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Reduce closure ovality with optimized packing and transport
- 1. Closure Ovality issue • Closure ovality is one of the most common problem encountered in plastic closures. • In ovality issue, Plastic closures loose their original round shape and become oval shape. • The Ovality issue in plastic closures may be minor (0.5-2.0 mm) or major (> 2 mm) in nature. • Oval closures are difficult to apply on bottles resulting in closure rejection while application. • Major ovality in closures can result in misapplied/ tilt capping resulting in poor closure performance.
- 2. Factors responsible for closure ovality • Plastic closures may attain Oval shape due to : - Manufacturing Process factors - Machine malfunctioning - Material quality problems - Storage factors and conditions - Transportation errors - Handling issues
- 3. Major causes identification for closure ovality • To identify major causes of closure ovality, risk assessment of each probable cause carried out using Risk Probability Numbering (RPN) where - RPN = Severity X Occurance X Detection At a scale of 1 to 10 (lower to higher magnitude): - Severity of effect is taken low (5) for all causes. - Occurance of cause is taken based on frequency. - Detection numbering done based on monitoring. (RPN score mentioned against each cause)
- 4. Fish-bone diagram for Closure Ovality causes Measurement Materials Method Machine Impropertemp. monitoring (RPN: 5x2x1=10) Mixed PP material (RPN: 5x2x1=10) OverStacking during boxes storage (RPN: 5x4x3= 60) BarrelTemper. error (RPN: 5x2x1=10) Problem Statement Highercooling water Temp.atCCM (RPN:=5x5x2=50) PP Closure Ovality issue (Effect severity : Low, score 5) Thermameter Calibration error (RPN: 5x2x2=20) DifferentLiner Meterial (RPN: 5x2x1=10) Instantboxpacking withoutCooldown (RPN: 5x2x2= 20) Higertemperature setting on CCM (RPN: 5x2x1=10) High speed of CCMmachine (RPN:5x2x1= 10) OverQuantity of shellin boxes (RPN: 5x2x2=20) DifferentPP Material (RPN:5x2x1=10) Temperature measuring error (RPN: 5x2x2=20) High temperature during closure packing/Less aircooling by fan (RPN: 5x2x8= 80) Human Error (RPN: 5x2x1=10) Boxes less compression Strength (RPN: 5x7x2=70)
- 5. Fish-bone diagram for Closure Ovality causes Environment Manpower Trasportation Temperature monitoring error (RPN: 5x5x4= 100) Mishandling while shifting of boxes (RPN: 5x5x4 =100) Loading/Unloading Error (RPN: 5x5x2=50) Training Error (RPN: 5x2x2= 20) HotStorage Condition atW/H (RPN: 5x5x4= 100) Packing error (RPN: 5x5x4= 100) Over stacking in vehicle during transit (RPN: 5x8x2=80) Excess Humidity (RPN: 5x5x4= 100) Tightboxtaping (RPN: 5x5x4=100) Over loading in the vehicle (RPN: 5x6x2=60) PP Closure Ovality issue (Effect severity : Low, score 5) Tightropes on boxes (RPN: 5x5x2=50)
- 6. Fish-bone diagram for Closure Ovality causes Cause and Effect Diagram (Bottlerend causes) Measurement Materials Method Machine ProblemStatement HumanErrorin measuring (RPN: 5x2x2=20) Errorinstacking pattern (RPN: 5x5x4=100) High speed of Cappermachine (RPN: 5x5x2=50) ImproperAnalyses & recording (RPN: 5x2x2 =20) Overstacking inW/H (RPN: 5x2x4=40) CapperChucks incompatability (RPN: 5x4x4=80) PP Closure Ovality Issue CapperChute setting is notproper (RPN: 5x2x2=20) Pressco CVS impropersetting (RPN: 5x5x2=50) Overloading of closure inhopper (RPN: 5x5x2=50)
- 7. Major causes identified for Closure Ovality 1. In Method : “Higher temperature of closures during boxes packing due to less air cooling ” (RPN: 5x2x8 = 80) - Specification : Closure packing temperature 28 +- 2 deg C. (Ref. trial report on closure packing temperature)
- 8. Trial data on Closure packing temperature 1 Closure temperature while packing : Trial Date : 03-01-2016 Stack Height : 4+4 rows = 8 rows (8*5 = 40 Box) Sn. Ovality % 1 15.00 2 8.00 3 1.50 29° C - 30° C 200 Nos 0 3 39° C - 40° C 200 Nos 11 19 34° C - 35° C 200 Nos 6 10 Closure Packing Temp. Number of Samples Checked Major Oval Caps Miner Oval Caps
- 9. Major causes identified for Closure Ovality 2. In Machine : “ Higher temperature of mould cooling water in CCM machine ” (RPN: 5x5x2 = 50) - Specification : CCM mould cooling water temp. 15 +- 1 deg C (Ref. trial report on mould cooling water temp.)
- 10. Trial date on CCM cooling water temperature 2 CCM machine cooling temperature :- Trial Date : 12-11-2015 Stack Height : 4+4 rows = 8 rows (8*5 = 40 Boxes) Sn. Ovality % 1 9.50 2 3.00 3 0.50 15° C 200 Nos 0 1 21° C 200 Nos 5 14 18° C 200 Nos 2 4 CCMmachine Punch Temp. Number of Sample Checked Major Oval Caps Minor Oval Caps
- 11. Major causes identified for Closure Ovality • In Method : “ Over Stacking of closure boxes during storage in warehouse ” (RPN: 5x4x3= 60) - Specification : Maximum 8 rows stacking (4+4 on pallets) (Ref. trial report on closure boxes stacking in warehouse)
- 12. Trial data on Closure boxes stacking 3 Closure boxes stacking in warehouse : Trial Date : 03-10-2015 Carton Compression Strength : 800 Kgf , Storage duration : 2 months Sn. Ovality % Remark 1 15.00 3 Bulged boxes in lower pallet 2 8.50 OK 3 1.00 OK 4+4 = 8 stacks 200 Nos 0 2 6+6 = 12 stacks 200 Nos 12 18 5+5 = 10 stacks 200 Nos 8 9 Trial Parameter stack Height Number of Sample Checked Major Oval Caps Minor Oval Caps
- 13. Major causes identified for Closure Ovality • In Material : “ Closure boxes less compression strength” (RPN: 5x7x2=70) - Specifications : Closure boxes compression strength to be min. 800 Kgf, inhouse checked by CS machine. (Ref. below trial report on box compression strength)
- 14. Trial data on carton compression strength 4 Carton Compression strength : Trial Date - 07-11-2015 Stack Height : 4+4 rows = 8 rows (8*5 = 40 Boxes) Sn. Ovality % Remark 1 21.50 6 Bulged boxes in lower pallet 2 9.50 2 bulged boxes in lower pallet 3 0.50 OK 800 Kgf 200 Nos 0 1 400 Kgf 200 Nos 18 25 600 Kgf 200 Nos 5 14 Box Compression Strength Number of Sample Checked Major Oval Cap Minor Oval Cap
- 15. Major causes identified for Closure Ovality 5. In Transportation : “Over stacking in vehicle during transportation” (RPN: 5x8x2=80) - Specification : Maximum 5 rows stacking of closure boxes during transportation. (Ref. trial report on closure boxes stacking in transit)
- 16. Trial data on closure boxes stacking while transit 5 Stack height during transportation : Transit duration : 24 Hrs Boxcompression strength : 800 Kgf, Lot Size : 240 Boxes S.no Ovality % Remarks 1 19.00 4 Bulged boxes in lowest row 2 12.50 OK 3 2.50 OK 5 stacks 200 Nos 0 5 Boxes Stack height during transit Number of Sample Checked Major Oval Cap Miner Oval Cap 26 6 stacks 200 Nos 8 17 7 stacks 200 Nos 12
- 17. Major causes identified for Closure Ovality 6. At Bottling end : “ Improper setting of Pressco online closure CVS causing higher closure rejection” (RPN: 5x5x2=50) - Specification : Closure CVS setting as per defect sensitivities defined by OEM (with password protection). (Ref. trial data on closure CVS to be submitted by unit)
- 18. Summary of Tests Ideal Operating Conditions 1. Closure temperature while packing: 300 C max 2. CCM machine cooling temperature: 150 C max 3. Closure box stacking height: 4 + 4 nos. max 4. Carton compression strength: 800 kgf min 5. Stacking height during transportation: 4 + 4 max
- 19. Next Steps 1. SOP – Prepare SOP for closure box packing, boxes storage, stacking and transportation. 2. Implementation of manufacturing, storage, handling and transportation SOPs. 3. Standardization of Process and Machine related parameters identified as major causes. 4. Pressco setting – Team is requested to verify and provide further data & inputs on pressco setting.