DEFECTIVE SEALING OF ICE

CREAM PREMIX PACK AT

IGLU MANUFACTURING AND
GELATO DESSERTS: A DMAIC
APPROACH
Company Background
DEFINE
PHASE
The Current Value Stream Map
Pareto Chart of Defect Classification
 INITIAL PROBLEM STATEMENT

August September October November December TOTAL BASELINE

No. of Products 3,033 3,258 3,408 3,633 3,524 16,856 3,371

Produced

No. of Defective 243 65 273 218 211 1,010 202

Sealing

% Defective 8% 2% 8% 6% 6% 30% 6%
Sealing
Overall Defective Sealing Rate

Defective Sealing
9%
8% 8%
8%

7%
6% 6%
6.0% 6.0% 6.0% 6.0% 6.0% 6%

5%

4%

3.2% 3.2% 3.2% 3.2% 3.2%

3%
2%
2%

1%

0%
August September October November December

Defective Sealing Baseline Target

 FINANCIAL IMPACT
Total Cost Rework per Defective pack

COST PER DEFECT COSTS

MATERIALS ₱1.14

LABOR ₱0.64

UTILITIES ₱0.17

TOTAL ₱1.95
COMPUTATION
FOR
SAVINGS
IMPROVED
SIPOC Diagram
SUPPLIER INPUT PROCESS OUTPUT CUSTOMER CTQ’S

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER CTQ’S

Local Supplier Skimmed milk Weighing Weighed ingredients Mixing Area Proportional mixture of
Manila Supplier powder, Milk powder ingredients
spray, white sugar, Correct Weight: 10
butter powder, kilograms
sweetener syrup
solids
Mixing Area Weighed ingredients Mixing Mixed ingredients Transferring Area Thorough mixed
ingredients
Receiving Area Mixed ingredients Transferring 10 kilograms of Weighing Area Correct Weight: 10
mixture in a container kilograms

Weighing Area Mixed ingredients Weighing Mixed ingredients with Shaking Area Correct Weight: 1 kilogram
stabilizer

Shaking Area Mixed ingredients Shaking Mixed ingredients with Bagging Area Mixture with no powder
with stabilizer and stabilizer and flavoring clumps
flavoring powder powder
Bagging Area Fine soft ice cream Bagging Ice cream premix Sealing Area Correct Weight: 1 kilogram
premix pack

Sealing Area Ice cream premix Sealing Sealed pack Labeling Area Properly sealed pack
pack
Labeling Area Sealed pack Labeling Finished products Storage Area Correctly labelled finish
products
Storage Room Labelled finish Shipping Delivered finish IGLU Franchisers On-time delivery and
products products defect free products
MEASURE
PHASE
PROCESS DESCRIPTION
PROCESS DESCRIPTION
Weighing (10 kilograms)
In this process, ingredients such as the skimmed milk powder, white sugar, butter powder,

milk powder spray, flavouring powder and sweetener syrup solids are weighed together into

10 kilograms.

Mixing
This is where the weighed ingredients are put into the mixer for thorough mixing of

ingredients.
Transferring
This is where the mixture is stored into a container.
Weighing (1 kilogram)
The mixture is weighed into 1 kilogram with the additional ingredients which is the stabilizer.

Shaking
This is where the shaking of mixture happens to avoid forming of the powder clumps.

Bagging
The mixture is transferred into the final packaging of the premix.

Sealing
The ice cream premix pack is sealed using the manual sealer machine.

Labelling
This is where stickers are attached to the pack according to their flavors..

Storing
The ice cream premix pack is placed in the storage area, ready for delivery.
MEASUREMENT SYSTEM ANALYSIS

Table 5. Attribute Gage R & R

Operator 1 Operator 2 All operators agree All operators agree
between each other with the standard
Sample # Attribute Trial 1 Trial 2 Trial 1 Trial 2 YES OR NO YES OR NO
1 Pass Pass Pass Pass Pass YES YES
2 Pass Pass Pass Pass Pass YES YES
3 Pass Pass Pass Pass Pass YES YES
4 Fail Fail Fail Pass Fail NO NO
5 Fail Fail Fail Fail Fail YES YES
6 Pass Pass Pass Pass Pass YES YES
7 Fail Fail Fail Fail Fail YES YES
8 Pass Pass Pass Pass Pass YES YES
9 Pass Pass Pass Pass Pass YES YES
10 Pass Pass Pass Pass Pass YES YES
% Appraiser Score 100% 90%
% Score vs. Attribute 100% 90%
Screen % Effective 90%
Score
Screen % Effective 90%
Vs. Attribute
P-CHART
P- chart of defective sealing
 TYPES OF DEFECTIVE SEALING

Plastic is over sealed or melted

Plastic is loosely sealed.

ANALYZE
PHASE
ISHIKAWA DIAGRAM
Potential X Matrix

Problem: Defective sealing

# Key Process Inputs Origin Appropriate

(x’s) Test/Analysis

Not following the

1 standard time Fishbone Diagram 1 sample t-Test

Low quality plastic

2 Fishbone Diagram 2 sample t-Test
VERIFICATION OF ROOT CAUSES

Potential Root Cause No. 1 – Not following standard time

Root Cause Not following standard time

The experiment was done by
observing the sealing time. In the
Description experiment, a worker was made to
seal 20 packs and the duration of
each seal is recorded and
evaluated. Data gathering was
done and completed in one day.

Theory If the standard sealing time of 5

seconds is strictly followed, rejects
will be reduced.
Data Gathered

Table 6. Raw Data of Sealing time of 20 samples

Sample Sealing Time Difference

1 5.24 0.24
2 5.08 0.08
3 4.89 0.11
4 5.18 0.18
5 4.4 0.6
6 5.26 0.26
7 4.69 0.31
8 5.89 0.89
9 6.1 1.1
10 4.9 0.1
11 5.01 0.01
12 4.94 0.06
13 6.47 1.47
14 5.29 0.29
15 4.37 0.63
16 5.53 0.53
17 4.87 0.13
18 5.79 0.79
19 4.17 0.83
20 5.07 0.07
Results

The hypothesis is tested using a one-sample

t-Test:

The hypothesis is tested using a one-sample t-Test:

A. Null Hypothesis Ho: μ=5
Alternative Hypothesis Ho: μ≠5

D. x-bar = 5.897
s = 1.165
E. Since t=3.44 which is greater than 2.093,
the null hypothesis must be rejected.
Potential Root Cause No. 2 – Low quality plastic

Data Gathered
Root Cause Low quality plastic
The experiment was done by
testing two different brands of
plastic. In the experiment, the
Description worker will seal 20 packs using the
current plastic used by the
company, and another 20 packs
using the proposed plastic; both will
follow the standard sealing time of 5
seconds.
Theory If the company will switch to a
plastic with better quality, rejects
will be reduced.
Data Gathered

Current Plastic

Fail 9 7 5 7 3

Total Sample 20 20 20 20 20

Proposed
Plastic
Fail 4 4 2 3 1

Total Sample 20 20 20 20 20
 Null Hypothesis There is no significant difference

Alternative There is a significance difference

Hypothesis

Low Quality Plastic Average

Current Plastic 0.45 0.35 0.25 0.35 0.15 0.31

Proposed Plastic 0.2 0.2 0.1 0.15 0.05 0.7

Initial Observation Switching to the proposed plastic will reduce

rejects.
Results
IMPROVE
PHASE
 SCALE:
1 – None 2 – Somewhat 3 – Moderate 4 – Very 5 – Extreme

Effectiveness Ease to Cost Total Score Action

Implement

5 5 5 125 IMPLEMENT

5 4 5 100 IMPLEMENT
 Cost Benefit Analysis

Root Solution Specific Material

Cause Task
Changing of - Provide PE plastic 004 Php 1.50 per
Low quality Plastic Brand another brand piece
of plastic
of plastic
which can be
sealed for
about 5
seconds to 35
seconds

Table 6. Cost of Material

Solution: Changing of Plastic Brand
:
Material Cost:
Present
= (40,452 pieces/year)(6%)(Php 1.14/piece) = Php 2,766.92 /year

Proposed
= (40,452 pieces/year)(3.2%)(Php 1.50/piece) = Php 1,941.70 /year

Savings
= Present - Proposed
= Php 2,766.92 - Php 1,941.70 = Php 825.22 /year

Labor Cost :
Bagging = 0.63 min /piece
Sealing = 0.15 min / piece
= 0.63min + 0.15 min = 0.78 min/piece (2processes)
Present
= (40,452 pieces/year)(6%)(0.78 min/piece) = 1,893.15 mins/year
= 31.55 hours / year
= 3.94 days/year (Php 400.00/day)
= Php 1,576.00 /year
Proposed
= (40,452 pieces/year)(3.2%)(0.78 min/piece) = 1,009.68 mins/year
= 16.83 hours / year
= 2.10 days/year (Php 400.00/day)
= Php 840.00 /year

Savings (Labor Cost)

= Present - Proposed
= Php 1,576.00 - Php 840.00 = Php 736 /year
Solution: Changing of Plastic Brand
:
Utility Cost ( Php 0.17 per pack )

Present
= (40,452 pieces/year)(6%)(Php 0.17/piece) = Php 412.61

Proposed
= (40,452 pieces/year)(3.2%)(Php 0.17/piece) = Php 220.06

Savings
= Present – Proposed
= Php 412.61 – Php 220.06 = Php 192.55 /year

Total Savings
=Material Cost + Labor Cost + Utility Cost
= Php 825.22 + Php 736.00 + Php 192.55

Total Savings= Php 1,753.77 annually

CONTROL
PHASE
FUTURE VALUE STREAM MAP
 Re-Orientation to Workers Module

Training Date: April 7, 2019 (Sunday)

Session Time: 2:00 – 4:00 P.M. (2 Hours)

No. of Employees Involved: 2 Employees

Training Topic: Standardization of the pressing time in sealing

Objective of the Training: At the end of the training program the company will strictly implement the

standard pressing time in sealing

About the Training:

The personnel of the company are scheduled for an orientation and training this April

7, 2019. The purpose of the training workshop is to make the personnel aware of the improvements made

in the company specifically in the sealing of the soft ice cream premix. Also, this is to make sure that the

improvements of the company will be sustained. This way, there will be a longer impact of the

improvement that is developed by the team.

Training Strategy:

 Hands on sealing with standard time

 Hands on sealing using the proposed plastic

 Hands on sealing using the proposed plastic with standard pressing time