Luc Nelen STEP-BY-STEP PROCESS IMPROVEMENT Luc Nelen - - PowerPoint PPT Presentation

Luc Nelen

• Chemical Engineer
• Nearly 40 years experience in

the industry in various fields (R&D, support, sales, etc.)

SPEAKER

SPEAKER

PROCESS IMPROVEMENT

Luc Nelen

luc.nelen@innosen.com

STEP-BY-STEP

AGENDA

• Introduction
• Basics of Process Improvement
• Fault-Mode Effective Analysis (FMEA)
• Examples of FMEA and solutions
• Conclusion

WHY? WHAT? HOW?

https://www.innosen.com/tours/3pc/

Make a Sensitivity Analysis

INTERNAL RATE OF RETURN (IRR) DEVIATION

space

• Estimate effect of errors in assumptions

QUALITY & QUANTITY

Both important

PRODUCTION

Can Quality

No quick fix Many small steps

No easy Shortcuts!

IMPROVEMENT PROCESS Measure Compare with Target Correct

Measure and figure out the corrective action

MEASURE

• Repeatability & Reproducibility (R&R)
• Can I trust my measurement?
• Operator
• Equipment

Repeatability and Reproducibility (R&R)

• Repeatability measures the variation in measurements taken

by a single person under the same conditions

• Reproducibility measures whether measurements can be

reproduced by different people etc.

HOW TO IMPROVE?

Fault-Mode & Effect Analysis (FMEA)

• Work backwards

to find solution

• Effect → Cause

FMEA EXAMPLE

Function Potential Failure Potential Effect of Failure S Severance 1 – 10 Potential Cause of Failure O Occurrence 1 - 10 Current Process Controls D Detection Rating 1-10 * Risk Priority Number (S-O-D) Criticality (S-O) Recommended Actions Responsibilit y & Target completion date Acti-

• n re-

sults Lacque- ring Sheets Unlacquered Sheets Blunting of press tooling 9 Lacquer tank starvation 3 None 5 135 27 Unlacquered cans getting to customer - Customer complaints and claims No double sheet detector fitted 10 Double Sheet Detector Fitted 1 90 90 Fit double sheet detector and missing lacquer detector Loss of customers due to quality issues Double sheet detector not adjusted correctly 7 Rely on

• perator’s

judgement 9 567 63 Install auto-calibrating double sheet detector Double sheet detector not working 2 Rely on

• perator

detecting malfunction 6 108 18 Install double sheet detector with "heartbeat"

• utput

Conveyor and oven speed not synchronized causing sheet to flip

• ver and

stick to another sheet 4 Rely on

• perator

seeing it happen and take out faulty sheets from oven 6 216 36 Install additional double sheet or missing lacquer detector after the oven *1-Detected 10 - Not Detected

FMEA FOR LACQUERING LINE

Measure and figure out the corrective action

A sensor that calibrates automatically

True “Fit and Forget” No operator intervention, no risk of wrong adjustments Large thickness range (0.08 - 1.6mm / 0.0031” – 0.063”) Works on both aluminium and tinplate For use on coating and printing lines, slitters and presses etc.

IS231 Double Sheet/End Detector

Protects machinery and product against problems caused by missing lacquer on blank sheets.

No need for operator adjustment Self‐adjusting and self‐calibrating Works with all white, coloured AND CLEAR LACQUERS Protects your equipment and your reputation from expensive quality issues Typically installed before/after the oven

• n coating lines or on press infeed

IS651 Missing Lacquer Detector

FMEA EXAMPLE

Function Potential Failure Potential Effect of Failure S Severance 1 – 10 Potential Cause of Failure O Occurrence 1 - 10 Current Process Controls D Detection Rating 1-10 * Risk Priority Number (S-O-D) Criticality (S-O) Recommended Actions Responsibility & Target completion date Acti-

• n re-

sults Lacque- ring sheets Skewed margins Weld wire breakage 5 Wrong setup

• f side

guides of coater

• r slitter

3 Manual supervision 9 135 15 Install skew measurement system IS415 and/or Margin inspector IS610 Damage to weld rolls Production too fast / process uncontrolled 3 Max speed not based on margin quality 7 105 15 Statistical data from IS415 helps finding max speed Microleakers Aestetical quality issues Customer complaints and claims

*1-Detected 10 - Not Detected

FMEA FOR LACQUERING LINE

Full protection from skewed sheets, even at high line speed Highly accurate measurements Increase production quality Achieve faster production rates – without the risk of extra scraps Provides useful statistical data

IS415 Skew Measurement System

Experience on modern high-speed coating lines shows that up to 1 sheet in every 2000 will skew or misalign badly as it goes through the rollers, no matter how well you control your process!

IS430 Sheet Translation Measurement

Adds protection against laterally displaced coating by detecting sheet misalignment at the coater

IS450 Sheet Registration Measurement

Adds protection against poor sheet registration by warning of sheet misfeeds at the coater

IS610 Plain Margin Inspector

Reliably detects contaminants in the margin of coated /printed sheets.

Detects any type of lacquer, even small drops of clear transparent lacquer Detects presence of other contaminants (e.g., grease/oil, rust, water marks) in the margin

Coating Thickness Measurement

Easy to use - Highly accurate measurements – World class R&R Wide range of probes for measuring coatings thickness / film weight on flat sheets, cans, aerosols, aluminium tubes, etc. IS9650 IS9560 SI9600 SI9507+

Enamel Rating

SI9100 IS9015 IS9019TR/IS9020TMR IS9029 IS9021

Enamel Rating

IS9017 IS9029 IS9024 IS9030

UV Loggers

IS310 IS315

CONCLUSION

There are no quick short-cuts in process improvement! It is a step to step process that requires proper analysis to achieve the best result. In this process you require tools in which you can trust, equipment with good R&R and sensors limiting human errors. Innosen offers a large range of products that can help you in this process. Our products are designed for accuracy and ease

• f use, many of them being fully automatic.

For more information, come see me or Blessie at the exhibition area WE ARE HERE TO HELP YOU