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Team : Surya Co : XMC Area : Toner Plant FGM : Mukul Anand

Toner Waste Reduction. Team : Surya Co : XMC Area : Toner Plant FGM : Mukul Anand GM : KP Singh Members : Saeed A Khan Leader Akhilesh Sharma Mabroor Khan Firasat Khayal

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Team : Surya Co : XMC Area : Toner Plant FGM : Mukul Anand

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  1. Toner Waste Reduction Team : Surya Co : XMC Area : Toner Plant FGM : Mukul Anand GM : KP Singh Members : Saeed A Khan Leader Akhilesh Sharma Mabroor Khan Firasat Khayal Atinder Singh Rajesh Kumar Sharma SC Yadav SC Chauhan Amar Singh Suresh Verma Project Time: Jan- March 2002

  2. Earth Award 2003 Background We are producing Toner (1025 & Bueno) for the plain paper copier at Rampur Plant in India. Toner manufacturing team is doing the quality projects impacting company’s objectives on ROA e.g : energy conservation, ,productivity and yield improvements & 3R. Team identified some of the following stations where team can save Toner losses. Here is the story of “Toner Waste Reduction” at Toner plant,Rampur. Toner manufacturing process. * * Additive Toner Blender (for 1025 Toner) 1025 Filling Machine) Bottle filling and packing Banbury (internal mixer) AFG-630 (Grinder) Classifier Turbo-Screen * Bueno Filling Machine) Henschel Blender (for Bueno Toner) Cartridges filling and packing * Key improvement identified by the team for Waste Reduction areas 1. Toner waste at A.T.Blender during discharge hopper coupling/de coupling. toner loss was at 1.4% 2. Toner wastage at Henschel Blender during material feeding. toner loss was 2% 3. Toner wastage at Bueno filling machine during cartridges filling. toner loss was 2% Team brainstorm all the three opportunity areas to minimise toner losses thereby reducing wastages by applying XIP tools.The improvement activities done by the team as follows -

  3. Sl. No. Problem Brainstormed Solution Toner wastage at A.T.Blender during discharge hopper coupling and de coupling (The out put of blender is collected in mobile hopper. Hopper is connected manually with the help of crocodile clamps.The gap between hopper top to blender out let is adjusted by the neoprene based flexible connector. The toner rest on the flex.connector inside bellow shaped portion falls on the ground during coupling and de coupling of the hopper by crocodile clamp handing vibrations) 1 Provided auto clamp unit.It is operated by process air,for its function up & down switch is provided. The operational vibrations are reduced. Provide auto clamp unit to eliminate vibrations Problem statement Toner Wastage at Henschel Blender (At the time of blending batch loading the inside air was releasing thru’ a small vent sock,it was choking frequently.Operator was shaking this sock by hand then starts the m/c.Some toner was leakage due to air locking) Provide large size of vent sock Provided large size vent sock unit and installed a timer for the auto air purging purpose.Air locking problem is solved. 2 Problem statement Provide timer for automatic air purging in vent sock Toner Wastage at Bueno filling machine during cartridges filling (The Bueno cartridges are assembled and opened one end for the toner filling purpose.Filling machine out put nozzle is feeding toner in the cartridges.During filling of toner,available air inside the cartridge releases thru’ the vent and carries out toner also.This air with toner was connected directly in the general vacuum cleaning unit.The vacuum cleaning material is going scrap because other cleaning waste material is contaminated also.) Provide cyclone Provided cyclone unit. The vacuum carries the toner particles and collecting in the cyclone.Only air is passing in the general dust collector. 3 Problem statement Provide separate dust collector

  4. Material Input Material Input Implemented solution no:1 Additive Toner Blender Machine Additive Toner Blender Machine Mazanine Floor After Implementation Provided auto clamp unit,operated by compressed air ON/OFF switch Dual Acting Pneumatic Cylinder Flexible Connector Crocodile Clamp Arms Flex. Connector Before Implementation Material loss during close mobile hopper fixing & removal by crocodile clamps Gap 2mm to remove hopper Close Mobile Hopper Lifted Position Close Mobile Hopper Flange (for out put collection) (for out put collection) Pneumatic Cylinder Arm Pneumatic Cylinder Arm Ground Floor

  5. Air Released Implemented solution no:2 After Implementation A-Provided large size vent sock with auto. Air purging thru’ solenoid valve & timer.Reduced the wastage. B-Provided wire rope with hook at ground floor & maz.floor to operate butter fly valve.No need to go at platform frequently to operate b/fly valve. Air Purging through solenoid v/v & timer Hook I N P U T Maz.Floor Before Implementation Small size,manual purge vent sock locks the air during material feeding in to the Blender.Loss of material was there. B.fly valve Matl. Input Air Vent MOTOR CHW Out Put HENSCHEL BLENDER Wire rope CHW In Put Hook CMH After Implementation

  6. Modified (Toner filling m/c) Implemented solution no:3 Vent Sock To General Vacuum Cleaner Unit New vent sock provided (3 feet long & 4” dia. 5micron filter cloth) Material input Maz. Floor Air Vent Line to General Dust Collector (Filter Unit) Toner Input (Rotary Valve) Valve Tangential Joint in the cyclone Drive Geared Motor General Vacuum Cleaning Hose Pipe -------------------------- ---------------------------------------------------------- ------------------- - ----------------- ---------------- ----------- ------- ---- --- Toner * C Y C L O N E Air Vent (during filling) ---------- -------- ----- -- Auger Toner Collection After Implementation Provided cyclone unit.Material is collecting in this cyclone during cartridges filling. * C A R T R I D G E Before Implementation Air vent during filling of cartridges carries toner fumes directly in the General vacuum cleaning system thru’ pipeline.Loss of toner was there. Butterfly Valve Fixture Cyclone “Plan” Tangential Entry of Toner Dual Acting Pneumatic Cylinder Vacuum

  7. 1. SAVINGS BY SOLUTION 1 BEFORE IMPLEMENTATION AFTER IMPLEMENTATION Financial Benefits 1025 Toner Produced from December 2002 to March 2003 = 18400 Kgs. Material saved @ 0.6% = 110 Kgs. Saving at DMC @ Rs. 266/Kg = Rs. 29260

  8. Deliver & Monitor Results 2. BY SOLUTION 2 SAVINGS BEFORE IMPLEMENTATION AFTER IMPLEMENTATION Financial Benefits Production in this year (from Jan’03 to Dec’03) = 90500 Kgs. Material saved @ 0.8% = 724 Kgs. Saving for this year @ Rs 266/kg DMC = Rs 1,92,584 (ongoing)

  9. 3. SAVINGS BY SOLUTION 3 Result After Implementation “Bueno” Toner loss reduced by 0.8% ( Increased in Yield ) 98.80 0.8% 98 Financial Benefit Cartridges produced in the Year 2002 = 190,000 Nos. Cartridges produced from July to Dec.’02 = 100,000 Nos. Saving for 800Kgs. @ Rs 266/-(DMC) = RS 212800/- TOTAL SAVINGS (Solutions 1+2+3) = 1634 Kgs = 3572 Lbs $ Saved {@ of $2.30 per Lbs } = 8468 USD % age Yield (“Bueno” Toner Filling m/c)

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