Optimisation of Printing Consumables and Impact on Green Printing

Optimisation of Printing Consumables and
Impact on Green Printing
C I Sebastian
Associate General Manager & Plant Head, Times of India Suburban Press, Kandivali,
Mumbai
Keywords:Direct Variable Cost (DVC), PDCA, Pareto Analysis, Cause
Prioritisation Matrix and Fish-Bone Diagram
Abstract
Rise in per page cost is major challenge in newspaper business. Raw material cost in the
newspaper business plays a major role in increasing the per page cost. Optimizing major
consumables like Plates, Blankets and Ink etc. would directly reduce the printing cost and
ultimately would increase the profitability.
Keeping this in mind we formed a Cross-Functional Team to work on this project for Problem
Solving. The team used PDCA (Plan, Do, Check, Act) methodology to identify opportunities for
improvement. Data was collected for the period starting April 2011 to March 2012. After Pareto
Analysis, we prioritized problem areas with the help of Cause & Effect Diagram and Cause
Prioritization Matrix to solve the problems step by step.
Our analysis resulted in various kind of optimization of raw material usage. In addition, this
project has led to the implementation of new breakthrough ideas such as Fabrication of Roller
Cleaning Tray and Centrifugal Machine etc. After completion of this project we have been able
to significantly reduce the DVC from Rs. 18.46 to Rs. 16.73 per lac pages. The consumables
cost reduced from Rs. 21.7 to Rs. 18.9 Cr. with the saving of Rs. 2.1 Cr. To sustain the above
benefits various control mechanisms were implemented like controlled use of consumables
and regular use of designed equipments.
Problem Definition
At The Times of India, Kandivali Plant, Mumbai, it has been observed that the
Direct Variable Cost (DVC) varies directly with printing. So, it was decided to
analyse the consumption pattern and to take necessary steps to reduce Direct
Variable Cost. In DVC we have taken 8 areas of consumption and segregated
them in 4 major categories, viz. Plates’ Cost, Chemicals’ Cost, Cleaning
Materials’ Cost and Blankets’ Cost as described in the figure given below:
Optimisation of Printing Consumables and Impact on Green Printing
135
Plates Cost
66%
Blankets
Cost
9%
DVC
100%
Chemicals
Cost
20%
Cleaning
Materials
Cost
5%
Figure 1: Showing DVC Segregation
Data Collection – Optimization of DVC
No.
Consumables
Quantity
Used
Consumable
Rates
Cost (Rs.)
Direct
Variable
Cost/Lac
1
Plate (No.)
1,206,284
116
13.96
5.33
2
Blanket (No.)
3,556
5,359
1.90
0.02
3
Wash (Litre)
252,800
83
2.10
1.12
4
Fount (Litre)
165,983
120
1.98
0.73
5
Cleaning Material (No.)
2,473,500
3
0.63
10.92
6
Cheese Cloth (Kg)
52,160
47
0.24
0.23
7
IPA (Litre)
15,395
80
0.12
0.07
8
Silicon (Kg)
10,650
89
0.09
0.05
Total Pages Printed: 226491 Lacs
TotalDirect Variable Cost : Rs. 18.46/Lac pages
Figure 2: Showing Direct Collection Sheet (DVC)
The base data was taken for the period April 2011 to March 2012 as shown
in the table above. This data show the consumables quantity, cost and direct
variable cost per one lac pages. We have considered all consumables direct
variable cost and decided to reduce this direct variable cost. The data source
was SAP and monthly MIS.
136
Times of India, Kandivali, Mumbai
Project Charter
Project Name
Optimization of Direct Variable Cost (DVC) at Kandivali Plant,
Mumbai and Impact on Green Printing.
Business Case
Continual improvement by doing optimization of raw materials
usage in the printing process and thereby reducing Direct Variable
Cost of Rs. 18.46 per one lac copies.
Problem Statement
Optimization of Direct Variable Cost (DVC) from Rs. 18.45 to Rs.
16.45 per one lac pages by March 2013.
Expected Savings
Rs. 2 Cr. per Annum.
Project Scope
Direct Variable Cost includes Cost of Blankets, Plates, Chemicals
and other consumables (Cleaning Cloths) but excluding the Cost of
Ink, Newsprint & Electricity.
Project Schedule
Team Members and Other Resources
Project Identification
01/04/2012
Champion
Mr. C.I Sebastian
Plan
15/04/2012
Team Leader
Mr. A. Satishkumar
Do
25/06/2012
Team
Members
Check
15/08/2012
Act
25/10/2012
Close
31/03/2013
Mr. Ajinkya Gokhale
Mr. Rajesh Deshpande
Mr. Atul Kale
Other
Resources
All Printers, SAP
Problem Identification
After collecting the data we have to find out the root causes for more consumption
of consumables. We segregated all consumables cost wise through Pareto
Chart.
60
40
20
r
he
Ot
M
at Cl
er ea
ial ni
(N ng
o.
)
No
.)
t(
Bl
an
t(
un
ke
Lit
re
)
Fo
W
as
h
(L
it
o.
)
Pl
at
re
)
0
e
Consumables
80
Percent
100
200000000
150000000
100000000
50000000
(N
Count
CONSUMPTION COSTWISE
Count
Percent
Cum%
139632198 21097677
66.3
66.3
10.0
76.3
19893063 19056604 6381630
9.4
85.7
9.0
94.8
3.0
97.8
4643413
2.2
100.0
Figure 3: Showing Pareto Diagram
Optimisation of Printing Consumables and Impact on Green Printing
137
Cause and Effect Diagram
We did analysis of consumables with the help of Cause and Effect diagram and
got vital information from this analysis. We considered Man, Material, Method
and Machine as the major conditions for analysis.
Cause and Effect Diagram : Optimization of DVC
Matter
Man
Weak developer
Excess usage of wash
Plate
Operator
New operator
Poor quality
Problem
Under developed
Less
Developer not
Chemicals
Using more wipes in a pad
compatible
Knowledge
Characteristics
Once in a month
Low skill level
Peel off
Blanket
Low mileage
Cleaning
Repeated cleaning
Characteristics
Excess wash
Cycle
Cleaning
absorbing
Less mileage
Twice in a month
Procedure
Cleaning cloth
Reduction
Mixing of blanket wash
Characteristics Low quality
of DVC
with water
More usage of wash
More
fount
consumption
More
usage
of
Monthly
Plate exposing
cleaning cloth
not proper
After one and
Fount
dozer
CTP
More
Fewer founts
half month
causing scum
Problem Plate under
Stoppages
Cleaning
Not working
developed
Plate
Cleaning
Turbos Wrong mounting
Properly
cracking
intermediate tanks
Piling and scum
Wrong
Ink and water
Cleaning all Cleaning
Blanket peel off Over heating
imposition
Balance
tanks
Technotrans
of machine
Plate
More cleaning
of blanket
Changing
Machine
Method
Figure 4: Showing Cause and Effect Diagram/Analysis
Cause Prioritization Matrix
138
S.
No.
Different Causes
Impact on
Consumables
Reduction
Feasibility
of Control
Process
Improvement
Grant
Rating
1
Using multiple splits in one edition
9
7
8
504
2
Using of private plates as dummy
plates
9
8
8
576
3
Improper bending and punching
6
5
4
120
4
Cleaning of technotrans
fortnightly
9
8
7
504
5
Cleaning of printing units
alternate day
9
8
7
504
6
We should increase the life of
blankets
8
7
7
392
7
Cleaning materials should be
recycled
9
8
7
504
8
Ink duct trays cleaning should be
weekly
7
6
5
210
9
Using single folders instead of
double folders during daytime for
printing
8
7
6
336
10
Equipments designed for rollers
cleaning
7
6
5
210
11
Plate with reduction in Hiline
presses
9
7
6
378
Figure 5: Showing Cause Prioritisation Matrix
Times of India, Kandivali, Mumbai
We have used Cause Prioritization Matrix to identify highly contributory
causes responsible for higher consumption. In this, we have prioritized causes
based on three categories, i.e. Impact on Consumables Reduction, Feasibility
of Control and Process Improvement and have given them rating on a 1 to 10
scale depending on their impact, starting from lower to higher, on problems
based on data and experience. We obtained grand rating by multiplication of
three categories. We considered the causes for improvement which has grand
rating more than 350 for more consumption. An attempt was made to nullify
the problems which are listed below.
Additional Consumption of Plates
obtained grand rating by multiplication of three categories. We considered the causes for improvement
• Usage of more dummy plates
which has grand rating more than 350 for more consumption. An attempt was made to nullify the
• More splits in Bombay times edition
problems which are listed below.
• Ineffectual space on plates in Manu-graph press
Additional Consumption of Plates
Increase in Consumption of Chemicals & Cleaning Cloth
¾ Usage of more dummy plates
• Every
daysplits
cleaning
of printing
units
¾ More
in Bombay
times edition
¾ Ineffectual
space on
plates
in Manu-graph
press& cleaning cloth
• Cleaning
of brush
roller
with
lots of wash
Increase in Consumption of Chemicals & Cleaning Cloth
¾ Every day cleaning of printing units
¾ Cleaning
brush
roller with lots of wash & cleaning cloth
Diagnosis
of ofthe
Problem
7. DIAGNOSIS OF THE PROBLEM:
Major
responsible
for higher
consumption
Majorfactors
factors responsible
for higher
materialmaterial
consumption
considered forconsidered
improvement.for
We involved
improvement. We involved Engineers, Technical Assistants and Wage-board
Engineers, Technical Assistants and Wage-board Employees of different departments for reduction of
Employees of different departments for reduction of materials.
materials.
Excess Usage
of Dummy Plates:
Excess 7.1
Usage
of Dummy
Plates
WHO?
Printers
WHAT?
Printing Plates Used as Dummy
Plates
WHEN?
01 May 2012 to 31 March 2013
WHERE?
Man and Manu-graph Presses
HOW?
Dummy plates contain no image
as shown in Figure 6 used on
the machine for non-printing
areas. So printed plates with
fewer images are used instead
of dummy plates
Figure 6: Showing Dummy Plates
Figure 7: Showing Image on Plate
Optimisation of Printing Consumables and Impact on Green Printing
139
7.2 Ineffectual Space on Plates in Manu-Graph Press:
Manu-Graph Printers
WHO?
7.2 Ineffectual Space on Plates in Manu-Graph Press:
Ineffectual Space on Plates in Manu-Graph Press
WHAT?
WHO?
WHEN?
WHAT?
Plate Width Reduction in ManuGraph Presses
Manu-Graph Printers
15 April 2012 to 31 March 2013
Plate Width Reduction in ManuGraph Presses
WHEN?
WHERE?
15 AprilManu-Graph
2012 to 31 March
2013
Presses.
WHERE?
Manu-Graph Presses.
HOW?
HOW?
Figure 8: Before Reduction
Figure 8: Before Reduction
In Manu-Graph press the plate
width is decreased by 10 mm
on both sides. There are no
In Manu-Graph
press the plate
complications
found
after
width isreduction.
decreased byThis
10 mmhelped to
on both sides. There are no
reduce the
per plate
cost by Rs.
complications
found
after
5. This helped to
reduction.
reduce the per plate cost by Rs.
5.
Figure 9: After Reduction
Figure 9: After Reduction
7.3 Cleaning of Brush Roller with More Wash and Cleaning Cloth:
Cleaning
of More
Brush
Roller
with More
Wash and Cleaning Cloth
7.3 Cleaning of Brush
Roller with
Wash
and Cleaning
Cloth:
WHO?
WHO?
WHAT?
WHAT?
In-house Fabrication
In-house Fabrication
of Washing of Washing
for Brush
Roller Cleaning
Device forDevice
Brush Roller
Cleaning
WHEN?
WHEN?
09 May 2012
to 15 2012
May 2012
09 May
to 15 May 2012
WHERE?
Manu-Graph Presses.
WHERE?
140
Mr. Samir Phatkar - Manu-graph
Mr. SamirEngineer
Phatkar - Manu-graph
Engineer
Manu-Graph Presses.
Times of India, Kandivali, Mumbai
In Manu-Graph press the brush roller cleaning is
complicated. Brush roller cleaning requires lot of
wash and cleaning cloth. To reduce this
engineering team fabricated in-house developed
washing device to clean this roller with less wash,
cloths and efforts.
HOW?
Figure 10: Brush Roller
Figure 12: Cleaning of Roller
Figure 11: Cleaning Tray
8. FINANCIAL SAVINGS
Financial
SavingsCALCULATION:
Calculation
8.1 Savings
from
plates:
Savings
from
Plates
Description
Before (April 11 to March 12)
After (April 12 to March 13)
Plate Consumption
1043263
951380
Description
Before (Apr-11 TO Mar-12)
Plates Consumption
Rate Per Plate
116
RateofPer
Plate
Saving
Plates
After (Apr-12 TO Mar-13)
1043263
116
951380
116 91883
Savings
in Rs.
Saving of Plates
116
Rs. 1.06 Cr. 91883
Rs. 1.06 Cr.
Savingsfrom
in Rs. Blankets
Savings
Description
Before (April 11 to March 12)
8.2 Savings from Blankets:
Blankets
Description
Consumption
3075
Blankets
Rate Per
Blanket Consumption
5359
After (April 12 to March 13)
Before (Apr-11 TO Mar-12)
SavingRate
of Blankets
Per blanket
Savings in Rs.
Saving of Blankets
1061
5359
2014
5359
Rs. 56.9 Lacs
1061
Rs. 56.9 Lacs
Savings (Rs.)
Plates
1.06 Cr
Blankets
56.8 Lacs
Chemical and cleaning cloth
0.49 Lacs
Total Savings in Rs.
After (Apr-12 TO Mar-13)
5359
3075
Savings
from
All Consumables
Savings
in Rs.
Description
2014
Rs. 2.13 Cr.
After completion of the project, the DVC has been reduced from Rs. 18.46
to Rs. 16.73 per Lac pages within a year resulting in total saving of
Rs. 2.13 Cr.
Optimisation of Printing Consumables and Impact on Green Printing
141
Impact of the Project
Customer/Stake Holder Satisfaction & Social Benefits:
• The internal and external customers are satisfied as the product quality is
improved.
• The reduction of consumables affects the inventory (order less stock instead
of more) for the company.
• The stake holders are more happy as the cost saving will reflect finally on
the profit margin.
• Reduction of plate consumption helping to reduce the efforts of people to
less plates changing.
• Less usage of aluminum for plate manufacturing helps to stock up the iron
ores.
• Decreased usage of harmful chemicals reducing the soil and water
pollution.
Acknowledgement
The project “Optimisation of Printing Consumables and Impact on Green
Printing” is a Continuous Improvement Group (CIG) initiative undertaken by
The Times of India Group’s Kandivali plant. The idea began as an initiative
to reduce consumption by optimizing processes & reducing wastages. This in
turn would in turn open the avenues for green printing. Even though printing
process as such is not a polluting or ecologically destructive industry, we
realised our responsibility of supporting the green movement by improving our
processes, though collective responsibility explored the possibilities through
systematic analysis.
With prices of consumables soaring, controlling Direct Variable Cost (DVC)
per page was an area of major concern. Optimising consumables without
compromising on print quality could deliver the dual benefit of cost reduction
and green printing. We did that with zeal and commitment.
We value the timely guidance and unstinted support which we received
from our Technical Director, Mr. Sanat Hazra, the Deputy Director, Mr. M.R.
Vasudevan and our CIG Head, Mr. Amit Sharma during the entire length of
this project.
We also acknowledge the effort and enthusiasm put in by Mr. Satishkumar
A, the team leader and his team comprising Mr. Ajinkya Gokhale, Mr. Rajesh
Deshpande and Mr. Atul Kale and the technical team of Kandivali plant for
taking the project to a laudable level.
142
Times of India, Kandivali, Mumbai
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