A

PRESENTATION ON
“PAPER WASTAGE REDUCTION IN WEB OFFSET
PRINTING”
OF

Conducted at

CHENNAI
Submitted by:

Santosh Kumar Gupta

Contact no: 09543008645
Email: [email protected]

AU, ISBR, Chennai

VISION

“To contribute towards the upliftment of

education in India and to provide highest
quality education materials”
Rajiv Beri
M.D
INTRODUCTION

* *HISTORY

1. It founded in England in 1843.

2. Verlagsgruppe Georg von Holtzbrinck GmbH, a large media group

created in 1971, whose headquarters are in Stuttgart, owns the
Macmillan group.

3. It has been operating in India since 1892.

4. The former Prime Minister of UK, Harold Macmillan, inaugurated the

company’s ITES operations in Bangalore in 1976.
* *PRODUCT
1. It publishes a wide range of books for schools, colleges, individual buyers, corporate and
academic books for reference and research.
2. It associates with rich authors.

3. It was chosen by UNICEF as a critical partner in the publication of the ‘Meena’ books – a
venture of high social impact aiming at empowering the underprivileged girl child.

4. It associates with premier institutes like IIM Calcutta, MDI Gurgaon, IIT Delhi and IIFT
Delhi.
* *MARKET

1. It is characterized by high-quality academic, educational, fiction and

non-fiction publishing in many forms.

2. A huge and an exciting opportunity.

3. The current export market estimated to be around Rs 8,000 million (US$

181.82 million)
(Source: Industry estimates).

4. It focuses on publishing innovative, need-based, stimulating and

enlightening books, which are true companions to teachers and students.
* *ACHIEVEMENTS

1. It is probable that almost every child in India who has studied in a public
school in the last 100 years or so has studied from some Macmillan book.

2. Shiv Khera's ‘You Can Win’, ‘Living with Honour’ and ‘Freedom is not
Free’ – having sold more than a million copies.

3. It has won 23 awards for excellence in publishing and production in the

last five years & also won the Capexil Award for highest exports in its
category continuously for the last 22 years.

4. It has been selected as a Business Super brand by Super brand Council of

India.
What is SIX SIGMA?

1. It is a management mandated and directed improvement program which focused on

BREAKTHROUGHS in financial performance and customer satisfaction.

2. Focused on the core business and customer needs.

3. Excellence : 3.4 defects per million opportunities.

Phases of Six Sigma

DMAIC

Define : Identify the problem

Measure : Quantify how serious it is
Analyze : Diagnose the cause
Improve : Prescribe a remedy
Control : Take steps to avoid relapse
DEFINE PHASE
OBJECTIVES
 Identifying & defining a prioritized area of improvement
that will benefit the company financially.
2. Finding through a business case what is important that
anything else to work on.
Define Opportunity
1. Voice of Business (VOB)
We are facing high paper wastages at various types and stages
of printing.
2. Critical to Process (CTP)
% of paper wastage per stage and printing type
% wastages in various types of printing
and various stages of printing
 In Reel Printing – 45%
 In Sheet fed Printing – 15%
 Transportation, Loading & Unloading – 15%
 Storage, Handling – 13%
 In Cutting of Sheet Fed – 8%
 In Other Methods – 4%

AREA TO IMPROVE(PARETO DIAGRAM)

• The company is facing a high paper wastages in Reel Printing or web offset
printing.

• We can take this as our opportunity and will work on it to reduce the paper
wastages and to improve the business performance and profitability.
REEL PRINTING
Machine – Web king Two
Colour Perfector

 Supplier –
Perfect Rotary Offset (P)
Ltd.
B-100, Sector – 2,
Noida-201301
 START
PROCESS
Filling ink
FLOW MAP OF Feeling Water

WEBKING Fitting plate

Loading reel

Start
printing

1st colour
printing

2nd colour

1st fold

2nd fold

cutting

Last fold

END
CONSUMABLE ITEMS FOR
WEBKING OFFSET PRINTING

 Paper – Dy or Cr

 Printing Ink – Black, Magenta, Yellow, Crayon

 Chemicals

 PS Plate

 Knife

 Rope
MEASURE PHASE - OBJECTIVE

 Measuring the wastage amount and in what way such wastages

reducing the business performance.

Types of Wastages in Reel printing

(Opportunity)

 Reel MAT not in good condition

 Printed Forms not meeting specification

 Reel End not suitable for printing

REEL MAT

 Reel MAT is the upper part of a reel.

 If the upper part of a reel is not suitable for printing than it is called as Reel MAT
Wastages.

Why wastages?

 The Reel MAT may get tore in transportation, while in storage.

 The upper part may get spoiled due to weather influence.

 There may be manufacturing error.

 Sometimes loading and unloading may cause damage.

 While shifting from one place to another inside the factory.

PRINTED FORMS
 These are the printed part of the paper to be used to make Book.
 One form contains two sides of printing.
 In total, one form contains 16 pages (8 pages both sides)
 If there is any printing error in a form, it is rejected and taken as paper
wastage.
 Forms used for inspection also taken as wastages.
Rejection Criteria for Printed Form
 Overlapping of text on other side of the paper.
 Less quality printing in terms of colour.
 If some scratches on form.
 Colour displacement.
 Improper folding of forms.
 Torn forms.
 Text and picture registration error.
 Last part of the reel before new reel is loaded
REEL END

 Reel end is the last part of the reel.

 If only few amount of paper is there on reel and one job is finished, than it
cannot be used for printing. Because it will require stoppage of machine
one more time when the reel completes and new reel is to be loaded.

 Last part of the reel is left because at last the quality is not that much good
for printing.

 Due to waving also paper is not suitable for printing.

DATA COLLECTION PROCEEDURE

 Data are taken for one colour (Black) printing.

 We took 8 reels as sample for calculating wastage.

 The samples are randomly chosen.

 These are taken at four different days i.e. 2 per day.

 The unit for paper weight is Kilogram (Kg).

 Wastage is calculated on per reel basis as percentage of wastage per reel.

 Wastage is calculated separately for each opportunity or type of wastage.

LOSS TO THE BUSINESS
(70 GSM PAPER)

 Cost of Blank Paper – Rs. 45 per Kg + Rs. 5 per kg for storage, handling,
inspection etc. = Rs. 50 per kg

 Cost of printed paper (from) –55 per kg

 Total wastage as Reel MAT and Reel End = 107kg + 14Kg = 121 kg

 So, loss to the business = 121 kg * Rs. 50 = Rs. 6050

 Total wastage as printed form = 179 kg

 So, loss to the business = Rs. (179*55) = Rs. 9845.

 Total Loss = Rs. 6050+ 9845 =Rs. 15895 in 8 reels only.

*Contd……

 Production is done in 2 shifts.

 8 reels are used per day.

 Now, we can see that per day approximately the company is loosing Rs.
15895.

 So, for one month it is loosing around Rs. 15895*30 = Rs. 4,76,850.

 And for one year the loss may be amounted to Rs. 57,22,200 (apprx.).
ANALYZE PHASE - OBJECTIVE
 Finding all the possible causes of the problem.
 Finding among causes which causes can be controlled and which cannot be
controlled.

PROBLEM
 High Paper wastage in Reel Printing

CAUSES
 The causes of the problem have been divided into four major heads.
1. Manpower
2. Machine
3. Method
4. Material
 Various sub causes have been found out under each major head.
 A fish Bone diagram has been prepared which shows the various causes of the
problem
 FISH BONE (CAUSE & EFFECT) DIAGRAM FOR PAPER WASTAGE IN REEL
PRINTING

. MACHINE MANPOWER

Over compliance
Less care while handling reel
Incorrect setting of due to negligence
Ink rollers drive
motor Ink spills on paper Lack of training on settings of m/c
Slow response
Incorrect Speed to m/c problem
Frequent stoppage of
Less Co-ordination among employees
m/c Carelessness while
Leakage of Ink
changing plate
Registration
Improper loading of reel into
Problem
Lack of Training on the machine
folding & inspection

Lack of regular
checking
Paper Wastage in
Reel Printing
Short run job Frequent Improper registration from
change in m/c one reel to another
Less diameter reel for
No full use of a reel setting
single long run job
Low initial setup Hard loading floor More than one joint per
area reel
More than one job per reel
Manual method Improper method of unloading
of testing form Waving in paper
Rigid working hour
Less care in transportation
Improper method
Incorrect handling Low reel surface
of transferring
while loading into quality
Low packing quality
the m/c
Plate change in Low grade winding Improper storage
between the Manual folding quality
current reel problem Fluff on paper

METHOD MATERIALS
MULTI VOTING
 By multi voting technique we found out the
following most important causes of the paper
wastage in reel printing.

1. Frequent stoppage of machine

2. Short run job
3. More than one job per reel
4. Less care in transportation
5. Less care in handling
6. Improper unloading of reel
7. Less diameter reel for long run job
8. Slow response to machine problem
9. Registration problem
10. Lack of training on folding & inspection
IMPROVE PHASE - OBJECTIVE

 In this stage we will find out the ways to improve on the main
causes of paper wastage in reel printing.

 By way of discussion we found various possible solutions to

above given causes.
 Solutions for the Main problems

Solutions for Frequent Stoppage of Machine

 Should do long run job.

 Flexible refreshment break by workers.
 Less quantity reel for small job.
 Proper training to workers regarding setting of the Machine.
 Proper feeding of paper.
 A supervisor can be appointed to direct the workers on how to
reduce the frequent stoppage.

Solutions for Short run job

 Only long run job should be carried out by reel printing.

 Short run job should be done by sheet fed printing.
 Minimum number of short run job order should be taken.
Solutions for More than one job per reel

 Single job i.e. one type of form should be printed with one reel.
 Required amount of reel should be used for the required amount
of printing.
 Order for larger volume of book should be taken.
Solutions for Less care in Transportation
 Instruction should be given to the transportation company for
proper handling of the reel.
 Reels should be covered properly.
 Proper care should given while loading from factory.
 These should be properly tied.
Solutions for Less diameter reel for long run job
 For long run job reel of big diameter i.e. more weighted reel
should be used.
 Training should be given to workers on how much paper should
be used for printing a particular number of forms.
 Big diameter reel must be kept available for long run job.
Solutions for Less care in Handling

 While moving reels proper care should be given.

 Edge protector can be used.
 Should have smooth flooring.
 Half used reels should be covered properly.
 Reels should be kept at dry place.

Solutions for Improper Unloading of Reel

 Reels should be unloaded properly.

 Foam bed can be used to unload.
 Reels should be loaded horizontally not vertically.
Solutions for Slow response to machine problem
 Always there must be someone to ensure the smooth flow of work.
 Proper Training should be given to workers to fix the problem immediately.
 Regular checking must be done to avoid any machine problem.
 For big problem the engineer can be called immediately.
 Workers should be given required authority to take immediate steps to
resolve the problem.

Solutions for Registration Problem

 Sample should be collected to ensure proper registration.
 Skilled personnel should be recruited for better performance.
 Training should be given to workers on checking whether properly
printed or not.

Solutions for Lack of training on folding & inspection

 Care should be taken while feeding to folding equipment.

 Automatic folding can be done by having extra equipment.
 A supervisor can be appointed at work area to inspect the quality
of printing and to check other printing problem.
Multi Voting
 Through multi voting we found out following solutions that can minimize the
wastage level to a considerable level.
1. Should do long run job.
2. Flexible refreshment break by workers.
3. Short run job should be done by sheet fed printing.
4. Single job i.e. one type of form should be printed with one reel.
5. Proper care should given while loading from factory.
6. Edge protector can be used.
7. Foam bed can be used to unload.
8. Reels should be loaded horizontally not vertically.
9. For long run job reel of big diameter i.e. more weighted reel should be used.
10. Proper Training should be given to workers to fix the problem immediately.
11. Workers should be given required authority to take immediate steps to resolve the
problem.
12. Sample should be collected to ensure proper registration.
13. A supervisor can be appointed to inspect the quality of printing and to check other
printing problem.
Recommendations
 If long run jobs are carried out, there will not be frequent
stoppage of machine and no need of changing plate in between
one job which will considerably reduce printed form wastages.

 With long run job with big diameter wastage in the form of Reel
MAT in new reel can be minimized.

 It will increase the per labour productivity.

 Quality ink must be used to so that it does not damage the paper.

 Flexible refreshment time can reduce the stoppage of machine for

lunch break, tea break etc, which will result to increased
productivity.

 If one job is carried out in one reel, the wastage due to changing
of plate and reel end wastages can be reduced.
Contd…..

 If proper care is taken in transportation, loading and unloading, it

will reduce the wastages as there will be less reel mat wastage.

 Edge protector will save the reel to be cut from side and thus will
save reel mat wastage.

 If trained workers are appointed and they are given required

authority, they can take immediate steps to solve any problem as
soon as possible.

 Proper collection of sample in regular interval can help to reduce

printed form wastages.

 With a supervisor various problem can be solved like regular

checking will be done which will reduce the wastages.
Control Phase - Objectives
 Setting standards to stick on to the increased performance by
continuously applying the given solutions.

 No further deviation should arise.

 Early action can be taken to ensure no further wastages.

Control Chart
 After implementing the given solutions again data can be taken to
find out whether everything is going right or not.

 If something wrong immediate steps can be taken to resolve the

problem.
Improvement which can be achieved
 By applying above mentioned solutions and recommendation the
overall wastages can be reduced.

 Reel MAT wastages, printing wastages and reel end wastages can
be reduced considerably.

 We have targeted to bring down the overall wastage percent to 2

%.

 This can increase the sigma level to 5.

 KAIZEN IMPROVEMENT (WEBKING MACHINE)

1. Water chilling unit

2. Brush at level unwinding to remove dust

3. Pneumatic shaft for wastage reduction and quick change over

4. Extra plate at folding unit to avoid cross fold

5. Completed bearer overhaul on machine and reconditioned.

6. Ensure uniform break time period for machine overhaul

 5S

SEIRI (Sort)

NEEDED NOT NEEDED

ink Waste paper
Tools Used plate
Trolley Waste form
Range Waste cloth
Kerosene Extra air pipe
Sponge for cleaning Employees cloth
Water bucket Waste calendar
Ladder Unused motor
Reel should be covered Unused board
knife Reel end still on pneumatic shaft
Reel improperly kept Old forms on the table
Rope Shoes
Fan Brush
Mug Unused pneumatic shaft
Cup board Big plastic cane
Tables
Exhausted water tank
Sweep stick
Duster
Tools case
Brush for cleaning
Dust bin
Empty pneumatic shaft
Contd…..

 SEITON (SET IN ORDER)

 The unwanted things are taken out and all the needed things are
kept at their respective place.

 SEISO (SHINE)
 Cleaning is done of the area nearby to the machine. Dusts are
taken out.

 SEIKETSU (STANDARDIZE)
 Standard is set that the things must be kept at their respective
place, regular cleaning should be done.

 SHITSUKE (SUSTAIN)
 Instructions are given to maintain the standard.
Kanban initiatives
 A sticker is used to mark the next reel to be used for printing.

 Two dustbin were used so that when one is full other can be used
to throw out the dusts till the other one is empty.

 A container is used to store the wastages.

Conclusion
 By applying above mentioned recommendation the paper wastages in
reel printing can be minimized to an acceptable level.

 This will cause financial benefit to the organization.

 Job can be finished very early.

 It will increase the confidence of the workers as with less wastages

they will be satisfied.

 This can increase the profit of the organization. And as such it will
increase the stakeholders value.

 Customer value will also increase as they will get good quality book at
required time.

 Organization's creditworthiness will also increase.

 With the help of Kaizen, 5S and Kanban methodology smooth flow of

work and continuous improvement can be achieved.
OUR LEARNINGS