73

CHAPTER 5

IMPLEMENTATION OF TFMEA IN A COMPANY

MANUFACTURING TEA THROUGH CTC METHOD

5.1 INTRODUCTION

As mentioned earlier, black tea is manufactured by employing

orthodox and CTC methods. The practicality of applying TFMEA in black tea
manufacturing in a real time situation was appraised in the previous chapter. In this
chapter, an implementation study conducted in a company manufacturing tea by
employing CTC method is described. This description is made with a prelude of a
brief description on the CTC method of manufacturing black tea.

5.2 CTC METHOD OF MANUFACTURING BLACK TEA

The steps involved in the manufacturing of black tea by employing CTC

method are shown in Figure 5.1. Each step impacts the quality of tea. The activities
carried out under each step and their impacts on the quality of tea are deliberated in
the following subsections (Sarma, 2000; Food and Agriculture Organization of the
United Nations, 1988; Krishna Vigyan Kendra, 1999).

5.2.1 Plucking of tea

Generally tea shoots are handpicked and in some cases shears are used
for harvesting the tea shoots. The shoots that are plucked are generally gathered in
nylon bags and they are shifted to the tea factory either by head loads or by trucks.

5.2.1.1 Quality aspects in the plucking of tea

To manufacture good quality tea, it is essential to pluck the tea shoots

which have two leaves and a bud. Care should be taken to ensure that the tea shoots
 74

4. Fermenting

3. Rolling 5. Drying

2. Withering 6. Sorting

7. Packing and sending

it to the store houses for
further marketing.

1. Plucking of Tea

Figure 5.1. The steps of manufacturing black tea by CTC method

 75

are not damaged or bruised and are shifted quickly to the factory.

5.2.2 Withering

The first step in black tea production is the withering of tea shoots under
controlled conditions. Withering is the process by which water is removed from the
green tea shoots plucked from the field. Freshly plucked, tea shoots contain about
80% moisture and this must be reduced by 30% to 70% over a period of 17 hours.
During the process of withering, the tea shoots are placed on wire mesh troughs or
trays and air is circulated (either fan-forced or natural) to remove the moisture. Care
should be taken to ensure that while the water is removed, the tea shoots are not
damaged and the greenness or freshness of the tea shoots is preserved. In addition to
physical changes, certain biochemical changes occur during the withering process.
Through the withering process, the rate of fermentation is enhanced due to the
acceleration of polyphenoloxidase. Proteins are hydrolyzed to become amino acid
which is responsible for the aroma of the tea. Caffeine content is optimized which
influences black tea quality. Level of organic acids is enhanced which helps to
improve the flavor of tea.

5.2.2.1 Quality aspects in the withering process

The following conditions are to be met during withering process for

enhancing the quality of black tea.
• Ambient air should be used when hygrometric difference is above 3oC. If the
hygrometric difference is below 3oC, hot air may be used along with a
suitable proportion of ambient air.
• The temperature of hot air should be below 35oC.
• To get even wither, the trough should be loaded with 2-3 kgs of tea shoots
per square feet.
• Well ventilated lofts with access for drawing large volume of air should be
provided.
 76

• The ideal quality of air for withering is low dry bulb temperature with high
hygrometric difference.
• Reversible air flow system should be used to get better withering and to
avoid handling of leaves manually.
• The plenum chamber should have tapering cross section so as to maintain
uniform pressure throughout the length of the trough.

5.2.3 Rolling

This is a process of gently crushing or rolling a batch of tea shoots.

Rolling process is carried out using a machine called CTC roller. During rolling, the
tea shoots are crushed into small bits to press out the juice and thereby coat a thin
film of juice on the surface of the leaf particles to enhance chemical changes. In
CTC tea manufacture, the rotor vane machine is used to precondition the tea shoots
before being fed into the CTC machine. In the case of orthodox tea manufacture,
the tea shoots are being rolled at the final stage in a table and jacket arrangement
whereas in CTC rolling, before entering the CTC machine, the tea shoots are passed
through a machine called the rotor vane. The tea shoots coming out of the rotor
vane are cut into pieces and this output is sent to the CTC rollers. The CTC roller
machine has a series of cylindrical rollers with hundreds of small sharp "teeth" that
Crush, Tear, and Curl. The primary function of rolling is to crush the leaf into small
sizes.

5.2.3.1 Quality aspects in the Rolling process

The following conditions are to be met during rolling process to enhance

the quality of black tea.
• Green leaf sifter should be used to avoid jamming of machine.
• Leaf shredder should be used to avoid overheating of tea in the rotor vane.
• A ball breaker should be used after the rotor vane to cool the tea before it is
fed into the CTC roller.
 77

• Temperature of the rotor vane tea should be maintained within 35oC in order
to facilitate the enzyme activity.
• Magnet may be fixed on all the conveyers to remove foreign particles.
• CTC machine should be cleaned daily to ensure good quality of tea is
manufactured.

5.2.4 Fermentation

Fermentation is carried out to bring about the chemical changes that are
necessary to make tea liquor palatable. It is an oxidation process by which the
rolled leaf loses its green color and acquires copper color. It also results in
formation of aroma of the fermented tea.

5.2.4.1 Quality aspects in the fermentation process

The following conditions are to be met during fermentation to enhance

the quality of tea.
• Co-current air flow arrangement is essential to supply more oxygen during
the initial stage of fermentation.
• The air should be fresh, cool and saturated with moisture.
• The optimum temperature of dry bulb ranges between 25oC and 27oC and the
relative humidity of the air should be around 95%.
• A post fermentation ball breaker is essential.
• Fermenting drum must be cleaned using hot water or steam to avoid bacterial
contamination.

5.2.5 Drying

When the tea shoots are oxidized to the ideal level, the oxidation is
stopped by drying the tea shoots with hot air. During this process, the moisture level
of the tea shoots are brought down from 60% to about 3% and the extracted sap
 78

dries on the shoots thereby darkening the color of the tea to dark brown or black.
Drying is generally done at a temperature of around 100o C.

5.2.5.1 Quality aspects in the drying process

• Correct inlet and exhaust temperature should be maintained to get uniform

firing. Proper loading of drier is also essential to get uniform firing.
Overloading should be avoided since it causes back pressure and results in
uneven drying.
• Correct drying time and temperature should be maintained as longer drying
time affects the quality and flavor of black tea. Shorter time results in thin
liquor. When the temperature is above the optimum level, then the tea
becomes bitter.
• In the Fluid Bed Drier (FBD), the desirable inlet temperature ranges from
120 to125oC, while the exhaust temperature should be maintained at 60-
65oC.
• It is advisable to fix magnet in the drier mouth to prevent iron particles from
mixing with tea.

5.2.6 Sorting and grading

Sorting is carried out to remove fiber from the bulk tea and separate the
tea particles based on their shapes and sizes relevant to trade requirements. Sorting
enhances the uniformity in the appearance and quality of tea liquor.

5.2.6.1 Quality aspects in the Sorting and grading process

• Use of stainless steel meshes is desirable for carrying out good sorting.
• Meshes should be always dense as loose meshes cause uneven grading.
 79

5.2.7 Packing

After black tea is manufactured, it is packed carefully in waterproof air

tight bags. Since black tea is a highly hygroscopic material, it easily picks up
moisture from the atmosphere if packing is not properly made and thereby the shelf
life period of the tea is greatly affected.

5.2.7.1 Quality aspects of packing black tea

• Maximum three percent moisture level is advisable when packed. If the

moisture content of tea reaches 6%, the shelf life of tea is affected.
• Tea should not be stored in open condition.
• Bins should be used for storing of the manufactured tea.
• Tea should be cooled to ambient condition, before it is taken to bins.
• It is advisable to pass tea under powerful magnet grills to ensure iron free tea
while packing.

5.3. Background of Highfield tea industry

The implementation study being reported here was carried out in a

company by name High Field tea industry. This company is situated in Coonoor,
Nilgiris district, Tamil Nadu State, India. Highfield tea industry was started in the
year 1970. Currently 160 employees are working in this tea manufacturing
company. Out of them, 140 are laborers involved in plucking tea leaves and
processing them. Remaining employees are holding managerial positions of the
High Field tea industry. The High Field tea industry is facing tough competition in
the global market. The management of the High Field tea industry has realized that
improving quality of tea and its manufacturing process is imperative to face the
global competition. In this background, the practicality of TFMEA implementation
was investigated in Highfield tea industry. The details of this work by following the
steps enumerated to carry out the hypothetical case study (these steps are given in
chapter 3) are presented in the next section.
 80

5.4 IMPLEMENTATION STUDY

To begin with, the benefits of employing TQM practices for achieving

continuous quality improvement in the process of manufacturing tea was explained
to the management of the High Field tea industry. It was also explained to the top
management that by implementing TFMEA it would be useful to overcome the
various defects that are encountered in the manufacturing of black tea by employing
the CTC method. After a detailed discussion, the management of High Field tea
industry granted permission to conduct the implementation study in their premises
to investigate the effectiveness of applying TFMEA technique in black tea
manufacturing companies employing CTC method. The steps followed to conduct
this implementation study are described below.

Step I: Exposing TFMEA programme to the management

A detailed discussion was held with the top management of the Highfield tea
industry to expose the salient features of the TFMEA technique. It was also
explained to them that TFMEA programme is capable of improving the quality of
black tea manufactured and also improving the processes employed for
manufacturing it. After participating in this discussion, the managerial personnel
gained sufficient knowledge about TFMEA program. As TFMEA is a simple
technique, managerial personnel could easily grasp its features and were eager to
involve in the TFMEA programme of the Highfield tea industry.

Step II: First joint meeting with managerial employees and laborers on
TFMEA programme

A joint meeting of a group comprising laborers of the Highfield tea

industry and the managerial employees was convened. It was explained to the
participants that unless black tea with high degree of quality is produced, it was not
possible to face the stiff global competition prevailing among the tea producing
nations and conquer the international market. It was emphasized that, urgent steps
 81

needed to be taken to improve the quality of black tea produced in the Highfield tea
industry and that TFMEA technique could be used to improve the quality of black
tea. The participants were informed that, more details on using TFMEA technique
would be explained to them in the following week.

Step III: Second joint meeting with managerial employees and laborers on the
conduct of TFMEA programme

The second meeting of managerial employees and laborers was convened

a week later. During this meeting, the method of using TFMEA technique was
explained to the participants using lucid language. The participants of this meeting
were requested to start the TFMEA program by listing the various defects that affect
the quality of black tea produced at the High Field tea industry. The defects that
affect the quality of tea produced in High field tea industry as listed by the
participants during this meeting are listed below.
• Soft withering.
• Non-uniform size of particles and poor grades of black tea
• Under-fermentation
• Over-fermentation
• Greenness of black tea
• Stewing
• Case hardening
• Smoke smell of black tea
• Flakiness, excessive stalk and fiber

Step IV: Discussion with managerial employees about laborers’ interest

towards TFMEA programme

During the fourth step of the implementation study on the TFMEA

technique, the managerial employees were apprised of the interest shown by the
laborers towards involving and supporting the TFMEA programme in the Highfield
 82

tea industry. After a detailed discussion, the managerial employees approved the
list of defects identified during the third step to be overcome by implementing the
TFMEA programme.

Step V: Invitation to the laborers for becoming members of TFMEA team

It was decided to approach the laborers in groups and invite them to join
as TFMEA team members. Accordingly, the laborers were invited and the names of
laborers willing to join as TFMEA team members to solve the problems in the
production of black tea at the High Field tea industry were noted down.

Step VI: Formation of TFMEA team

From the list of laborers who were willing to join as members of

TFMEA team, the managerial employees approved the selection of five laborers to
join as TFMEA team members. Moreover, five managerial employees who were
willing to join as TFMEA team members were also included in the TFMEA team.
Thus a TFMEA team having equal participation of managerial employees and
laborers was constituted at the High Field tea industry. The names of the members
of the TFMEA team thus formed are shown in Table 5.1.

Table 5.1. TFMEA team formed at High Field tea industry

Serial
Name Designation
Number
1 Shanthosh Foreman - Drying section
2 Sampath Foreman - Withering section
3 Rajamanickam Foreman - Rolling section
4 Kumar Foreman - Maintenance section
5 Ganesh Foreman - Quality Control section
6 Gracy Laborer
7 Rasilin Laborer
8 Sarasu Laborer
9 Sheela Laborer
10 Helen Laborer
 83

Step VII: First meeting of TFMEA team

During the first meeting of the TFMEA team, the brainstorming

technique was explained to the members of the TFMEA team. The TFMEA team
members were briefed about the rules to be followed while participating in the
brainstorming session. The TFMEA team members were asked to strictly adhere to
the rules while participating in the brainstorming sessions. In this meeting, it was
decided to develop TFMEA tables pertaining to five sections of the High Field tea
industry namely withering, rolling, drying, maintenance and quality control.

Step VIII: Conduct of first brainstorming session and development of TFMEA

tables

A meeting of the TFMEA team was convened and the first brainstorming
session was conducted. During the brainstorming session, the TFMEA team
members were asked to identify the primary cause of defects encountered in
withering, rolling and drying processes. After thorough deliberations, the defects
encountered in these sections of the High Field tea industry were identified by the
members. After the defects were identified, the causes of these defects were also
found out and the details of the information thus derived are presented below.

Withering: The major machinery used while carrying out withering are listed
below.
• Withering fan
• Withering troughs
• Hot air ducts
• Conveyors and Leaf hoist
Unexpected breakdown of the above mentioned machinery is the major cause for
failures and defects in the withering process.

CTC Rolling: The failures encountered during the operation of CTC rolling
machine are listed below:
 84

• Wear and tear on the surfaces

• Uneven cell sharpening
• Improper meshing of rollers
• Failure of bearing
• Failure of drives

In the rolling section, another machine called the green leaf sifter is used.
Though the construction of this machine is simple, it is a high speed machine with
unbalanced masses. The failures encountered during the operation of this machine
are listed below:
• Bearing failure
• Wear and tear of the meshes

Rotor vane is another machine used in the rolling section. Even though
this is a slow speed machine, it often fails due to regular wear and tear. The failures
noticed during the operation of this machine are detailed below.
• Wear and tear of elements
• Failure of bearing
• Drive failure

Drying: Tray drier with heater is mostly used for drying. Though the tray drier is a
slow speed machine, it has numerous moving components. While this machine is
operated, the following failures are observed.
• Wear and tear of the moving parts
• Hot air leakage
• Misalignment of the drier trays
• In the heater, the following failures are noticed while in operation
• Hot air leakage
 85

• Wear and tear of the surfaces

• Damages of parts

During the conduct of this brainstorming session, depending on the

severity of the failures, the degree of importance attached to each section was
determined. Subsequently, the TFMEA team developed the TFMEA tables. As
mentioned earlier, these TFMEA tables were developed pertaining to five sections
namely withering, rolling, drying, maintenance and quality control. The TFMEA
tables developed by the TFMEA team at the High Field tea industry are shown in
Tables 5.2 - 5.10. In these tables, the TFMEA members have also indicated the
recommended actions and the ratings assigned to each failure.

Step IX: Approval of TFMEA tables by the top management

The TFMEA tables were submitted to the top management. The top
management approved and appreciated the recommended actions. However top
management was non-committal over the implementation of all the recommended
actions. Hence it was not possible to implement X, XI, XII, XIII steps of TFMEA
programme at Highfield tea industry. The practical issues of implementing these
steps are discussed in the next section.

5.5 PRACTICAL IMPLICATIONS

Since the top management of Highfield tea industry did not grant the
necessary approval to implement the actions suggested through the conduct of the
TFMEA programme, it was decided to investigate the practicality of the proposed
actions by preparing a questionnaire to elicit the responses of top management
personnel of Highfield tea industry. The questions asked using the Likerts’ scale of
range 0-10 are shown in Tables 5.11 - 5.13. As shown, the ten failure modes
identified through the development of TFMEA tables in the Highfield tea industry
and the recommended activities for preventing such failures were mentioned in
 86

Table 5.2. TFMEA – Withering

Process Name: Withering Members present: All TFMEA team members

Present Departments Recommended

TFMEA number Failure Mode Cause of failure Effects of failure Rating Approved by
control Maintenance Drying activities

Supply of raw material

to the various 1. Keeping a log
Leaf hoist machines is delayed book and check
1. Due to non-
and and thereby the sheet for recording
lubrication General
1 Overhead duration of Nil 7 8 4 periodic lubrication
2. Safety pin Manager
conveyor manufacturing is
failure
failure extended. Hence poor 2. Checking safety
grades of tea are mechanism
produced
Withering does not
take place. Soft
withering occurs due
to improper withering.
Soft withering causes
the following defects. Periodic check for
Withering Bearing and General
2 Nil 7 8 5 fan balance to be
fan failure motor failure • Thin tea Manager
undertaken
liquor.
• No briskness
• Increase of
energy
consumption
1. Non-
cleaning of 1. Periodic cleaning
a. Catch of fire in the
duct results and inspection to
duct
Failure of hot in damage to insulate the ducts General
3 b. Smoke smell in tea Nil 7 8 6
air supply insulation 2.Training of Manager
and decrease of quality
2. Improper workers in operating
c Wastage of hot air
operation of the dampers
damper
 87

Table 5.3. TFMEA – Maintenance

Process Name: Maintenance Members present: All TFMEA team members

Present Departments Recommended

TFMEA number Failure Mode Cause of failure Effects of failure Rating Approved by
control Withering Drying activities

Supply of raw material

to the various 1.Checking
Leaf hoist machines is delayed lubrication regularly
1. Due to non-
and and thereby the 2. Checking safety
lubrication General
1 Overhead duration of Nil 8 7 4 mechanism and
2. Safety pin Manager
conveyor manufacturing is undertaking
failure
failure extended. Hence poor maintenance work
grades of tea are
produced
Withering does not
take place. Soft
withering occurs due
to improper withering.
Soft withering causes Periodic check for
Withering Bearing and the following defects. the fan balance and General
2 Nil 8 7 5
fan failure motor failure • Thin tea taking corrective Manager
liquor. action
• No briskness
• Increase of
energy
consumption
1. Non-
cleaning of
a. Catch of fire in the 1. Periodic cleaning
duct results
duct and repair to
Failure of hot in damage to General
3 b. Smoke smell in tea Nil 8 7 6 damaged parts of
air supply insulation Manager
and decrease of quality ducts
2. Improper
c Wastage of hot air 2.To insulate it
operation of
damper
 88

Table 5.4. TFMEA – Drying

Process Name: Drying Members present: All TFMEA team members

Cause of Present Departments Recommended

TFMEA number Failure Mode Effects of failure Rating Approved by
failure control Withering Maintenance activities

Supply of raw material

to the various
Leaf hoist machines is delayed
1. Due to non- Maintaining log
and and thereby the
lubrication book for carrying General
1 Overhead duration of Nil 4 7 8
2. Safety pin out regular Manager
conveyor manufacturing is
failure maintenance
failure extended. Hence poor
grades of tea are
produced
Withering does not
take place. Soft
withering occurs due
to improper withering.
Soft withering causes
Withering Bearing and the following defects. Maintaining log General
2 Nil 5 7 8
fan failure motor failure • Thin tea book for fan balance Manager
liquor.
• No briskness
• Increase of
energy
consumption
1. Non-
cleaning of
a. Catch of fire in the
duct results
duct
Failure of hot its their non- Training laborers in General
3 b. Smoke smell in tea Nil 6 7 8
air supply insulation operating dampers Manager
and decrease of quality
2. Improper
c Wastage of hot air
operation of
damper
 89

Table 5.5. TFMEA – Rolling

Process Name: Rolling Members present: All TFMEA team members
Departments
Present
TFMEA number Failure Mode Cause of failure Effects of failure Rating Quality Recommended activities Approved by
control Maintenance
Control
1. Periodically check
Defects such as cutting angle of cells and
greenness, flakiness and recording
Wear and tear of General
4 Uneven rolling non-uniform size of Visual 7 8 7 2. Periodically check
surfaces Manager
particles Poor grades of bearing alignment
tea are produced 3. Periodically check the
roller meshing and record
1. Checking for alignment
1.Misalignment Under fermentation or
and recording
and bearing failure over fermentation
Fermenting 2. Checking rpm of drum General
5 2.Failure of drive causes very poor quality Visual 9 6 9
drum failure and recording Manager
due to wear and of tea and hence
3. Checking chain drives
tear revenue loss.
and recording
Defects such as
excessive stalk and
Sudden fiber, and poor grades 1.Periodic checking of
General
6 breakdown of Bearing failure of tea are produced. Visual 9 6 7 bearing condition and
Manager
green leaf sifter This results in the recording
dropping of the price of
tea.
1.Entry of foreign
material like nuts, 1. Periodic inspection of
Wastage of raw
Breakdown of bolts etc. along machine and recording
material, poor grades of General
7 rotor vane with the raw Nil 8 6 8 2. Checking the tightness of
tea results in loss of Manager
machine material resistors regularly and
revenue
2. Loosening of recording it
resistors
 90

Table 5.6. TFMEA – Maintenance

Process Name: Rolling Members present: All TFMEA team members
Departments
Present
TFMEA number Failure Mode Cause of failure Effects of failure Rating Quality Recommended activities Approved by
control Rolling
Control
1. Periodically check
cutting angle of cells and
Defects such as take corrective action
greenness, flakiness and 2. Periodically check
Wear and tear of General
4 Uneven rolling non-uniform size of Visual 7 8 7 bearing alignment and
surfaces Manager
particles Poor grades of correct it
tea are produced 3. Periodically check the
roller meshing and make
adjustments.
1.Misalignment 1. Checking for alignment
Under fermentation or
and bearing failure and correcting it
over fermentation
Fermenting 2.Failure of drive 2. Checking rpm of drum General
5 causes produces very Visual 8 6 9
drum failure due to wear and and correcting it Manager
poor quality of tea and
tear: 3. Checking chain drives
hence revenue loss.
3.Failure of crank and making adjustments .
Defects such as
excessive stalk and
Sudden fiber, and poor grades 1.Periodic checking of
General
6 breakdown of Bearing failure of tea are produced. Visual 7 6 8 bearing condition and
Manager
green leaf sifter Hence results in the taking corrective action
dropping of the price of
tea.
1.Periodic inspection of
1.Entry of foreign machine and undertaking
material like nuts, regular maintenance work
Wastage of raw
Breakdown of bolts etc. along 2.Introduction of magnetic
material, poor grades of General
7 rotor vane with the raw Nil 8 6 8 separator, fluid couplings
tea results in loss of Manager
machine material and electronic shear pin
revenue
2. Loosening of 3. Checking the tightness of
resistors resistors regularly and
correcting it
 91

Table 5.7. TFMEA – Quality Control

Process Name: Rolling Members present: All TFMEA team members

Present Departments
TFMEA number Failure Mode Cause of failure Effects of failure Rating Recommended activities Approved by
control Maintenance Rolling
1. Taking regular samples
Defects such as
of tea and giving feedback
greenness, flakiness and
Wear and tear of to maintenance personnel to General
4 Uneven rolling non-uniform size of Visual 8 7 7
surfaces take corrective action when Manager
particles Poor grades of
defects are noticed.
tea are produced
1. Checking for under
1.Misalignment
Under fermentation or fermentation and over
and bearing failure
over fermentation fermentation from the tea
Fermenting 2.Failure of drive General
5 causes produces very Visual 6 8 9 samples and recording it for
drum failure due to wear and Manager
poor quality of tea and sending feedback to
tear:
hence revenue loss. maintenance personnel
3.Failure of crank
Defects such as
excessive stalk and
Sudden fiber, and poor grades Training of laborers on
General
6 breakdown of Bearing failure of tea are produced. Visual 6 7 8 maintenance of green leaf
Manager
green leaf sifter Hence results in the sifter
dropping of the price of
tea.
1.Entry of foreign
material like nuts,
Wastage of raw
Breakdown of bolts etc. along Training of laborers on
material, poor grades of General
7 rotor vane with the raw Nil 6 8 8 maintenance of rotor vane
tea results in loss of Manager
machine material machine
revenue
2. Loosening of
resistors
 92

Table 5.8. TFMEA – Drying

Process Name: Drying Members present: All TFMEA team members
Departments
Present
TFMEA number Failure Mode Cause of failure Effects of failure Rating Quality Recommended activities Approved by
control Maintenance
Control
1. Misalignment 1. Poor grades of tea
2. No oiling 2. In case of sudden Weekly visual inspection,
Failure of drier General
8 3. No cleaning breakdown of machine, Visual 9 9 6 maintaining a record of
conveyer Manager
4. Damage to the entire raw material maintenance carried out
safety shear pin will be wasted
1. Poor quality black tea
1. Leak in heat
Failure of 2. Loss of heat Regular inspection and General
9 exchanger surfaces Visual 9 9 6
heater 3. Fire hazard recording Manager
and tubes
4. Smoke smell in tea
1. Over-heating of tea
causes the defect case- Installing sensors in the
Failure of
Human error and hardening dryer to maintain the drier General
10 temperature Manual 8 7 9
negligence. 2. Under-heating of tea temperature at the optimum Manager
control
causes the defect level.
stewing’.
 93

Table 5.9. TFMEA – Maintenance

Process Name: Drying Members present: All TFMEA team members
Departments
Present
TFMEA number Failure Mode Cause of failure Effects of failure Rating Quality Recommended activities Approved by
control Drying
Control
Weekly visual inspection,
1. Misalignment 1. Poor grades of tea
regular cleaning of
2. No oiling 2. In case of sudden
Failure of drier conveyor, maintaining a General
8 3. No cleaning breakdown of machine, Visual 9 9 6
conveyer record of maintenance Manager
4. Damage to the entire raw material
carried out to check and
safety shear pin will be wasted
maintain the shear pin
1. Poor quality black tea
1. Leak in heat
Failure of 2. Loss of heat Regular inspection, General
9 exchanger surfaces Visual 9 9 6
heater 3. Fire hazard maintenance and recording Manager
and tubes
4. Smoke smell in tea
1. Over-heating of tea
Installing sensors in the
causes the defect case-
Failure of dryer to maintain the drier
Human error and hardening General
10 temperature Manual 7 8 9 temperature at the optimum
negligence. 2. Under-heating of tea Manager
control level. Conducting periodic
causes the defect
maintenance of the sensors
stewing’.
 94

Table 5.10. TFMEA – Quality Control

Process Name: Drying Members present: All TFMEA team members
Departments
TFMEA number Failure Mode Cause of failure Effects of failure Present control Rating Recommended activities Approved by
Drying Maintenance
Weekly visual inspection,
regular cleaning of
1. Misalignment 1. Poor grades of tea conveyor, maintaining a
Failure of 2. No oiling 2. In case of sudden record of maintenance
General
8 drier 3. No cleaning breakdown of machine, Visual 6 9 9 carried. Taking samples of
Manager
conveyer 4. Damage to the entire raw material tea to check for defects and
safety shear pin will be wasted identify causes and give
feedback to maintenance
personnel
1. Poor quality black tea
1. Leak in heat
Failure of 2. Loss of heat Regular inspection, General
9 exchanger Visual 6 9 9
heater 3. Fire hazard maintenance and recording Manager
surfaces and tubes
4. Smoke smell in tea
Defects are
identified after
1. Over-heating of tea
production is Installing sensors in the
causes the defect case-
Failure of completed and dryer to maintain the drier
Human error and hardening General
10 temperature the samples are 9 8 7 temperature at the optimum
negligence. 2. Under-heating of tea Manager
control sent to the tea level. Conducting periodic
causes the defect
tasters for fixing maintenance of the sensors
stewing’.
the price in the
auction.
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Table 5.11. Questionnaire used to assess the practicality of implementing TFMEA at Highfield Tea industry
Name of the responder: Date:
Designation:
The following table shows the information drawn from TFMEA tables, developed at Highfield tea industry. You are requested to express your opinion on the practicality of applying
TFMEA at Highfield tea industry by ticking the scale presented in the last column.
TFMEA Failure Action suggested to overcome To what extent you assess that action suggested in column (e) can be
Cause of Failure Effects of Failure
number Mode the failure implemented in Highfield Tea Industry (Please tick)
(c) (d)
(a) (b) (e) (f)
1. Regularly recording and
Supply of raw material to
Leaf hoist analyzing the percentage of
the various machines is
and 1. Due to non- different grades of tea and
delayed and thereby the
1 Overhead lubrication taking corrective action.
duration of manufacturing
conveyor 2. Safety pin failure 2. Regular visual inspection of
is extended. Hence poor
failure surface of rollers and recording
grades of tea is produced
and taking corrective action.
Withering does not take
place. Soft withering occurs 1. Check Alignment, record
due to improper withering. and take corrective action
Soft withering causes the 2. Check Bearings, record and
Withering Bearing and motor following defects. take corrective action
2
fan failure failure
• Thin tea liquor.
3. Check Drives, record and
• No briskness
take corrective action
• Increase of energy
consumption
1. Periodic Checking of
bearing condition and
recording
1. Non-cleaning of a. Periodic inspection of
a. Catch of fire in the duct
duct results its their machine & record
Failure of hot b. Smoke smell in tea and
3 non-insulation b. Introduction of magnetic
air supply decrease of quality
2. Improper operation separator, fluid couplings,
c Wastage of hot air
of damper electronic shear pin
c. Checking the tightness of
resistors regularly and
recording it

Signature
 96

Table 5.12. Questionnaire used to assess the practicality of implementing TFMEA at Highfield Tea industry
Name of the responder: Date:
Designation:
The following table shows the information drawn from TFMEA tables, developed at Highfield tea industry. You are requested to express your opinion on the practicality of applying
TFMEA at Highfield tea industry by ticking the scale presented in the last column.
TFMEA Failure Action suggested to overcome the To what extent you assess that action suggested in column (e) can be
Cause of Failure Effects of Failure
number Mode failure implemented in Highfield Tea Industry (Please tick)
(c) (d)
(a) (b) (e) (f)
1. Regularly recording and
Defects such as analyzing the percentage of
greenness, flakiness and different grades of tea and taking
4 Uneven Wear and tear of
non-uniform size of corrective action.
rolling surfaces
particles Poor grades of 2. Regular visual inspection of
tea are produced surface of rollers and recording
and taking corrective action.
1. Check Alignment, record and
1.Misalignment and
Under fermentation or take corrective action
bearing failure
over fermentation causes 2. Check Bearings, record and take
5 Fermenting 2.Failure of drive
produces very poor corrective action
drum failure due to wear and
quality of tea and hence 3. Check Drives, record and take
tear:
revenue loss. corrective action
3.Failure of crank
Defects such as excessive
1. Periodic Checking of bearing
Sudden stalk and fiber, and poor
condition and take corrective
6 breakdown of grades of tea are
Bearing failure action
green leaf produced. Hence results
sifter in the dropping of the
price of tea.
1. Periodic inspection of machine
1.Entry of foreign
& record
material like nuts,
Breakdown of Wastage of raw material, 2. Introduction of magnetic
7 bolts etc. along with
rotor vane poor grades of tea results separator, fluid couplings,
the raw material
machine in loss of revenue electronic shear pin
2. Loosening of
3. Checking the tightness of
resistors
resistors regularly and recording it

Signature
 97

Table 5.13. Questionnaire used to assess the practicality of implementing TFMEA at Highfield Tea industry
Name of the responder: Date:
Designation:
The following table shows the information drawn from TFMEA tables, developed at Highfield tea industry. You are requested to express your opinion on the practicality of applying
TFMEA at Highfield tea industry by ticking the scale presented in the last column.
TFMEA Failure Action suggested to To what extent you assess that action suggested in column (e) can be
Cause of Failure Effects of Failure
number Mode overcome the failure implemented in Highfield Tea Industry (Please tick)
(c) (d)
(a) (b) (e) (f)
1. Weekly visual inspection
1. Misalignment 1. Poor quality tea 2. Regular cleaning of
2. No oiling 2. In case of sudden conveyor
8 Failure of drier
3. No cleaning breakdown of machine, the 3. Maintaining a record of
conveyer
4. Damage to safety entire raw material will be maintenance carried out
shear pin wasted 4. To check and maintain the
shear pin
1. Poor quality tea
1. Leak in heat
9 2. Loss of heat Regular inspection and
Failure of heater exchanger surfaces
3. Fire hazard recording
and tubes
4. Smoke smell in tea
1. Over-heating of tea
Installing sensors in the dryer
Failure of causes the defect case-
10 Human error and to automate the drier to
temperature hardening
negligence. maintain temperature to
control 2. Under-heating of tea
optimum level.
causes the defect stewing’.

Signature
 98

those questionnaires. The respondents were given the option of indicating the rate of
successful application of the actions suggested using Likerts’ scale of range 0-10.
The responses were obtained from four top management personnel. One of the
respondents was the manager of the Highfield tea industry who has vast experience
in the manufacturing of tea. The other three respondents were senior employees
with rich experience in the manufacturing of tea and were working in withering,
rolling and drying sections of the Highfield tea industry.

The analysis of the feedback received from these respondents of

Highfield tea industry are discussed here by presenting Figures 5.3 – 5.12. The
average values are depicted in Figure 5.13. The responses by the respondents
against the failure modes are analyzed here. As shown in figures 5.5, 5.11and 5.9,
the responses with regard to TFMEA numbers 3, 9 and 7 have an average value 8
and above in the Likerts’ scale of range 0 - 10 and there is not much variation in the
responses of the individual respondents. This implies that all the respondents
overwhelmingly agree that the actions suggested by the TFMEA team to overcome
failures with respect to these TFMEA numbers have a very high probability of
successful implementation at the Highfield tea industry. As shown in Figures 5.3,
5.4, 5.7, 5.10 and 5.12, the TFMEA numbers 1,2,5,8 and 10 have an average value
of less than 8 but more than 6 in the Likerts’ scale of range 0 to 10. Moreover in the
case of TFMEA numbers 2 and 10, there is considerable variation in the responses
of the individual respondents and there is no unanimity in giving a high value. As
shown in figures 5.6 and 5.8 the TFMEA numbers 4 and 6 have a average value less
than 6 but more than 5. In the case of TFMEA number 4, there is very high
variation in the responses of the various respondents but in the case of TFMEA
number 6 there is not much variation among the various respondents. These
findings are supported by presenting the mean and standard deviation of the
responses of the respondents in Table 5.14. As shown, the standard deviation of the
values of the responses of the respondents against the failure modes titled ’Leaf
hoist and overhead conveyor failure’ and ‘Fermenting drum failure’ is the least with
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the value 0.5. Hence, in the case of overcoming these failure modes, the
respondents’ responses do not vary much. On the other hand, the standard deviation
of the values of the responses of the respondents was highest against the failure
mode titled ‘Failure of heater’. This implies that the responses of respondents varied
with regard to the overcoming of this failure mode. This kind of variation in the
responses of the respondents indicated that the easiness and complexities of the
actions suggested by the TFMEA team members at Highfield tea industry varied
widely. In this context, the need of categorizing the actions suggested by the
TFMEA team members at Highfield tea industry into different categories was
realized. In this background, the need of classifying the actions based on their
easiness and complexities of implementing them in the Pandian tea industry was
realized. The average of values indicated by the respondents to anticipate the rate
of success in implementing the suggested actions are shown in Table 5.14, Table
5.15, Figure 5.2 and Figure 5.13.

Table 5.14 Average and standard deviation of the responses of the respondents
Respondents’ responses
TFMEA

Average
number

in the Likert’s scale of

value
Standard
TFMEA title 0 – 10 Deviation
1 2 3 4
Failure of hot air
3 8 9 8 7 8.25 0.8165
supply
9 Failure of heater 8 10 9 6 8.25 1.7078
Breakdown of rotor
7 7 9 8 8 8 0.8165
vane machine
Leaf hoist and
1 overhead conveyor 8 8 7 8 7.75 0.5000
failure
Fermenting drum
5 6 7 7 7 6.75 0.5000
failure
Failure of drier
8 7 6 6 8 6.75 0.9574
conveyor
Failure of temperature
10 7 5 6 8 6.5 1.2910
control
2 Withering fan failure 6 8 6 4 6 1.6330
4 Uneven cutting 5 6 7 4 5.5 1.2910
Sudden breakdown of
6 6 6 5 5 5.5 0.5774
green leaf sifter
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Figure 5.2 Average and standard deviation of the responses of the respondents

Figure 5.3. Responses agianst the suggestions to overcome leaf hoist and
overhead conveyor failure
 101

Figure 5.4. Responses agianst the suggestions to overcome withering fan failure

Figure 5.5. Responses against the suggestions to overcome failure of hot air
supply
 102

Figure 5.6. Responses against the suggestions to overcome uneven cutting

Figure 5.7. Responses against the suggestions to overcome sudden breakdown of

fermenting drum failure
 103

Figure 5.8. Responses against the suggestions to overcome sudden breakdown of

green leaf sifter

Figure 5.9. Responses against the suggestions to overcome breakdown of rotor

vane machine
 104

Figure 5.10. Responses against the suggestions to overcome failure of drier

conveyer

Figure 5.11. Responses against the suggestions to overcome failure of heater

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Figure 5.12. Responses against the suggestions to overcome failure of

temperature control

1. Leaf hoist and overhead

conveyor failure
2. Withering fan failure
3. Failure of hot air supply
4. Un even rolling
5. Fermenting drum failure
6. Sudden breakdown of
green leaf sifter
7. Break down of rotor vane
machine
8. Failure of drier conveyor
9. Failure of heater
10. Failure of temperature
control

Figure 5.13. Graph showing average value of the responses against the failure
modes
 106

Based on the analysis of the responses of the respondents, the ease of

implementing the actions suggested by the TFMEA team to overcome the various
failures were categorized under the titles ‘Very Easy to implement’ , ‘Easy to
implement’, ‘Difficult to implement’, ‘Very Difficult to implement’. The rules
designed to categorize these failures are shown in table 5.16. The categorization of
failure modes made using these rules is presented in table 5.17.

Table 5.15. Respondent’s anticipation over the successful implementation of

actions as suggested by the TFMEA team at Highfield tea industry.

Respondent’s average values

TFMEA indicating the successful
Name of failure mode
number application of actions in the e
Likert’s scale of 0 – 10
3 Failure of hot air supply 8.25
9 Failure of heater 8.25
7 Breakdown of rotor vane machine 8
Leaf hoist and overhead conveyor
1 7.75
failure
5 Fermenting drum failure 6.75
8 Failure of drier conveyor 6.75
10 Failure of temperature control 6.5
2 Withering fan failure 6
4 Uneven cutting 5.5
Sudden breakdown of green leaf
6 5.5
sifter

Table 5.16. Actions implementable categorization chart

Value of the response
Average value < 3
Average value >3 and less than 6
Average value >6 and less than 8
Average value >8
Category of actions suggested
Very difficult to implement
Difficult to implement
Easy to implement
Very Easy to implement
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Table 5.17. Categorization of failure modes

Category of the respondents
Failure
Failure mode assessment over the successful
number
overcoming of the failure
3 Failure of hot air supply Very easy to implement
9 Failure of heater Very easy to implement
7 Breakdown of rotor vane machine Very easy to implement
Leaf hoist and overhead conveyor
1 Easy to implement
failure
5 Fermenting drum failure Easy to implement
8 Failure of drier conveyor Easy to implement
10 Failure of temperature control Easy to implement
2 Withering fan failure Easy to implement
4 Uneven cutting Difficult to implement
Sudden breakdown of green leaf
6 Difficult to implement
sifter

As shown, it is evident that, most of the actions suggested by the

TFMEA team to overcome the failure modes are very easy or easy to implement at
the Highfield tea industry. The percentage categorization of the actions suggested
from the viewpoint of the respondents is presented in Table 5.18.

Table 5.18. Percentage categorization of implementation potential of the

actions suggested by the TFMEA team members
Serial Percentage
Category of actions suggested
number categorization
1 Very difficult to implement 0%
2 Difficult to implement 20 %
3 Easy to implement 50%
4 Very Easy to implement 30%

As shown in Table 5.18, 80 % of the actions suggested by the TFMEA

team members are either ‘very easy’ or ‘easy’ to implement in Highfield tea
industry. 20 % of the actions suggested by the TFMEA team members are ‘difficult
to implement’ at the Highfield tea industry. It is significant to note that none of the
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actions fall under the ‘very difficult to implement’ category. In the context of these
observations, it is inferred that the top management of Highfield tea industry may
be persuaded to start implementing the very easy actions and then proceed to the
‘easy’, and then the ‘difficult’ actions. Under these circumstances, the roadmap
presented in the previous chapter is suggested for persuading the top management to
implement the TFMEA programme in the Highfield tea industry.

5.6 FINANCIAL IMPLICATIONS

In order to ascertain the financial benefits derived from the

implementation of the TFMEA programme the role of the failure modes in
overcoming the defects in the tea manufactured at Highfield tea industry was
correlated. This correlation is shown in table 5.19.

Table 5.19 Failure modes and associated defects in tea

number

Defects that can be

Serial

Failure mode overcome in the tea by

preventing the failure mode
Soft withering causing, thin
1 Withering fan failure.
tea liquor, no briskness
2 Failure of hot air supply, Failure of heater Smoke Smell of tea
3 Uneven cutting Greenness of tea
Uneven cutting ,Uneven rolling,
Flakiness, excessive stalk
4 Fermenting drum failure, Sudden
and fiber,
breakdown of green leaf sifter machine
Leaf hoist and overhead conveyor failure,
Uneven cutting, Sudden breakdown of Non uniform size of
5 green leaf sifter machine, Breakdown of particles and poor grades of
rotor vane machine, Failure of drier tea
conveyor
Case hardening, over burnt
6 Failure of temperature control
tea, bitterness
Stewing - less keeping
7 Failure of temperature control
quality of tea
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Furthermore, the data related to the volume of production, price of tea sold in the
market, the various defects present in the tea and the price drop on account of
defects were gathered by interviewing the top management personnel of Highfield
tea industry. A systematic analysis was carried out using these data. The findings of
this analysis are presented in the Table 5.20.

Annual Tea production of tea at Highfield tea industry = 10,00000 kgs

Annual Revenue in the absence of failures
= Annual Production × Average price per
kilogram
= 1000000 × 90 = INR 90 millions
Revenue Loss due to defects = INR 3.95 millions

The implementation of TFMEA in Highfield tea industry will result in

increasing the revenue to the tune of INR 3.95 millions annually (increase of 4.5 %
of the total revenue generated by the Highfield tea industry at present).

The High Field tea industry has an annual tea production of 1,000000
kgs of tea. This tea is sold at an average price of INR 90 per kilogram when there
are no defects in the tea. It is observed that when there is a defect, there is a price
drop from the average price of tea. This price drop results in loss of revenue to the
tea manufacturing company. Due to all the major defects mentioned in Table 5.19,
the High Field tea industry suffers a revenue loss of INR 3.95 millions annually. On
fully implementing all the actions suggested by the TFMEA team, it will be
possible for the Highfield tea industry to wipe out this loss and increase its revenue
by 4.5% INR annually.
 110

Table 5.20. Financial analysis on the effects of implementing TFMEA in Highfield Tea Industry
Annual
Average price of Average Loss due
Quantit Loss due
one kilogram of price of to defect
Percentage of y in to defect
Serial tea in the absence tea when for one
Defect in the tea occurrence of Kilogra in
number of this defect in there is Kg in
this defect ms millions
INR defect INR
(D ) INR
(A) (B) ( C)
C×D
Soft withering causing, thin tea 15% of total
1. 90 85 5 150000 0.75
liquor and no briskness production
2. Smoke smell of tea 90 3% 80 10 30000 0.3
3. Greenness of tea 90 5% 83 7 50000 0.35
Flakiness, excessive stalk and fiber,
4. over- fermentation and under- 90 20% 88 2 200000 0.4
fermentation
Non-uniform size of particles and
5. 90 10% 88 2 100000 0.2
poor grades of tea
Case hardening over burnt tea,
6. 90 15% 82 8 150000 1.2
bitterness
Stewing - reduction of shelf life of
7. 90 5% 75 15 50000 0.75
tea
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5.7 CONCLUSION

As mentioned in chapter 3, in xzorder to implement TFMEA in a tea

manufacturing company, 13 distinct steps are required to be meticulously carried
out. Among these 13 steps, the steps 10-13 could not be implemented at the High
Field tea industry as permission from the top management could not be obtained for
implementing the recommended actions for overcoming the failures in the tea
industry. Since the top management of the High Field tea industry was
noncommittal in granting the necessary approval, the results of the implementation
study could not be evaluated by actually implementing them at High Field tea
industry. However, in order to overcome this difficulty, a questionnaire was
designed to elicit the views of the managerial employees on the practicality of
implementing the TFMEA technique in the tea industry employing CTC method. A
thorough analysis was carried out using the feedback received from these
respondents. The results of this analysis have clearly indicated that TFMEA is a
technique which is practically implementable to overcome failures in tea industry
and thereby helps to improve quality of the tea and productivity of its
manufacturing process. The implementation study conducted in High Field tea
industry projects that, by implementing the TFMEA technique, it is possible to
overcome defects and also increase the annual revenue of the tea manufacturing
companies.