RECIEVER AS PER GRADING
CDR CLASSIFICATION
Total Production
48478963
cdr
111.78
mg/cdr
yield
Avg. Dye coater & finishing yield of ug lines ( line no 19-40,51 - 60)
month
Sheet3
CDR RECEIVED FROM CONVEYOR
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
CDR RECEIVED FROM HANDLER
DYE COATING ON CDR
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
CDR TRANSFER TO SCANNER
CDR TRANSFER TO SPUTTER
CDR TRANSFER TO RECIEVER AS PER GRADING
CDR CLASSIFICATION
A1
EDGE CLEANING OF CDR
CDR TRANSFER TO CONVEYOR
CDR RECEIVED FROM CONVEYOR
I0621 SKR
CDR CURING
I0621 SKR
FINISH CDR READY TO TRNASFER
I0621 SKR
X
3
X
6
X
7
X
21
X
26
X
Easy to implement
Fast to implement
Cheap to implement
REDUCTION IN DISPENSE VOLUME OF DBE THROUGH PRESENT DISP. PARAMETERS
YIELD LOSS, DISC QUALITY
YIELD LOSS, DISC QUALITY
REDUCTION IN DISPENSE VOLUME OF DYE THROUGH PRESENT DISP. PARAMETERS
YIELD LOSS, DISC QUALITY
Input Indicators…………
Blank substrate
Major Categories of causes of Problem Statement
HIGH DBE
DBE Consumption Per CD-R
Total
DBE Consumption Per CD-R
Total
Cause & Effect Matrix
The following 3 Cause (X’s) has been found from CE Matrix which is having an Effect ( Y’s ) on the Project having sum value higher than 100.
Cause:
DBE Dispense Time ( Sec.)
Time of Dispense Valve opening, during this time DBE is flow out from the Nozzle.
X2
DBE Dispense Pressure ( Mbar)
Pressure of N2 apply on DBE in Tank enable the DBE to Flow out from Nozzle
X3
S. No.
Y2
Yield ( % )
IT is the % Ratio of Good CDR scan by the Scanner from the Total Check CDR .
I0621 SKR
Other data that should be collected at the same time
DBE Dispense Time ( Sec.)
Time of dispense valve opening during this time dbe is flow out from the nozzle
Steag ug lines
DBE Dispense Pressure ( Mbar)
Pressure of N2 apply on dbe in tank enable the dbe to flow out from nozzle
Steag ug lines
Steag ug lines
Other data that should be collected at the same time
DBE Consumption (MG/CDR)
Steag ug lines
manually
Yield ( % )
IT is the % Ratio of Good CDR scan by the Scanner from the Total Check CDR .
Steag ug lines
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48478963
111.78
590468.41
3393.53
369758.74
Total Production
Total Production
Total Production
152
Total Production
101
overall dbe consumption
1.5
111
1
new dye dispense nozzle trial for reduction in dye dispense amount for dye coating
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
MBD001D9602.unknown
5008.unknown
DBE Consumption break up of Line
Avg. Consumption / cdr = 111 mg
pareto
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
C
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g
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
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One-way ANOVA: 0.4 sec, 0.3 sec, 0.2 sec
Source DF SS MS F P
Factor 2 2018.71 1009.36 176.99 0.000
Error 27 153.98 5.70
Individual 95% CIs For Mean Based on Pooled StDev
Level N Mean StDev +---------+---------+---------+---------
+---------+---------+---------+---------
Result shows by reducing the dispense time DBE Consumption decrease
I0621 SKR
One-way ANOVA: 220 Mbar, 200 Mbar, 180 Mbar
Source DF SS MS F P
Factor 2 279.53 139.77 30.90 0.000
Error 27 122.12 4.52
Individual 95% CIs For Mean Based on
Pooled StDev
--+---------+---------+---------+-------
I0621 SKR
Six Sigma Project Template.PPT/*
Exhaust damper position impact analysis (1 is min. open & 6 is max. open)
It can be seen thro the data collected that exhaust position does not affect the DBE collection in the recycle tank.
st.edge
MG/CD-R
1
34
4
3.3514
3.4136
0.0622
0.0207
0.0270
20.73
2
36
5
3.4120
3.4703
0.0583
0.0194
0.0253
19.43
3
40
5
3.4015
3.5570
0.1555
0.0518
0.0676
51.83
4
53
1
3.4015
3.6048
0.2033
0.0678
0.0884
67.77
5
34
5
3.5396
3.5995
0.0599
0.0299
0.0390
29.95
6
35
3
3.4005
3.4692
0.0687
0.0343
0.0448
34.35
7
36
3
3.4195
3.4878
0.0683
0.0341
0.0445
34.15
8
37
3
3.2172
3.2696
0.0524
0.0262
0.0342
26.20
9
38
1
3.2184
3.2851
0.0667
0.0334
0.0435
33.35
10
39
1
3.4108
3.4849
0.0741
0.0371
0.0483
37.05
11
53
4
3.4288
3.5080
0.0792
0.0396
0.0516
39.60
12
56
1
3.4350
3.5568
0.1218
0.0609
0.0794
60.90
13
57
1
3.4126
3.4960
0.0834
0.0417
0.0544
41.70
14
60
3
3.3722
3.4520
0.0798
0.0399
0.0520
39.90
15
33
1
3.3352
3.4506
0.1154
0.0385
0.0502
38.47
16
33
4
3.4236
3.5012
0.0776
0.0259
0.0337
25.87
17
34
2
3.4268
3.5825
0.1557
0.0519
0.0677
51.90
18
38
3
3.3929
3.6119
0.2190
0.0730
0.0952
73.00
19
38
5
3.5164
3.6456
0.1292
0.0646
0.0842
64.60
20
40
3
3.4116
3.4967
0.0851
0.0426
0.0555
42.55
21
40
2
3.4458
3.5245
0.0787
0.0394
0.0513
39.35
22
39
5
3.2987
3.3758
0.0771
0.0385
0.0503
38.55
23
59
1
3.2259
3.2851
0.0592
0.0296
0.0386
29.60
24
59
3
3.4125
3.4958
0.0833
0.0417
0.0543
41.65
25
60
1
3.4026
3.4771
0.0745
0.0373
0.0486
37.25
26
58
3
3.4697
3.5687
0.0990
0.0495
0.0645
49.50
27
60
5
3.4478
3.5268
0.0790
0.0395
0.0515
39.50
28
56
5
3.4012
3.4785
0.0773
0.0387
0.0504
38.65
29
58
1
3.4436
3.5249
0.0813
0.0407
0.0530
40.65
30
58
5
3.3968
3.4754
0.0786
0.0393
0.0512
39.30
Ave.
40.91
DAMPER
LINE
CUP
EXHAUST DAMPER SETTING( 1 IS MIN. OPEN & 6 IS MAX. OPEN)
DBE COLLECTION IN RECYCLE TANK(KG)
33
A
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
1
34
4
25.79
1
34
4
20.73
1
34
4
20.73
1
34
4
20.73
1
34
4
18.79
1
34
4
26.68
1
34
4
20.73
1
34
4
16.18
2
36
5
23.98
2
36
5
19.43
2
36
5
19.43
2
36
5
19.43
2
36
5
17.62
2
36
5
25.49
2
36
5
19.43
2
36
5
15.67
3
40
5
58.00
3
40
5
51.83
3
40
5
51.83
3
40
5
51.83
3
40
5
47.03
3
40
5
69.57
3
40
5
51.83
3
40
5
35.09
4
53
1
71.25
4
53
1
67.77
4
53
1
67.77
4
53
1
67.77
4
53
1
62.89
4
53
1
89.85
4
53
1
67.77
4
53
1
45.39
5
34
5
32.56
5
34
5
29.95
5
34
5
29.95
5
34
5
29.95
5
34
5
27.56
5
34
5
42.71
5
34
5
29.95
5
34
5
22.58
6
35
3
38.02
6
35
3
34.35
6
35
3
34.35
6
35
3
34.35
6
35
3
31.69
6
35
3
46.98
6
35
3
34.35
6
35
3
23.79
7
36
3
36.90
7
36
3
34.15
7
36
3
34.15
7
36
3
34.15
7
36
3
30.88
7
36
3
46.23
7
36
3
34.15
7
36
3
22.91
8
37
3
29.47
8
37
3
26.20
8
37
3
26.20
8
37
3
26.20
8
37
3
24.15
8
37
3
34.79
8
37
3
26.20
8
37
3
19.28
9
38
1
37.02
9
38
1
33.35
9
38
1
33.35
9
38
1
33.35
9
38
1
30.35
9
38
1
44.62
9
38
1
33.35
9
38
1
22.58
10
39
1
40.76
10
39
1
37.05
10
39
1
37.05
10
39
1
37.05
10
39
1
33.59
10
39
1
51.48
10
39
1
37.05
10
39
1
25.67
11
53
4
44.89
11
53
4
39.60
11
53
4
39.60
11
53
4
39.60
11
53
4
36.21
11
53
4
52.45
11
53
4
39.60
11
53
4
26.71
12
56
1
66.09
12
56
1
60.90
12
56
1
60.90
12
56
1
60.90
12
56
1
55.09
12
56
1
79.67
12
56
1
60.90
12
56
1
40.19
13
57
1
45.87
13
57
1
41.70
13
57
1
41.70
13
57
1
41.70
13
57
1
38.26
13
57
1
55.21
13
57
1
41.70
13
57
1
28.32
14
60
3
43.61
14
60
3
39.90
14
60
3
39.90
14
60
3
39.90
14
60
3
35.87
14
60
3
53.67
14
60
3
39.90
14
60
3
26.95
15
33
1
43.29
15
33
1
38.47
15
33
1
38.47
15
33
1
38.47
15
33
1
34.87
15
33
1
52.44
15
33
1
38.47
15
33
1
26.01
16
33
4
32.06
16
33
4
25.87
16
33
4
25.87
16
33
4
25.87
16
33
4
23.28
16
33
4
35.61
16
33
4
25.87
16
33
4
20.52
17
34
2
56.88
17
34
2
51.90
17
34
2
51.90
17
34
2
51.90
17
34
2
46.71
17
34
2
69.07
17
34
2
51.90
17
34
2
35.29
18
38
3
76.43
18
38
3
73.00
18
38
3
73.00
18
38
3
73.00
18
38
3
65.70
18
38
3
91.26
18
38
3
73.00
18
38
3
49.17
19
38
5
72.89
19
38
5
64.60
19
38
5
64.60
19
38
5
64.60
19
38
5
58.04
19
38
5
84.27
19
38
5
64.60
19
38
5
43.22
20
40
3
46.91
20
40
3
42.55
20
40
3
42.55
20
40
3
42.55
20
40
3
37.69
20
40
3
57.29
20
40
3
42.55
20
40
3
29.16
21
40
2
42.21
21
40
2
39.35
21
40
2
39.35
21
40
2
39.35
21
40
2
35.17
21
40
2
52.67
21
40
2
39.35
21
40
2
26.20
22
39
5
43.29
22
39
5
38.55
22
39
5
38.55
22
39
5
38.55
22
39
5
35.14
22
39
5
52.69
22
39
5
38.55
22
39
5
24.99
23
59
1
34.29
23
59
1
29.60
23
59
1
29.60
23
59
1
29.60
23
59
1
27.46
23
59
1
42.02
23
59
1
29.60
23
59
1
21.09
24
59
3
45.05
24
59
3
41.65
24
59
3
41.65
24
59
3
41.65
24
59
3
37.88
24
59
3
55.46
24
59
3
41.65
24
59
3
27.81
25
60
1
41.26
25
60
1
37.25
25
60
1
37.25
25
60
1
37.25
25
60
1
33.15
25
60
1
50.39
25
60
1
37.25
25
60
1
24.25
26
58
3
53.69
26
58
3
49.50
26
58
3
49.50
26
58
3
49.50
26
58
3
44.19
26
58
3
65.91
26
58
3
49.50
26
58
3
25.39
27
60
5
43.58
27
60
5
39.50
27
60
5
39.50
27
60
5
39.50
27
60
5
35.49
27
60
5
53.14
27
60
5
39.50
27
60
5
27.89
28
56
5
44.25
28
56
5
38.65
28
56
5
38.65
28
56
5
38.65
28
56
5
34.88
28
56
5
52.01
28
56
5
38.65
28
56
5
26.59
29
58
1
45.29
29
58
1
40.65
29
58
1
40.65
29
58
1
40.65
29
58
1
36.07
29
58
1
54.06
29
58
1
40.65
29
58
1
28.35
30
58
5
43.33
30
58
5
39.30
30
58
5
39.30
30
58
5
39.30
30
58
5
35.65
30
58
5
52.59
30
58
5
39.30
30
58
5
26.78
Ave.
45.30
Ave.
40.91
Ave.
40.91
Ave.
40.91
Ave.
37.05
Ave.
54.68
Ave.
40.91
Ave.
27.80
30.8
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
1
34
4
25.79
1
34
4
20.73
1
34
4
18.79
2
36
5
23.98
2
36
5
19.43
2
36
5
17.62
3
40
5
58.00
3
40
5
51.83
3
40
5
47.03
4
53
1
71.25
4
53
1
67.77
4
53
1
62.89
5
34
5
32.56
5
34
5
29.95
5
34
5
27.56
6
35
3
38.02
6
35
3
34.35
6
35
3
31.69
7
36
3
36.90
7
36
3
34.15
7
36
3
30.88
8
37
3
29.47
8
37
3
26.20
8
37
3
24.15
9
38
1
37.02
9
38
1
33.35
9
38
1
30.35
10
39
1
40.76
10
39
1
37.05
10
39
1
33.59
11
53
4
44.89
11
53
4
39.60
11
53
4
36.21
12
56
1
66.09
12
56
1
60.90
12
56
1
55.09
13
57
1
45.87
13
57
1
41.70
13
57
1
38.26
14
60
3
43.61
14
60
3
39.90
14
60
3
35.87
15
33
1
43.29
15
33
1
38.47
15
33
1
34.87
16
33
4
32.06
16
33
4
25.87
16
33
4
23.28
17
34
2
56.88
17
34
2
51.90
17
34
2
46.71
18
38
3
76.43
18
38
3
73.00
18
38
3
65.70
19
38
5
72.89
19
38
5
64.60
19
38
5
58.04
20
40
3
46.91
20
40
3
42.55
20
40
3
37.69
21
40
2
42.21
21
40
2
39.35
21
40
2
35.17
22
39
5
43.29
22
39
5
38.55
22
39
5
35.14
23
59
1
34.29
23
59
1
29.60
23
59
1
27.46
24
59
3
45.05
24
59
3
41.65
24
59
3
37.88
25
60
1
41.26
25
60
1
37.25
25
60
1
33.15
26
58
3
53.69
26
58
3
49.50
26
58
3
44.19
27
60
5
43.58
27
60
5
39.50
27
60
5
35.49
28
56
5
44.25
28
56
5
38.65
28
56
5
34.88
29
58
1
45.29
29
58
1
40.65
29
58
1
36.07
30
58
5
43.33
30
58
5
39.30
30
58
5
35.65
Ave.
45.30
Ave.
40.91
Ave.
37.05
Edge wash cups CONSUMPTION VS TIME
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
S.No
L#
C#
MG/CD-R
1
34
4
26.68
1
34
4
20.73
1
34
4
16.18
2
36
5
25.49
2
36
5
19.43
2
36
5
15.67
3
40
5
69.57
3
40
5
51.83
3
40
5
35.09
4
53
1
89.85
4
53
1
67.77
4
53
1
45.39
5
34
5
42.71
5
34
5
29.95
5
34
5
22.58
6
35
3
46.98
6
35
3
34.35
6
35
3
23.79
7
36
3
46.23
7
36
3
34.15
7
36
3
22.91
8
37
3
34.79
8
37
3
26.20
8
37
3
19.28
9
38
1
44.62
9
38
1
33.35
9
38
1
22.58
10
39
1
51.48
10
39
1
37.05
10
39
1
25.67
11
53
4
52.45
11
53
4
39.60
11
53
4
26.71
12
56
1
79.67
12
56
1
60.90
12
56
1
40.19
13
57
1
55.21
13
57
1
41.70
13
57
1
28.32
14
60
3
53.67
14
60
3
39.90
14
60
3
26.95
15
33
1
52.44
15
33
1
38.47
15
33
1
26.01
16
33
4
35.61
16
33
4
25.87
16
33
4
20.52
17
34
2
69.07
17
34
2
51.90
17
34
2
35.29
18
38
3
91.26
18
38
3
73.00
18
38
3
49.17
19
38
5
84.27
19
38
5
64.60
19
38
5
43.22
20
40
3
57.29
20
40
3
42.55
20
40
3
29.16
21
40
2
52.67
21
40
2
39.35
21
40
2
26.20
22
39
5
52.69
22
39
5
38.55
22
39
5
24.99
23
59
1
42.02
23
59
1
29.60
23
59
1
21.09
24
59
3
55.46
24
59
3
41.65
24
59
3
27.81
25
60
1
50.39
25
60
1
37.25
25
60
1
24.25
26
58
3
65.91
26
58
3
49.50
26
58
3
25.39
27
60
5
53.14
27
60
5
39.50
27
60
5
27.89
28
56
5
52.01
28
56
5
38.65
28
56
5
26.59
29
58
1
54.06
29
58
1
40.65
29
58
1
28.35
30
58
5
52.59
30
58
5
39.30
30
58
5
26.78
Ave.
54.68
Ave.
40.91
Ave.
27.80
I0621 SKR
S.No.
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48478963
111.78
590468.41
3393.53
369758.74
Total Production
Total Production
Total Production
152
Total Production
101
overall dbe consumption
1
new dye dispense nozzle trial for reduction in dye dispense amount for dye coating
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
MBD001D9602.unknown
GRAPH
8-DBE
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48478963
111.78
590468.41
3393.53
369758.74
Total Production
Total Production
Total Production
152
Total Production
101
B
Overall Avg. consumption in edge was process
41 mg/cdr
62
62
41
103
6
109
0.5
109.5
1.5
111
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Pilot Implementation Plan for DBE Cons. Reduction
Line No. 28, 34,25,&26 were selected for Pilot Implementation and the following activity was done:
pareto
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Sheet1
mg/cd-r
62
41
6
0.5
1.5
ACTION POINTS
RECOVERY FROM
TRIAL INITIATED
S.O.P MAKE
EXHAUST
TARGET DATE
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Before
Improve
GRAPH
Month
Steag DBE Consumption Trend(mg/CD-R)
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
PROCESS
Sheet1
mg/cd-r
62
41
6
0.5
1.5
ACTION POINTS
RECOVERY FROM
TRIAL INITIATED
S.O.P MAKE
EXHAUST
TARGET DATE
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Before
Improve
GRAPH
Month
Steag DBE Consumption Trend(mg/CD-R)
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Global Implementation
Sheet1 (2)
Global implementation plan of trial DBE Dispense Time reduction from 300 msec. to 200 msec. on steag lines
Implementation Date
Line no.
Responsibility
11.01.08
19,20,21,22,23,24,25
Vikas/Amitabh
12.01.08
26,27,28,29,30,31,32
Vikas/Amitabh
14.01.08
51,52,53,81,82,83
Vikas/Amitabh
15.01.08
40,41,42,44,45,46
Vikas/Amitabh
16.01.08
54,55,56,57,58,59,60
Vikas/Amitabh
17.01.08
33,34,35,36,37,38,39
Vikas/Amitabh
Sheet1
Global implementation plan of trial DBE Pressure reduction from 200 to 180 mbar on steag lines
Implementation Date
Line no.
P1 & P2
Process Customer : Quality/ Production-Downstream
Critical Customer Requirement : DBE Consumption Less Than 95 Mg/Disc.
Outcome Indicator: Overall Average DBE Consumption Less Than 95 MG / Disc
Checking Items:
Input-Process-Outcome Indicators
Control Limit
Checking Item
P2 : Dispense Time d
I0621 SKR
Before
Improve
control
Chart3
111.71
111
111
110
110
108
107
97
96.8
96.6
93.5
90.6
91
GRAPH
Month
Steag DBE Consumption Trend(mg/CD-R)
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48484008
111.21
587514.53
3393.88
369797.22
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the Dye Dispense Pressure & Time of Dye Coating Process
DBE Consumption Dye Coating Process( Mg/ CDR)
present status
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48478963
111.78
590468.41
3393.53
369758.74
Total Production
Total Production
Total Production
152
Total Production
101
overall dbe consumption
1
new dye dispense nozzle trial for reduction in dye dispense amount for dye coating
present status
present status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
MBD001D9602.unknown
GRAPH
8-DBE
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.116
0.117
644919
3,552.79
387129
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
Total Production
48478963
111.78
590468.41
3393.53
369758.74
Total Production
Total Production
Total Production
152
Total Production
101
Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
before project status
all head
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 57
Dispense on CD-R 43.5
106.20
0.20
117.37
106.05118.23
3.3213.05
P-Value0.786
Mean111.78
StDev5.32
C
o
u
n
t
P
e
r
c
e
n
t
step
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
Before
During
97.51
97.02
96.1
96.57
96.22
97.07
96.78
97.46
97.31
97.61
97.36
97.62
97.02
97.55
96.88
97.12
96.13
96.83
96.43
97.23
96.87
97.34
96.89
97.18
96.17
96.98
Sheet1
month
month
action
Before
After
month
5
6
7
I0621 SKR
Sample X N Sample p
1 49013 52365 0.935988
2 51264 54380 0.942700
Estimate for difference: -0.00671174
Test for difference = 0 (vs < 0): Z = -4.59 P-Value = 0.000
Ho: OK Production Before and After Change are Equal
Ha: Ok Production Before Change is Less Than After Change
Since the p-value is less than the predetermined a-level of significance
we reject the null hypothesis (H0 ) and claim support for the alternative hypothesis (Ha ).
I.e. OK Production Before Change is Less than After Change.
I0621 SKR
MCL CD-R lines have similar set-up & process .
The solution and success story can be replicated on these lines.
These replications required no investments on the lines.
We will start the implementation on mcl lines by Nov’08
I0621 SKR
Last PO Value(Euro)/ Kg.
108.96
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)
19,632,033
31,122,044
0.111
0.111
613875
4,821.64
525389
formula used
production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
33.7
costing
Total Production
Total Production
Total Production
152
Total Production
101
Dispense on CD-R 54
Dispense on CD-R 48
Dispense on CD-R 53
Dispense on CD-R 44
TANK FOR LINE FEEDING
FILLING TO EVERY LINE IN SOLVENT TANK
DYE TANK TRANSFER TO LINE
AIR VENT /IDEAL DISP.
AIR VENT /IDEAL DISP.
DYE DISPENSE ON CDR
REQUIREMENT FOR CIRCUIT FLUSHING
COLLECT IN RECYCLE TANK
DYE COATED DISC CLEANNING
FINISH
SEND BACK TO LAB
SEND BACK TO LAB
SEND BACK TO LAB
LAB USE
FOR CUP CLEANNING
TOTAL CONSUMPTION
62
41
6
0.5
1.5
62
103
109
109.5
111
0
20
40
60
80
100
120
97.51
96.10
96.22
96.61
97.02
96.57
97.07
96.89
95.00
95.50
96.00
96.50
97.00
97.50
98.00
April'07
May'07
June'07
Avg.
MONTH
YIELD ( % )
C
o
u
n
t
P
e
r
c
e
n
t
s
t
e
p
O
t
h
e
r
D
B
E
C
o
n
s
u
m
p
t
i
o
n
i
n
F
l
u
s
h
i
n
g
OPEN & 6 IS MAX. OPEN)
DBE COLLECTION IN
1AOptimizing the DBE Dispense Time of Edge Cleaning Process
BOptimizing the DBE Dispense Pressure of Edge Cleaning Process
41 mg/cdr
target24 mg/cdr
IMPLEMETAT
DBE DISPENSE PRESSURE 180 Mbar 25,2612.03.08200 Mbar
0.3 Sec
s.no.line no before dbe consuption during dbe consumption avg reduction
12845.26 mg/ cdr 32.26 mg/cdr 13 mg/cdr
23443.56 mg/ cdr 30.50 mg/cdr
process parameters changed
Month
Total
Consumptio
111.71
111.00
111.00
110.00
110.00
108.00
107.00
97.00
85.00
90.00
95.00
100.00
105.00
110.00
115.00
Avg.Jan'07
s.no.line no before dbe consuption during dbe consumption avg reduction
12534.47mg/ cdr 26.35 mg/cdr
process parameters changed
7.85 mg/cdr
111.71
111.00
111.00
110.00
110.00
108.00
107.00
97.00
96.80
96.60
85.00
90.00
95.00
100.00
105.00
110.00
115.00
reduction from 300 msec. to 200 msec. on steag lines
Implementation DateLine no.Responsibility
reduction from 200 to 180 mbar on steag lines
Steag DBE Consumption Trend (mg/CD-R)
111.71
111.00111.00
110.00110.00
108.00
107.00
97.00
96.80
96.60
93.50
90.60
91.00
85.00
90.00
95.00
100.00
105.00
110.00
115.00
1Optimizing the DBE Dispense Pressure & Time of Edge Cleaning Process
before project status 41mg/cdr
96.61
96.86
96.89
97.33
96.20
96.40
96.60
96.80
97.00
97.20
97.40
Avg.
Avg.
YIELD ( % )
Sample X N Sample p
1 49013 52365 0.935988
2 51264 54380 0.942700
Estimate for difference: -0.00671174
Test for difference = 0 (vs < 0): Z = -4.59 P-Value = 0.000
Ho: OK Production Before and After Change are Equal
Ha: Ok Production Before Change is Less Than After Change
Since the p-value is less than the predetermined a-level of significance
we reject the null hypothesis (H0 ) and claim support for the alternative hypothesis (Ha ).
I.e. OK Production Before Change is Less than After Change.
Last PO Value(Euro)/ Kg.1.88
PO No.A1POC/002741
Average Production / Month with Ciba Dye (Jan.07 to Mar.07)19,632,033
Average Production / Month with Sony Dye (Jan.07 to Mar.07)31,122,044
DBE Consumption (Gms./ CDR) with Ciba Dye (Average)0.111
DBE Consumption (Gms./ CDR) with Sony Dye (Average)0.111
Targeted Reduction 0.095
Current Consumption (Kgs.)5,633.70
Expected Consumption (Kgs.) after reducing Cons. To 0.095
Gms/CDR4,821.64
Saving Monthly88,487
10.62
formula used production(steagline)*o.e.e*diff in d.b.e( in gm)*lines*cost of dbe/c.t of line
Project Title : DBE Consumption Reduction from 117mg/Disc to 95mg/disc